Embodiments herein generally relate to printing apparatus fuser systems and methods. Temperature uniformity across a belt fuser becomes a problem when using thin belts for rapid warm up fusers. In particular, fusing different paper widths presents a problem with portions of the belt outside the paper path becoming too hot. This is normally addressed by using segmented lamps or segmented induction heating coils together with several sensors and controllers for each of the segments.
More specifically, fusing of different media thicknesses and sizes causes problems of fuser overheating outside the paper for narrow media and poor fusing for thick media. The paper size problem is generally addressed by using several heating lamps with widths optimized to several paper sizes. This restricts the allowable paper sizes and also may require run length restrictions and decreased throughput to limit maximum temperature on the fuser surface. Increases in paper thickness may require decreases in throughput or set-point changes which require a large dead time.
The systems and methods of embodiments herein provide an improved manner in which to prevent overheating and uneven heating of a heating belt for a fuser within a printing apparatus. The embodiments described below incorporate a heat pipe in addition to a separate heater in a belt fusing system to achieve axial uniformity for any paper width and to allow simplified single source heating (uniform width heater that is not segmented). The heat pipe will maintain near isothermal conditions independent of the paper width or the heat input distribution. Thus, no shaping of the heating profile is required and only one sensor and controller would be needed. In embodiments herein, the heat pipe can be made thin with ribs for added structural stiffness. The belt allows separation of the belt heating heat pipe roll from the high pressure fusing nip. The embodiments herein allow for easily replaceable belts.
The embodiments herein use an apparatus comprising a media path that is adapted to transport media sheets within the printing apparatus. Fuser rolls are positioned along the media path, and the fuser rolls are adapted to fuse marking material on the media sheets as the media sheets pass between the fuser rolls. A heating belt is positioned to pass a first location between the fuser rolls and to pass a second location separate from the fuser rolls. A heater is positioned in the second location, and the heater is adapted to heat the heating belt. In addition, an iso-thermalizing roller is in contact with the heating belt. In some embodiments, the elements can be positioned in any order. In other embodiments, the elements are positioned such that the heating belt passes the elements in the following order: the heater, the fuser rolls, and then the iso-thermalizing roller.
A method using these apparatuses transports the media sheets along the media path within the printing apparatus and fuses marking material on the media sheets by transporting the media sheets between the fuser rolls that are positioned along the media path. As mentioned above, in some embodiments, the heating belt can pass the elements in any order. In other embodiments, the elements are positioned such that the heating belt passes the elements in the following order: the heater, the fuser rolls, and then the iso-thermalizing roller.
The passing of the heating belt over the iso-thermalizing roller distributes heat evenly across the heating belt because the iso-thermalizing roller comprises a fluid containing roller that is adapted to evenly distribute heat along its surface. The heater does not need to perform the slow and complicated operation of heating different parts of the heating belt differently. Instead, the heater can comprise a simplified induction-type heater or radiant-type heater uniform heater that applies an even amount of heat to all widths of the heating belt.
The embodiments herein achieve temperature uniformity for any media size and rapid set point changes to accommodate sheet to sheet media thickness variations. The embodiments herein combine rapid induction heating of a belt with a heat pipe for temperature control (uniformity). The embodiments herein are easily scalable to meet a wide speed range.
These and other features are described in, or are apparent from, the following detailed description.
Various exemplary embodiments of the systems and methods are described in detail below, with reference to the attached drawing figures, in which:
As mentioned above, fusing of different media thickness and sizes causes problems of fuser overheating outside the paper for narrow media and poor fusing for thick media. The paper size problem is generally addressed by using several heating lamps with widths optimized to several paper sizes. This restricts the allowable paper sizes and also may require run length restrictions and decreased throughput to limit maximum temperature on the fuser surface. Increases in paper thickness may require decreases in throughput or set-point changes which require a large dead time. A belt fuser allows separation of the fusing function from the heating function. With a belt system incorporating two rolls, heating can be accomplished at one of the rolls while fusing can be performed at the other roll. Separation of these functions allows the high pressures required in the fusing nip to be supplied at the fusing roll while the heating can be accomplished at the heating roll where forces are low. The embodiments described below incorporate a heat pipe in addition to a separate heater in a belt fusing system to achieve axial uniformity for any paper width and to allow simplified single source heating.
More specifically, as shown in
The heating source can be either induction heating 110, radiant lamp heating 108, or any other heating means which can supply heating to the roll. The induction heating can be applied to the heat pipe roll material and/or to the belt material.
Induction heating is advantageous because of the speed with which it can cycle on and off. Heating of the quartz envelope of a lamp to high temperature (probably substantially above heat roll temperature depending on the radiant energy balance) becomes a limiting factor in reducing warm-up time. The induction heating can be provided by a combination of eddy current losses and magnetic hysteresis losses depending on the composition of the heat roll and belt. Where hysteresis losses are dominant, the maximum temperature can be limited by the Curie temperature of the belt/heating roll material.
The belt and heating roll can be formed of composite materials separating the heat pipe function from the heating function, i.e. a magnetic hysteresis layer may be formed on either the belt and/or heating roll. Since the heat pipe tends to maintain the axial temperature uniformity, axial variations in heating rate can be easily tolerated as the heat pipe spreads the heat evenly across its outer surface. The heat pipe uses the phase change properties of the internal fluid to achieve high effective conductivity. See U.S. Pat. No. 5,689,767, which is fully incorporated herein by reference, for details of heat pipes. The heat pipe promotes the flow of condensed liquid to high heat input areas and flow of evaporated vapor to cooler heat loss areas. The limiting physical phenomena which enter into the design are liquid flow to heat input areas, peak heat flux in boiling over the heat input areas and maximum vapor flow rate to the heat outflow areas of the heat pipe. In one example, water can be used as the working fluid for the heat pipe, although as would be understood, different materials can be used within the heat pipe, depending upon the specific application of the device. If water were used, the peak heat flux in nucleate boiling for liquid-vapor equilibrium at 480 K would be:
For example, if one wanted to provide 1000 Watts of heating, they would need a minimum heat pipe heating surface area of:
This calculation assumes the heat pipe is rotating fast enough to prevent the un-wetted portions from becoming hotter than the critical temperature required for nucleate boiling. For an estimate of the condensed liquid flow, it will be assumed that there is a level heat pipe and this will determine the difference in liquid height required to produce the requisite liquid flow. For 1000W heat transferred by the heat pipe, at 480 K one would need to have a flow of working fluid of:
A two dimensional approximation of the liquid flow, where the liquid height is the driving force for the flow due to gravity, we obtain the approximate expression for the volume flow per unit width of liquid as:
For a width of 1 cm, the required volume flow rate is:
For a length of 0.5 m, the required difference in liquid height is:
If the liquid height at the right end is assume to be 2 mm the liquid height on the left end is:
The required vapor velocity for 1000 W and a heat pipe diameter of 35 mm is:
This vapor velocity is far below choked flow conditions and would require very little pressure drop along the length of the heat pipe as well as little drag opposing the liquid flow. Condensation heat transfer would not be a limiting condition for thin liquid layers. Thus, the design of the heat pipe heating roll system requires a large enough heat input area in contact with the liquid to maintain the heating flux below the peak heat flux for nucleate boiling. From the approximate liquid flow analysis, very small liquid height gradients are required for carrying the liquid from the condensing regions to the boiling regions. If heating is to be supplied from one end, then slight tilting of the heat pipe may be desirable. Otherwise, a liquid height of a few mm or such as to wet the entire length within some levelness specification would be sufficient. The vapor flow does not limit the operation of the heat pipe for roll diameters typically used in fusing systems. To assess the effectiveness of the heat pipe in maintaining axial temperature uniformity on the belt surface, a numerical example was implemented based on a 3-dimensional thermal model. Two belt fusers were used: (i) a 0.27 mm thick polyimide belt, and (ii) a 0.001″ thick nickel belt. In both cases, an iron heating roll and a heat pipe heating roll were used. The maximum power input to the heating roll was set to 1500 Watts and the temperature set point was 200° C. on the surface of the heating roll. The example was run for warm-up and a 100 copy run at 55 ppm/362 mm/s.
Both
The temperature rise in the induction heating section depends on the power applied, the speed of the belt, the length of the induction heating zone, and the thickness, electrical properties, and heat capacity of the belt. The belt is designed to minimize the time required for changing the belt temperature. The rapidity with which set point changes can be accomplished also depends on the type of controls instituted in the induction heating power supply. The range of possible controllers goes from simple cycle stealing, to pulse width modulation, to frequency modulation. The simplest controllers for induction heating power supplies allow cycle stealing at, for example, 120 hz. If the process speed is 10 ips, and the induction heating zone is 2 inch, the transit time is 0.2 seconds. Thus, in this simplified example, there would 24 cycles during transit through the heating zone. This allows switching between any of 24 power levels within the 0.2 second transit time. Better controls can be instituted by using pulse width modulation which allows 128, 256, or any other number of different power levels. Whichever controller type is used, this fuser allows rapid switching of the temperature set point. The time required for the set point switch is one transit time through the induction heating section.
Since the transit time is on the order of the inter-copy gap time, this fuser allows page to page variation in the set point when supplied with information regarding the incoming sheet thickness or desired set point for optimal fusing at the rated throughput. Any width of media can be fused with little overheating outside the paper path by using the iso-thermalizing roll. Advantages of embodiments herein include accommodation of thick paper without sacrifice in productivity or the need for large dead time and the prevention of overheating outside the paper path, as demonstrated in
More specifically,
To achieve better temperature uniformity in high productivity color engines where the belt features a thick SiR overcoat, an external iso-thermalizing roll 120 may be used as in combination with a tension roll 118 as in
Thus, the systems and methods of embodiments herein provide an improved manner in which to prevent overheating and uneven heating of a heating belt for a fuser within a printing apparatus. The embodiments described below incorporate a heat pipe in addition to a separate heater in a belt fusing system to achieve axial uniformity for any paper width and to allow simplified single source heating (uniform width heater that is not segmented). The heat pipe will maintain near isothermal conditions independent of the paper width or the heat input distribution. Thus, no shaping of the heating profile is required and only one sensor and controller would be needed. In embodiments herein, the heat pipe can be made thin with ribs for added structural stiffness. The belt allows separation of the belt heating heat pipe roll from the high pressure fusing nip. The embodiments herein allow for easily replaceable belts.
As shown in flowchart form in
The passing of the heating belt over the iso-thermalizing roller distributes heat evenly across the heating belt because the iso-thermalizing roller comprises a fluid containing roller that is adapted to distribute heat along its surface. The heater does not need to perform the slow and complicated operation of heating different parts of the heating belt differently. Instead, the heater can comprise a simplified induction-type heater or radiant-type heater uniform heater that applies an even amount of heat to all widths of the heating belt.
It will be appreciated that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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