This application claims the benefit under 35 U.S.C. §119(a) of Korean Patent Application No. 10-2004-0069561, filed in the Korean Intellectual Property Office on Sep. 1, 2004, the entire disclosure of which is incorporated herein by reference.
1. Field of the Invention
The present invention relates to a device for fusing a predetermined toner image on paper. More particularly, the present invention relates to a fusing device which controls the heating range of a fusing unit by inputting an eddy current generated by a transformer to a terminal corresponding to the size of paper selected from a plurality of terminals of the fusing unit.
2. Description of the Related Art
A conventional image printing apparatus comprises a fusing device which applies a predetermined pressure and amount of heat to a toner so as to fuse a predetermined toner image on paper. The fusing device includes a fusing unit which applies a predetermined amount of heat to the toner, and a pressurizer which applies predetermined pressure to the toner. The fusing unit includes a heater which generates heat used to fuse a toner image on the paper, and a toner fusing layer which transfers heat generated by the heating body onto the paper.
The fusing unit 10 of
Additionally, in a conventional fusing unit using a halogen lamp as a heat source, a warm-up time of several seconds to several minutes is required for the unit to reach a target fusing temperature after energy is supplied to the fusing unit. Thus, a user is required to wait for a long warm-up time when printing an image, regardless of the paper size.
Accordingly, a need exists for a system and method for more efficiently and quickly heating a fusing unit by considering a paper size.
The present invention substantially solves the above and other problems and provides other advantages, and provides a fusing unit for locally heating a toner fusing layer corresponding to the size of paper within a short warm-up time by using a predetermined eddy current.
The present invention also provides a fusing unit for locally heating a toner fusing layer corresponding to a paper size within a short warm-up time by simultaneously using induction heating and resistance heating.
The present invention also provides a fusing device for locally heating a toner fusing layer of a toner fusing unit corresponding to a paper size within a short warm-up time by using an eddy current generated by a transformer.
The present invention also provides a fusing device for locally heating a toner fusing layer of a toner fusing unit corresponding to a paper size within a short warm-up time by simultaneously using induction heating and resistance heating.
According to an aspect of the present invention, a unit is provided for fusing a toner image on paper, the unit comprising a heater to which an induced current is input and which is resistance-heated, a terminal unit having at least three or more terminals for supplying the induced current to a region of the heater corresponding to the size of the paper, and a toner fusing layer for fusing the toner image on the paper by heat transferred from the region of the heater.
According to another aspect of the present invention, a unit is provided for fusing a toner image on paper, the unit comprising a heater being resistance-heated by a predetermined alternating current and generating an alternating magnetic flux by the alternating current, a terminal unit having at least three or more terminals for supplying the alternating current to a region of the heater corresponding to the size of the paper, and a toner fusing layer for generating an eddy-current in response to the alternating magnetic flux and being induction-heated by the eddy current.
According to still another aspect of the present invention, a device is provided for fusing a toner image on paper, the device comprising a power supply unit to which a predetermined alternating current is input and which generates an induced-current in response to the alternating current, a fusing unit being resistance-heated by the induced-current and fusing the toner image on the paper using the generated heat, and a controller for controlling the induced-current supplied to the fusing unit according to the size of the paper.
According to yet another aspect of the present invention, a device is provided for fusing a toner image on paper, the device comprising an alternating current generator for generating a predetermined alternating current, a fusing unit being resistance-heated and induction-heated by the alternating current and fusing the toner image on the paper using the generated heat, and a controller for controlling the alternating current supplied to the fusing unit according to the size of the paper.
The above and other aspects and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings, in which:
Throughout the drawings, like reference numerals will be understood to refer to like parts, components and structures.
The rectifier 230 generates a DC signal by rectifying the AC signal supplied by the line filter 220. The rectifier 230 is a bridge rectifier comprising four diodes D1, D2, D3, and D4, and rectifies the AC signal into the DC signal according to the polarities of the four diodes D1, D2, D3, and D4. In yet other embodiments of the present invention, another type of line rectifier may be used as the rectifier 230 without departing from the scope of the present invention.
The AC generator 240 generates an AC signal from the DC signal supplied by the rectifier 230. The AC generator 240 comprises two capacitors C2 and C3, and two switches SW1 and SW2, and converts the DC signal rectified by the rectifier 230 into the AC signal by selectively switching the switches SW1 and SW2 on and off. The AC generator 240 generates a high-frequency or low-frequency AC signal from the DC signal generated by the rectifier 230 according to an application of the fusing device. In yet other embodiments of the present invention, another type of AC generator may be used as the AC generator 240 without departing from the scope of the present invention.
The insulation unit 250 generates an induced-current from the AC signal generated by the AC generator 240, and supplies the generated induced-current to the heater 262. The heater 262 comprises a heating body (not shown), which is resistance-heated by the induced-current, and a thin insulating layer (not shown) for preventing the heating body and a toner fusing layer (not shown) of the fusing unit 260 from being shorted to each other.
Accordingly, the current input by the power supply unit 210 is not directly supplied to the heating body, but the induced-current generated using the insulation unit 250 is supplied to the heating body, such that the insulation unit 250 electrically insulates the power supply unit 210 from the heating body. Hereinafter, a high-frequency transformer having a smaller volume than that of a low-frequency transformer, will be described as an example of the insulation unit 250. In yet other embodiments of the present invention, another type of transformer may be used as the insulation unit 250 without departing from the scope of the present invention
When an AC signal flows through a primary coil 252 of the transformer 250, a magnetic field around a secondary coil 254 changes, and an induced-current is generated in the secondary coil 254 by the changing magnetic field. The induced-current generated by the transformer 250 is supplied to the heater 262 of the fusing unit 260. The size of the induced-current can be controlled by a winding ratio of the primary coil 252 and the secondary coil 254. A current from the power supply unit 210 that flows through the primary coil 252 of the transformer 250 causes an induced-current in the secondary coil 254 of the transformer 250 by electromagnetic induction. The generated induced-current is supplied to the heater 262 of the fusing unit 260. Since the induced-current generated by the transformer 250 is supplied to the secondary coil 254 rather than the current of the power supply unit 210, the power supply unit 210 and a heating body (not shown) of the heater 262 are electrically insulated from each other. Thus, a thin insulating layer may be used for preventing the heating body and the toner fusing layer from being shorted to each other, as compared with conventional devices.
The fusing unit 260 is resistance-heated by the induced-current generated by the insulation unit 250. When the paper (not shown) passes through the fusing unit 260, the fusing unit 260 fuses a toner image on the paper using generated heat. The heater 262 of the fusing unit according to an embodiment of the present invention is comprised of a heating body and an insulating layer. The heater 262 is further comprised of a plurality of terminals 1, 2, and 3, to which the induced current is input, and wherein the plurality of terminals are connected to the heating body. The exemplary heater 262 shown in
As noted above, the fusing device comprises a controller 270, and a selector 280. A user inputs a user's command for selecting a paper size to be printed by using the selector 280. The selector 280 may be a user interface comprised of a touch screen or a key panel unit having a plurality of manipulation keys.
The controller 270 controls the induced-current supplied to the heater 262 according to the size of the paper selected by the selector 280. The controller 270 is illustrated as one type of a switch. In yet other embodiments of the present invention, another type of controller may be used as the controller 270 without departing from the scope of the present invention.
When the entire surface of the toner fusing layer of the fusing unit 260 is required to print the paper selected by the selector 280, the switch 270 is switched to a contact point 3′ connected to the third terminal 3 of the heater 262. Since the induced-current generated by the insulation unit 250 is always input to the first terminal 1, and in this case, also input to the third terminal 3, the entire surface of the heating body of the heater 262 is heated and the entire surface of the toner fusing layer is heated by heat generated in the heating body. When only a portion of the toner fusing layer of the fusing unit 260 is required to be heated so as to print the paper selected by the selector 280, the switch 270 is switched to a contact point 2′ connected to the second terminal 2 of the heater 262. Since the induced-current generated by the insulation unit 250 is always input to the first terminal 1, and in this case, also input to the second terminal 2, only a portion of the heating body of the heater 262 is heated and only a portion of the toner fusing layer is heated by the heat generated in the heating body.
Three terminals 1, 2, and 3, are electrically connected to the heating body 330. A first terminal 1 and a third terminal 3 are directly connected to both ends of the heating body 330, and a second terminal 2 may be connected to the heating body 330 via the insulating layer 340. Since the toner fusing layer 320 may be formed of a conductive metal, the heating body 330 and the toner fusing layer 320 can be connected to each other at a predetermined position of the heating body 330 so that the toner fusing layer 320 can be used as the second terminal 2.
When the entire surface of the heating body 330 is to be heated, the induced-current generated by the insulation unit 250 is supplied to the first terminal 1 and the third terminal 3 through the switch 270. When only a portion of the heating body 330 is to be heated, the induced-current generated by the insulation unit 250 is supplied to the first terminal 1 and the second terminal 2 through the switch 270.
A fusing roller is illustrated as one type of toner fusing layer 320 in the heater 262 of the fusing unit 260 shown in
The heating body 330 may be comprised of a coil. In yet other embodiments of the present invention, another type of heating body may be used as the heating body 330 without departing from the scope of the present invention.
As the thickness of the insulating layer 340 inserted between the toner fusing layer 320 and the heating body 330 increases, heat generated in the heating body 330 is not effectively transferred to the toner fusing layer 320. Thus, as the thickness of the insulating layer 340 decreases, heat generated in the heating body 330 can be more effectively transferred to the toner fusing layer 320. In addition, a tube-expansion adhesion portion 350 is fixedly disposed within the heating body 330 and closely adheres the heating body 330 and the toner fusing layer 320 to each other, so that heat generated in the heating body 330 can be more effectively transferred to the toner fusing layer 320.
The induced-current is supplied to the terminals corresponding to the size of the paper selected by the selector 280, and which are selected from among a plurality of terminals 1, 2, and 3, connected to the heating body 330 so that the toner fusing layer 320 can be locally heated when needed.
The fusing unit 450 of
If the AC signal flows through the induction coil, the induction coil is resistance-heated by its electrical resistance and a variable alternating magnetic flux is generated in the induction coil. Due to the alternating magnetic flux, an eddy current is generated in a toner fusing layer (not shown) placed on an upper portion of the induction coil, and the toner fusing layer is induction-heated by the eddy current. Induction heating used to heat the toner fusing layer and resistance heating will be described in greater detail below with reference to
The controller 460 supplies the AC signal to the terminals corresponding to the size of the paper selected by the selector 470 from among the plurality of terminals 4, 5, and 6, and the toner fusing unit is induction-heated and resistance-heated by the supplied AC signal.
The fusing unit 450 shown in
Since the AC signal generated in the AC generator 440 is directly input to the fusing unit 450 shown in
The coil 530 of the fusing unit 450 shown in
The induction coil 530 also has an electrical resistance. Thus, when a predetermined AC signal is input to the induction coil 530, heat corresponding to the resistance of the induction coil 530 is generated. Heat generated by the resistance of the induction coil 530 is resistance heat, and is indicated by arrows B shown in
Since the toner fusing layer 520 of the fusing unit according to embodiments of the present invention is simultaneously heated by using resistance heating generated in the induction coil 530, and by induction heating generated in the toner fusing layer 520, the fusing unit using induction heating has a shorter warm-up time than the fusing unit using only resistance heating, in which, Joule heat generated in the resistance coil inside the toner fusing portion is transferred to the toner fusing unit via the insulating layer.
The ratio of induction heat and resistance heat in a total amount of heat of the toner fusing unit can be adjusted according to the materials used for the induction coil 530, the number of turns of the induction coil 530, the materials used for the toner fusing layer 520, and a frequency of the AC signal applied to the induction coil 530, without departing from the scope of the present invention. For example, in the fusing device comprising coils made of copper and the toner fusing layer made of iron, when an AC signal having a voltage of 220 V, power of 1.2 kW, and frequency of 4.5 kHz, is input to the induction coil 530, it takes 20 seconds to heat the toner fusing layer 520 to a target fusing temperature of 180° C. When an AC signal having a voltage of 220 V, power of 1.2 kW, and frequency of 130 kHz, is input to the induction coil 530, it takes 12 seconds to heat the toner fusing layer 520 to the target fusing temperature of 180° C.
As described above, in the fusing device according to embodiments of the present invention, only the portion, or region of the toner fusing layer of the fusing unit through which the paper passes, is heated according to the size of the paper selected by the selector. Thus, in the fusing device according to embodiments of the present invention, an image printing apparatus is prevented from malfunctioning by a rapid temperature increase in a region in which the paper does not pass, and the life span of the image printing apparatus is extended by preventing uneven heating of the toner fusing unit.
In the fusing device according to embodiments of the present invention, since the power supply unit and the heater are electrically insulated from each other using the transformer, the fusing device comprises a fusing unit having a thin insulating layer. Thus, the toner fusing unit can be heated to the target fusing temperature more quickly and efficiently. Additionally, the heater may comprise any number of terminals at specific positions according to an application of the fusing device to provide greater flexibility as to which portion of the fuser is heated, as well as providing more efficient heating.
In the fusing device according to embodiments of the present invention, since the toner fusing unit is simultaneously heated by using induction heating and resistance heating, the toner fusing unit can be locally heated more quickly to the target fusing temperature.
While the invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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