Multilayer Heater with Embedded Sensor and Wiring
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Solution Overview
Problem
In fixing apparatuses, excessive heating in areas where the sheet does not pass leads to issues like heater warping, belt deterioration, and speed unevenness, and current temperature control methods are complex due to the need for insulated wiring between the heater and temperature sensors.
Innovation Solution
A heater with a multilayer structure, where heat generating members and temperature sensors are in separate layers, and wiring patterns for power supply are integrated between these layers, allowing for precise temperature control while keeping the circuits insulated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the heater heats the entire surface including areas where the sheet does not pass, then the temperature distribution is uniform, but energy is wasted and heater warping occurs
Solution Approach 1:
The heater surface is divided into multiple independent heating zones corresponding to different sheet sizes. Each zone can be independently controlled to heat only the required area, eliminating energy waste in unused regions while maintaining uniform temperature in the active heating area through dedicated temperature control for each zone.
2Measurement precision
If temperature sensors and power wiring are completely insulated from each other, then accurate temperature control is achieved, but wiring complexity increases
Solution Approach 1:
The temperature sensor and power wiring are placed in different layers of a multilayer substrate structure. This spatial separation in the vertical dimension provides complete electrical insulation between the sensor circuit and power wiring, ensuring accurate temperature control while eliminating the need for complex insulation measures in the horizontal plane.
3Reliability
If the heater heats areas where the sheet does not pass, then the heating coverage is complete, but heater warping and belt deterioration occur
Solution Approach 1:
Different regions of the heater surface are assigned different heating characteristics. The heating zones are configured to match the sheet size, providing intensive heating only where needed. This localised heating approach maintains reliable heater operation by avoiding overheating of unused areas while ensuring complete heating coverage for the active sheet region.
4Measurement precision
If multiple temperature sensors are used to control different heating zones, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The heating system is divided into multiple zones, each with its own temperature sensor and control circuit. This segmentation allows independent temperature control for each heating zone, improving overall temperature control precision. The multilayer substrate integrates these sensors and wiring in a compact manner, managing the increased device complexity through structured organisation.
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 enables efficient heating only where the sheet passes, reducing energy waste and simplifying temperature control by embedding sensors and wiring patterns within the insulating substrate, thus improving the apparatus's efficiency and reliability.
Implementation Method 1
a heat generating member (51) in a first layer... configured to generate heat
Implementation Method 2
a sensor (57) in a second layer different from the first layer and configured to detect a temperature of the heat generating member
Data Source
AI summary
A heater includes a heat generating member in a first layer, a sensor that is in a second layer different from the first layer and configured to detect a temperature of the heat generating member, and a wiring pattern in one or more third layers between the first and second layers to supply power to the heat generating member.