Helical Induction Coil Stabilization in Fixing Rollers
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Solution Overview
Problem
Existing image heating apparatuses face issues with non-uniform heating due to potential electrical shorts and deviations in the winding position of the exciting coil, leading to increased energy consumption and longer warm-up times, especially when the exciting coil is directly wound around a magnetic core.
Innovation Solution
The apparatus incorporates a cylindrical rotatable member with a helical exciting coil and a magnetic core, where the exciting coil is positioned inside a hollow portion of the rotatable member, and a resin material layer is placed between the coil and the magnetic core to stabilize the coil's position and prevent shorts, allowing for efficient induction heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the exciting coil is directly wound around the magnetic core material, then the structure is simplified, but electrical shorts may occur and winding position may deviate leading to non-uniform heating
Solution Approach 1:
An insulating bobbin is introduced as an intermediary component between the exciting coil and the magnetic core material. The bobbin serves multiple functions: providing electrical insulation to prevent shorts, maintaining precise winding position to ensure uniform magnetic flux distribution, and supporting the coil structure without requiring direct contact between the coil and magnetic core.
2Reliability
If the exciting coil is wound around the magnetic core material through the bobbin, then electrical shorts are prevented, but the outer diameter of the fixing roller increases leading to higher energy consumption
Solution Approach 1:
A thin insulating bobbin is used instead of thick structural components. The bobbin provides necessary electrical insulation while maintaining a compact profile, minimizing the increase in outer diameter and thus reducing the energy required to heat the fixing roller.
3Stability of the object's composition
If the outer diameter of the fixing roller increases, then the exciting coil can be stabilized, but the time to heat the fixing roller increases and excessive electric power is needed
Solution Approach 1:
The thin insulating bobbin provides sufficient structural support to stabilize the exciting coil position without significantly increasing the outer diameter of the fixing roller, thus avoiding excessive warm-up time and power consumption.
Solution Approach 2:
Instead of increasing the outer diameter (radial dimension) to stabilize the coil, the solution uses the axial dimension of the bobbin to provide structural support and position stability, maintaining a compact radial profile while ensuring coil stability.
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
This configuration ensures uniform heating, reduces the outer diameter of the fixing roller, decreases heat capacity, and lowers energy consumption by stabilizing the exciting coil and preventing electrical shorts, thus achieving faster warm-up times and reduced power usage.
Implementation Method 1
The exciting coil is configured to cause the electroconductive layer to generate heat through induction heating
Implementation Method 2
The magnetic core is provided inside the helix of the exciting coil and configured to induce magnetic flux generated by the exciting coil
Data Source
AI summary
An image heating apparatus includes a cylindrical rotatable member, an exciting coil, a magnetic core, and a resin material layer provided between the exciting coil and the magnetic core. The exciting coil is a metal wire coated with heat-resistant resin. The resin material layer is provided between the exciting coil and the magnetic core and is a layer that is different from the heat-resistant resin of the metal wire. The resin material layer is provided on a surface of the magnetic core in a helical shape along the exciting coil. As viewed in a direction perpendicular to a longitudinal direction of the rotatable member, the exciting coil enters the resin material layer in a radial direction of the exciting coil.