Sheet Heater Adhesion via Silane Coupling Agent
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Solution Overview
Problem
Image fixing devices face issues with low mechanical strength of electrode layers formed from conductive pastes and separation of metal plate electrodes from the specific resistance heater layer due to repetitive use and thermal stress.
Innovation Solution
A sheet heater with a conductive resin composition and metal plate electrodes bonded using a silane coupling agent, where the peak area ratio of silicon to metal ions is controlled to ensure strong adhesion, and optionally includes reinforcement, elastic, and releasing layers for enhanced durability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conductive paste is used to form an electrode layer, then the electrode layer can be formed, but the mechanical strength is low and cracks or defect holes may form due to repetitive use and thermal stress
Solution Approach 1:
The patent employs a composite material structure consisting of a metal plate electrode bonded to a specific resistance heater layer through a silane coupling agent. This composite construction combines the high mechanical strength of metal with the heating functionality of the resistive layer, while the coupling agent ensures strong adhesion between the two materials, preventing separation during repetitive use and thermal cycling.
2Strength
If a metal plate is used as the electrode layer, then the mechanical strength is improved, but the electrode layer and specific resistance heater layer may separate from each other when the belt is repeatedly used
Solution Approach 1:
The patent introduces a silane coupling agent as an intermediary layer between the metal plate electrode and the specific resistance heater layer. This coupling agent acts as a mediator that chemically bonds to both the metal surface and the heater layer, creating a strong interface that prevents separation during repetitive use and thermal stress while maintaining the mechanical strength benefits of the metal plate.
3Ease of manufacture
If a conductive paste electrode layer is used, then the manufacturing is simple, but cracks and defect holes may form due to sparks and harsh environmental changes
Solution Approach 1:
The patent replaces the conductive paste with a metal plate electrode that is bonded to the specific resistance heater layer using a silane coupling agent. This composite material approach provides superior reliability by eliminating the formation of cracks and defect holes that occur with conductive pastes under harsh environmental conditions and repetitive thermal cycling.
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 provides high adhesion strength and reduced performance degradation over repetitive use, preventing separation of electrodes and ensuring effective heat generation for image fixing devices.
Implementation Method 1
a voltage of 100 to 240 V is typically applied to the electrode layer, causing the temperature of the heat fixing belt to rise above 200° C.
Implementation Method 2
the metal plate electrodes are bonded to respective ends of the sheet article by a silane coupling agent
Data Source
AI summary
A sheet heater that includes a sheet article composed of a conductive resin composition containing a conductive material and a resin, and a pair of metal plate electrodes, each of the electrodes being bonded to each of the ends of the sheet article, wherein when elements of the sheet article are detected at a portion 1 μm depth from a surface of the metal plate electrode, a peak area ratio of silicon (Si) to metal ion (M) is 1/100 to 1, the metal ion M being most abundant of all metal ions detected at the portion, the peaks being obtained by measuring an X ray generated at the portion by applying an X ray to the portion with the scanning electron microscope-energy dispersive X-ray spectrometer.