Heating Roller Layer Structure to Prevent Heat-Generating Film Peeling
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Solution Overview
Problem
Existing heating devices in image forming apparatuses face issues with peeling of the resistance heat generating layer due to rapid temperature changes, particularly at the junctions where different materials with varying thermal expansion coefficients are used, leading to potential rust and heating failures.
Innovation Solution
A heating roller design with an electrically insulating layer and resistance heat generating layer sequentially applied on a metal cylindrical substrate, without an anti-rust layer on the inner surface, to prevent peeling during temperature fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an anti-rust layer is added on the metal roller substrate, then rust prevention is improved, but the resistance heat generating layer may peel off during rapid temperature changes
Solution Approach 1:
The patent removes the anti-rust layer from the heating roller structure, extracting the component that causes peeling while maintaining rust prevention through the natural properties of the metal substrate in the heating environment
Solution Approach 2:
The patent changes the thermal expansion coefficient parameter by selecting a metal substrate with specific thermal properties that match the heat generating layer, reducing thermal stress during temperature changes and preventing peeling
2Adaptability or versatility
If different materials with varying thermal expansion coefficients are used, then functional requirements are met, but peeling occurs at the junctions during temperature changes
Solution Approach 1:
The patent selects materials with matched thermal expansion coefficients for the substrate and heat generating layer, changing the physical parameter to minimize thermal stress at junctions during temperature variations
Solution Approach 2:
The patent uses composite material selection where the metal substrate and heat generating layer are chosen to have compatible thermal properties, creating a stable composite structure that resists peeling during thermal cycles
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
Prevents peeling of the resistance heat generating layer, thereby maintaining consistent heating performance and preventing heating or fixing failures, even during rapid temperature changes, without the need for additional components.
Implementation Method 1
a resistance heat generating layer that generates heat by being energized
Implementation Method 2
a heating roller that is rotated to heat a member to be heated
Data Source
AI summary
A heating device includes a heating roller that is rotated to heat a member to be heated, in which the heating roller is provided with at least an electrically insulating layer and a resistance heat generating layer that are provided in this order on one or both of an inner peripheral surface and an outer peripheral surface of a cylindrical roller substrate made of metal on which rust occurs, without an anti-rust layer.