Solid Heater with Center Tap for Uniform Fuser Heating

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Solution Overview

Problem

Current center registered solid heaters face issues with heat transfer performance due to the need for multiple heating traces or relays to switch between taps, leading to cold spots and increased complexity, particularly when handling different media widths.

Innovation Solution

A single resistive heating trace with multiple taps is configured, where a tap is placed at the center to serve as a dedicated common for firing different heating zones, and reductions in the heating trace near the taps are made to mitigate cool zones, allowing for efficient heating of various media widths with reduced connector pins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple heating traces are used to handle different media widths, then adaptability is improved, but device complexity and heat transfer performance deteriorate due to cold spots

Engineering Contradiction:

Improveability to handle different media widthsVSAvoidnumber of heating traces and connector pins

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The heating trace is segmented into multiple zones with independent taps along its length, allowing selective activation of different segments to match various media widths. This segmentation enables adaptability without requiring multiple complete heating traces, reducing overall device complexity while maintaining the ability to handle different media sizes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A single heating trace is designed to serve multiple functions by incorporating taps at strategic locations that can activate different portions of the trace. This universal design allows one heating trace to replace multiple dedicated traces, handling various media widths with a single component rather than requiring separate heating elements for each media size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple heating traces with inter heating trace conductive taps are used, then adaptability is improved, but manufacturing precision deteriorates due to cold spots affecting latitudes

Engineering Contradiction:

Improveability to handle different media widthsVSAvoidtemperature uniformity and image quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The heating trace incorporates local quality variations through strategically placed taps and varying trace dimensions in different zones. Each segment is optimized for its specific function, with taps positioned to create appropriate thermal characteristics for different media widths, ensuring uniform heating without cold spots that would compromise manufacturing precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heating trace parameters such as width, thickness, and resistivity are varied locally along its length to compensate for thermal effects. By changing these parameters in different zones, the design achieves uniform temperature distribution across various media widths, preventing cold spots and maintaining consistent heating quality throughout the heating surface.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If a single heating trace with multiple taps is used, then device complexity is reduced, but heat transfer performance deteriorates due to cold spots at conductor interfaces

Engineering Contradiction:

Improvenumber of heating traces and connector pinsVSAvoidtemperature uniformity at conductor interfaces

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The heating trace design incorporates preliminary compensation features at conductor interface locations, such as pre-positioned taps or adjusted trace dimensions in anticipation of heat loss at connection points. This preliminary action prevents cold spots from forming at conductor interfaces by compensating for expected thermal losses before the heating process begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The design converts the potentially harmful cold spots at conductor interfaces into beneficial features by strategically placing taps or adjusting trace parameters in these regions. The conductor interfaces, which would normally create thermal disruptions, are transformed into controlled heating zones that contribute to overall temperature uniformity rather than creating defects.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 provides uniform heating, improves heat transfer performance, and reduces the number of connector pins required, addressing the limitations of multiple trace designs and cold spots in existing heater technologies.

Implementation Method 1

a resistive heater is disclosed that is adapted for heating a fuser belt with the heater comprising a substrate, a first resistive trace formed over the substrate

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS9606484B1Method for temperature leveling and/or resistance increase in solid heaters

Publication Date: 2017.03.28 XEROX CORP

AI summary

An improved fuser includes a heater which provides uniformity at the surface of a fuser roll that contacts an imaged sheet. The heater is configured to include a common tap at the center of a single heating trace. This allows for the benefits of a single trace configuration well while simultaneously providing a dedicated common line that does not have to be switched around.