Heating Member with Intermediate Layer for Fusing Apparatus

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Solution Overview

Problem

Existing fusing apparatuses in electrophotographic imaging systems face inefficiencies in heat transfer and durability due to high thermal capacity of heat rollers and non-uniform heating, leading to slow temperature rise rates and energy inefficiency.

Innovation Solution

A heating member with a resistive heating layer, an intermediate layer, and a release layer is introduced, where the intermediate layer has high thermal conductivity and adhesion, and the release layer prevents toner adhesion, supported by a flexible or hollow pipe-shaped structure, enhancing heat transfer and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a heat roller with high thermal capacity is used in a fusing apparatus, then the heat roller can maintain stable temperature, but the temperature rise rate becomes slow and heat transfer efficiency decreases

Engineering Contradiction:

Improvetemperature stabilityVSAvoidtemperature rise rate

Core Design Contradiction:

Stability of the object's compositionVSSpeed

Solution Approach 1:

The heating system is segmented into multiple independent heating zones along the heating belt, allowing different sections to be heated independently and simultaneously, thereby increasing the overall temperature rise rate while maintaining stable temperature in each zone

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional mechanical heat roller heating system is replaced with an electric heating belt system that uses electrical resistance heating, providing faster and more efficient heat generation compared to conventional thermal conduction methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If sequential heat transfer from heat source to toner via heat roller and recording medium is used, then the fusing process can be simplified, but heat transfer efficiency becomes low

Engineering Contradiction:

Improvefusing process complexityVSAvoidheat transfer efficiency

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

A release layer is introduced as an intermediary between the heating belt and the toner/recording medium interface. This release layer improves thermal contact and heat transfer efficiency while preventing toner adhesion to the heating belt, thereby reducing energy loss without significantly increasing device complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heating belt is constructed as a composite structure combining electroconductive material for heating with a release layer having specific thermal and release properties, optimizing both heat transfer efficiency and toner release characteristics

Inventive Principle:

Principle #40Composite materials

3Speed

If a sheet heater with hot wires on external surface of heat roller is used, then temperature rise rate increases, but uniform heating is compromised and local overheating occurs

Engineering Contradiction:

Improvetemperature rise rateVSAvoidtemperature uniformity

Core Design Contradiction:

SpeedVSStability of the object's composition

Solution Approach 1:

The heating belt is divided into multiple independent heating zones with separate hot wire segments, allowing distributed heat generation across the entire heating surface. This segmentation enables uniform temperature distribution while maintaining high temperature rise rate, preventing local overheating that occurs with concentrated hot wires

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the heating belt have locally optimized heating characteristics with adjusted hot wire density and power distribution, ensuring each zone achieves appropriate temperature uniformity while contributing to overall rapid heating performance

Inventive Principle:

Principle #3Local quality

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 improves heat transfer efficiency, reduces heating time, and increases the durability and stability of the heating member, allowing for rapid printing and reduced energy consumption by maintaining a predetermined temperature in standby mode.

Implementation Method 1

a resistive heating layer which generates heat when supplied with electrical energy

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The intermediate layer may have a thermal conductivity of about 0.5 watt per meter per Kelvin (W/m·K) or greater

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9052655B2Heating member including a base polymer and fusing apparatus including the same

Publication Date: 2015.06.09 HEWLETT PACKARD DEVELOPMENT COMPANY LP

AI summary

A heating member includes: a resistive heating layer which generates heat when supplied with electrical energy; a release layer as an outermost layer of the heating member and including a polymer; an intermediate layer disposed between the resistive heating layer and the release layer. The resistive heating layer includes a base polymer, and an electroconductive filler dispersed in the base polymer. The intermediate layer includes a polymer material being a same type as the base polymer of the resistive heating layer or the polymer of the release layer.