Heater Substrate Width Reduction via Dimensional Contact Arrangement
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Solution Overview
Problem
Existing image heating apparatuses face challenges in minimizing the width of the substrate while maintaining effective heat generation, as the arrangement of electrical contacts in the widthwise direction requires wide gaps to prevent short circuits, leading to increased substrate width and costs.
Innovation Solution
A heater design with a substrate featuring a first and second connecting portion with a gap in the longitudinal direction and a third and fourth connecting portion with a gap in the widthwise direction, allowing for heat generation by electric energy supplied from multiple terminals, reducing the gap between the third and fourth connecting portions to minimize substrate width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If electrical contacts are arranged in the widthwise direction of the substrate, then the length of the substrate can be reduced, but the gap between electrical contacts must be sufficiently wide to prevent short circuits, which increases the width of the substrate
Solution Approach 1:
The patent transitions from a two-dimensional arrangement where all electrical contacts are distributed across the substrate width to a three-dimensional arrangement where contacts are concentrated at one end. The electroconductive line layers extend in the longitudinal direction to connect contacts spatially separated along the length, effectively moving the contact arrangement to a different dimensional configuration that reduces width requirements.
Solution Approach 2:
Multiple electroconductive line layers (first, second, third, and fourth electroconductive line layers) are merged and extended in the longitudinal direction to connect electrical contacts that are spatially separated. This merging of conductive paths allows the substrate width to be reduced while maintaining electrical connectivity through the extended longitudinal arrangement.
2Area of stationary object
If the gap between electrical contacts is reduced to minimize substrate width, then the substrate size and cost are reduced, but the risk of short circuits due to creepage discharge increases
Solution Approach 1:
The patent resolves the electrical insulation problem by extending the electroconductive line layers in the longitudinal direction, effectively moving the electrical connection path from a widthwise arrangement to a longitudinal arrangement. This dimensional change increases the creepage distance along the length of the substrate while allowing the width to be minimized, thereby maintaining electrical insulation reliability.
Solution Approach 2:
The electroconductive line layers act as intermediaries that bridge the electrical contacts spatially separated in the longitudinal direction. These extended conductive layers provide a controlled electrical path that maintains proper insulation distances, preventing direct short circuits between contacts that would otherwise require large width gaps.
3Ease of manufacture
If the substrate width is reduced to lower costs, then manufacturing costs are reduced, but the arrangement of electrical contacts becomes more constrained
Solution Approach 1:
The patent segments the electrical contact arrangement into distinct groups: electrical contacts connected to the same voltage source contact are arranged adjacent to each other in the widthwise direction at one end, while electrical contacts connected to different voltage source contacts are arranged in the longitudinal direction. This segmentation allows for optimized space utilization and simplified manufacturing within the constrained width.
Solution Approach 2:
The patent applies different arrangement strategies to different groups of electrical contacts based on their voltage source connections. Contacts requiring the same voltage source are grouped together with minimal spacing, while contacts requiring different voltage sources are separated along the longitudinal direction with extended electroconductive lines, optimizing both space utilization and electrical insulation locally.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a compact heater with reduced substrate width, preventing short circuits and maintaining efficient heat generation, thus addressing the cost and size issues of existing designs.
Implementation Method 1
the electric power supply is supplied through the electrodes to the heat generating resistance layers so that the heat generating resistance layer generates heat
Data Source
AI summary
A heater usable with an image heating apparatus including first and second terminals includes: a first connector connectable with the first terminal; a second connector connectable with the second terminal and positioned with a gap from the first connector in a longitudinal direction of the substrate; a third connector connectable with the second terminal; a fourth connector connectable with the second terminal and positioned with a gap from the third connector in the widthwise; and heat generators arranged in the longitudinal direction. The heat generators include heat generators activatable by the first connector and the second connector, by the first connector and the third connector, and by the first connector and the fourth connector. A gap between the third connector and the fourth connector in the widthwise direction is smaller than a gap between the first connector and the second connector in the longitudinal direction.