Abstract: An apparatus and process are provided for forming a tubular article. A tube holder is mounted to a support stand via an automatic alignment device. A tubular metal sleeve is placed in the tube holder. A coating material is provided. A bullet-shaped or spherical element is passed through the metal sleeve such that the element runs along an inner circumferential surface of the metal sleeve. The automatic alignment device allows the metal sleeve and the tube holder to level themselves such that the element is substantially aligned with the metal sleeve as the element moves through the metal sleeve. The element spreads the coating material generally evenly along the inner circumferential surface of the metal sleeve as the element passes through the metal sleeve.

Abstract: An apparatus and process are provided for forming a tubular article. A tube holder is mounted to a support stand via an automatic alignment device. A tubular metal sleeve is placed in the tube holder. A coating material is provided. A bullet-shaped or spherical element is passed through the metal sleeve such that the element runs along an inner circumferential surface of the metal sleeve. The automatic alignment device allows the metal sleeve and the tube holder to level themselves such that the element is substantially aligned with the metal sleeve as the element moves through the metal sleeve. The element spreads the coating material generally evenly along the inner circumferential surface of the metal sleeve as the element passes through the metal sleeve.

Abstract: An apparatus and process are provided for forming a tubular article. A tube holder is mounted to a support stand via an automatic alignment device. A tubular metal sleeve is placed in the tube holder. A coating material is provided. A bullet-shaped or spherical element is passed through the metal sleeve such that the element runs along an inner circumferential surface of the metal sleeve. The automatic alignment device allows the metal sleeve and the tube holder to level themselves such that the element is substantially aligned with the metal sleeve as the element moves through the metal sleeve. The element spreads the coating material generally evenly along the inner circumferential surface of the metal sleeve as the element passes through the metal sleeve.

Abstract: An electrophotographic imaging device includes a print media transport assembly and a fuser positioned in association with the print media transport assembly. The fuser includes a heater assembly having a housing carrying a heater and a resilient pad. The resilient pad extends from the housing. A flexible belt is positioned around the heater assembly and adjacent to the resilient pad. A backup member is positioned in opposition to the heater assembly.

Abstract: In accordance with a first aspect of the present invention, a system is provided for fusing an unfixed toner image to a substrate comprising a rotatable hot fusing roll and a backup belt assembly. The belt assembly may comprise a backup belt and a housing structure including a nip forming pressure roll. The backup belt may be wrapped about the housing structure including the nip forming pressure roll. Preferably, the pressure roll applies a force to the belt so as to form the sole nip region between the rotatable fusing roll and the backup belt.

Abstract: An apparatus and process are provided for forming a tubular article. A tube holder is mounted to a support stand via an automatic alignment device. A tubular metal sleeve is placed in the tube holder. A coating material is provided. A bullet-shaped or spherical element is passed through the metal sleeve such that the element runs along an inner circumferential surface of the metal sleeve. The automatic alignment device allows the metal sleeve and the tube holder to level themselves such that the element is substantially aligned with the metal sleeve as the element moves through the metal sleeve. The element spreads the coating material generally evenly along the inner circumferential surface of the metal sleeve as the element passes through the metal sleeve.

Abstract: In accordance with a first aspect of the present invention, a system is provided for fusing an unfixed toner image to a substrate including a rotatable hot fusing roll and a backup belt assembly. The belt assembly may include a backup belt and a housing structure having a nip forming pressure roll. The backup belt may be wrapped about the housing structure including the nip forming pressure roll. The pressure roll includes a crown shape and the housing structure preferably includes structure for creating a generally uniform tension across the length of the belt in a direction transverse to a process direction.

Abstract: A fuser assembly within an image forming apparatus having a paper path along which substrates travel through the image forming apparatus including a heating member and a backup member cooperating with the heating member to form a nip therebetween for fusing images onto substrates passing through the nip. Also provided is structure for conveying substrates along the paper path to the nip, and a processor. The processor determines a relative humidity, determines if the relative humidity is above a predefined value corresponding to undesirable substrate curl; sets an interpage gap between conveyed substrates to a nominal value if the relative humidity is below the predefined value; and determines if the interpage gap should be increased beyond the nominal value if the relative humidity is above the predefined value. A corresponding method is provided.

Abstract: An apparatus is provided for fixing a toner image to a substrate including: a fixing member having a central axis and inner and outer surfaces; a heating element disposed within the fixing member for generating energy in the form of heat to heat the fixing member; and a back-up member cooperating with the fixing member to define a nip with the fixing member for receiving a substrate such that a toner image carried by the substrate is heated while in the nip. The heating element may have a center axis and be positioned near the fixing member inner surface such that the heating element center axis is spaced from the fixing member central axis.

Abstract: In accordance with an aspect of the present invention, an image heating apparatus is provided for fusing an unfixed toner image to a substrate including a housing base for supporting a heater, and a thin film or belt extending around the housing base and heater. The heater is held to the housing base by a fastener structure that may include a pair of retainer clips having opposing ends attached to the housing base and having a central portion extending across the heater for retaining the heater in position. The clips may include outwardly extending walls for engaging edges of the belt to maintain the lateral position of the belt.

Abstract: An apparatus is provided for fixing toner to a substrate including a heated fusing roller having a fusing surface. A heater element is located inside the fusing roller. A nip forming member cooperates with the fusing roller to define a fusing nip. A passive temperature control structure including a pair of members is located adjacent opposing end sections of the fusing roller, the passive temperature control structure operating to retain heat in the end sections. The passive temperature control structure may include heat reflecting members located adjacent to peripheral end portions of the hot roller to reflect heat back to the peripheral surface. In addition, the passive temperature control structure may include an end reflector facing axially toward an interior area or the hot roller for reflecting heat back to the interior of the hot roller.

Abstract: Fusing systems are provided that utilize a heated fusing roller in conjunction with a backup belt assembly to provide a large fusing region within a minimal amount of space. The heated fusing roller comprises a thin walled steel roll having an elastomeric inner layer and a non-resilient flouropolymer release layer. The thin wall steel core allows for relatively faster warm up times compared to conventional fusing systems. Moreover, the backup belt assembly allows for the varying of the pressure profile and the enhancement of media release. The utilization of this design minimizes the size of the system necessary to attain the adhesion of toner to the media, which in turn reduces the cost of the mechanism. Further, the use of the varying pressure nip minimizes the amount of friction between a belt support member and the belt itself, which may reduce friction, wear, and will reduce the risk of print quality defects.

Abstract: A method for controlling power to an electrical load using dual pulse width modulation (PWM) to minimize in-rush current to the electrical load, such as a heater element. An output from a power source, supplying an alternating current, is modulated by a first PWM control signal to provide a first modulated power level to the electrical load. The first modulated power level is modulated by a second PWM control signal to control power supplied to the electrical load at the first modulated power level. The first PWM control signal operates to control the number of half cycles of current in order to provide one-third, two-thirds or full cycle power. The second PWM control signal operates to define a duty cycle and period for providing the power defined by the first PWM control signal to the electrical load.

Abstract: A method of controlling a fuser having a heating member and a pressure member wherein the pressure member temperature is estimated from parameters set by a print engine and measured media throughput. Media throughput is used to determine a predicted pressure member steady temperature (SST) associated with the operating mode of the fuser. The predicted pressure member SST and an estimated pressure member starting temperature are used to calculate a pressure member temperature change, and the calculated temperature change is used to determine an estimated pressure member temperature. The print engine compares the estimated pressure member temperature to a predetermined temperature and reduces the heating member set point temperature if the predetermined temperature is exceeded to avoid the pressure member reaching a maximum temperature.

Abstract: A method of controlling a fuser having a heating member and a pressure member wherein the pressure member temperature is estimated from parameters set by a print engine and measured media throughput. Media throughput is used to determine a predicted pressure member steady state temperature (SST) associated with the operating mode of the fuser. The predicted pressure member SST and an estimated pressure member starting temperature are used to calculate a pressure member temperature change, and the calculated temperature change is used to determine an estimated pressure member temperature. The print engine compares the estimated pressure member temperature to a predetermined temperature and reduces the heating member set point temperature if the predetermined temperature is exceeded to avoid the pressure member reaching a maximum temperature.

Abstract: A method for controlling power to an electrical load using dual pulse width modulation (PWM) to minimize in-rush current to the electrical load, such as a heater element. An output from a power source, supplying an alternating current, is modulated by a first PWM control signal to provide a first modulated power level to the electrical load. The first modulated power level is modulated by a second PWM control signal to control power supplied to the electrical load at the first modulated power level. The first PWM control signal operates to control the number of half cycles of current in order to provide one-third, two-thirds or full cycle power. The second PWM control signal operates to define a duty cycle and period for providing the power defined by the first PWM control signal to the electrical load.