Patent Grant
11829091
This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application No. 2021-138826, filed on Aug. 27, 2021, in the Japan Patent Office, the entire disclosure of which is hereby incorporated by reference herein.
Embodiments of the present disclosure generally relate to a belt device, a fixing device, and an image forming apparatus.
One type of image forming apparatus such as a copier or a printer includes a fixing device using an endless belt as a belt device. The fixing device includes a heater inside the loop of the belt. The belt slides on the heater or on a sliding sheet on the heater.
This specification describes an improved belt device that includes a belt, a secured member, a pressure rotator, and lubricant. The belt is rotatable and has an endless shape. The belt includes an inner portion having an inner circumferential surface. The inner portion has an elastic power of 55% or more. The inner circumferential surface of the belt slides on the secured member. The pressure rotator includes a porous elastic body and presses the secured member via the belt to form a nip between the belt and the pressure rotator. The lubricant is interposed between the inner circumferential surface of the belt and the secured member.
A more complete appreciation of the disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:
The accompanying drawings are intended to depict embodiments of the present invention and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views.
In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.
Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms “a” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Identical reference numerals are assigned to identical components or equivalents and a description of those components is simplified or omitted.
With reference to drawings, a description is given of a belt device according to embodiments of the present disclosure, a fixing device using the belt device, and an image forming apparatus such as a laser printer using the belt device. The “belt device” in the present disclosure means a device including a rotatable endless belt, a secured member having a slide surface on which the inner surface of the belt slides, a pressure rotator in contact with the secured member via the belt forming a nip between the belt and the pressure rotator, and lubricant interposed between the secured member and the inner surface of the belt. The “fixing device” means a device that conveys a sheet as a recording medium to record an image to the nip between the belt and the pressure rotator and fixes unfixed toner onto the sheet. The “image forming apparatus” means an apparatus that includes the fixing device and applies developer or ink to the sheet to form the image on the sheet.
The laser printer is an example of the image forming apparatus. Therefore, the image forming apparatus of the present disclosure is not limited to the laser printer. In other words, the image forming apparatus may be a copier, a facsimile machine, a printer, a plotter, an inkjet recording apparatus, or a multifunction peripheral having at least two of copying, printing, facsimile transmission, plotting, scanning, and inkjet recording capabilities.
The identical or similar parts in each drawing are designated by the same reference numerals, and the duplicate description thereof is appropriately simplified or omitted. Further, size (dimension), material, shape, and relative positions used to describe each of the components and units are examples, and the scope of the present disclosure is not limited thereto unless otherwise specified.
Although the “recording medium” is described as the “sheet” in the following embodiments, the “recording medium” is not limited to the sheet of paper. Examples of the “recording medium” include not only the sheet of paper but also an overhead projector (OHP) transparency sheet, a fabric, a metallic sheet, a plastic film, and a prepreg sheet including carbon fibers previously impregnated with resin.
Examples of the “recording medium” include all media to which developer or ink can be adhered, and so-called recording paper and recording sheets. Examples of the “sheet” include thick paper, a postcard, an envelope, thin paper, coated paper (e.g., coat paper and art paper), and tracing paper, in addition to plain paper.
The term “image forming” used in the following description means not only giving an image having a meaning, such as a character or a figure, to a medium but also giving an arbitrary image having no meaning, such as a pattern, to a medium.
A configuration of the image forming apparatus according to an embodiment is described below.
The image forming apparatus 100 includes four process units 1K, 1Y, 1M, and 1C as image forming devices. Suffixes, which are K, Y, M, and C, are used to indicate respective colors of toners (black, yellow, magenta, and cyan toners in this example) for the process units. The process units 1K, 1Y, 1M, and 1C form images of color toners of black (K), yellow (Y), magenta (M), and cyan (C) corresponding to color separation components of a color image.
The process units 1K, 1Y, 1M, and 1C respectively include toner bottles 6K, 6Y, 6M, and 6C containing different color toners. The process units 1K, 1Y, 1M, and 1C have a similar structure except the color of toner. Thus, the configuration of the one process unit 1K is described below, and the descriptions of the other process units 1Y, 1M, and 1C are omitted.
The process unit 1K includes an image bearer 2K such as a photoconductor drum, a photoconductor cleaner 3K, and a discharger. The process unit 1K further includes a charging device 4K as a charger that uniformly charges the surface of the image bearer 2K and a developing device 5K as a developing unit that performs visible image processing to an electrostatic latent image formed on the image bearer 2K. The process unit 1K is detachably attachable to a main body of the image forming apparatus 100. Consumable parts of the process unit 1K can be replaced at one time.
An exposure device 7 is disposed above the process units 1K, 1Y, 1M, and 1C in the image forming apparatus 100. The exposure device 7 performs writing and scanning based on image data, in other words, irradiates the image bearer 2K with laser light L emitted by a laser diode and reflected by mirrors 7a based on the image data.
A transfer device 15 is disposed below the process units 1K, 1Y, 1M, and 1C in the present embodiment. The transfer device 15 corresponds to a transfer unit TM in
The intermediate transfer belt 16 is stretched around and entrained by the primary transfer rollers 19K, 19Y, 19M, and 19C, a drive roller 18, and a driven roller 17 to rotate in a circulating manner. A secondary transfer roller 20 is disposed opposite the drive roller 18 to contact the intermediate transfer belt 16. Note that, when the image bearers 2K, 2Y, 2M, and 2C serve as primary image bearers to bear images of the respective colors, the intermediate transfer belt 16 serves as a secondary image bearer to bear a composite image in which the images on the respective image bearers 2K, 2Y, 2M, and 2C are superimposed one on another.
A belt cleaner 21 is disposed downstream from the secondary transfer roller 20 in a direction of rotation of the intermediate transfer belt 16. A cleaning backup roller is disposed opposite the belt cleaner 21 via the intermediate transfer belt 16.
A sheet feeder 200 including a tray loaded with sheets P is disposed in a lower portion of the image forming apparatus 100. The sheet feeder 200 serves as a recording-medium supply device and can store a bundle of a large number of sheets P as recording media. The sheet feeder 200 is integrated as a single unit together with a sheet feed roller 60 and a roller pair 210 as a conveyor for the sheets P.
The sheet feeder 200 is detachably inserted in the main body of the image forming apparatus 100 to supply the sheet. The sheet feed roller 60 and the roller pair 210 are disposed at an upper portion of the sheet feeder 200 and convey the uppermost one of the sheets P in the sheet feeder 200 to a sheet feeding path 32.
A registration roller pair 250 as a separation conveyor is disposed near the secondary transfer roller 20 and upstream from the secondary transfer roller 20 in a sheet conveyance direction and can temporarily stop the sheet P fed from the sheet feeder 200. Temporarily stopping the sheet P causes slack on the leading-edge side of the sheet P and corrects a skew of the sheet P.
A registration sensor RS is disposed immediately upstream from the registration roller pair 250 in the sheet conveyance direction and detects passage of a leading end of the sheet. When a predetermined time passes after the registration sensor RS detects the passage of the leading end of the sheet, the sheet contacts the registration roller pair 250 and temporarily stops.
Conveyance rollers 240 are disposed downstream from the sheet feeder 200 to convey the sheet conveyed to the right side from the roller pair 210 upward. As illustrated in
The roller pair 210 includes a pair of an upper roller and a lower roller. The roller pair 210 can adopt a friction reverse roller (feed and reverse roller (FRR)) separation system or a friction roller (FR) separation system.
In the FRR separation system, a separation roller (a return roller) is applied with a certain amount of torque in a counter sheet feeding direction from a driving shaft via a torque limiter and pressed against a feed roller to separate sheets in a nip between the separation roller and the feed roller. In the FR separation system, the separation roller (a friction roller) is supported by a secured shaft via a torque limiter and pressed against a feed roller to separate sheets in a nip between the separation roller and the feed roller.
The roller pair 210 in the present embodiment is configured as the FRR separation system. That is, the roller pair 210 includes a feed roller 220 and a separation roller 230. The feed roller 220 is an upper roller of the roller pair 210 and conveys a sheet toward an inner side of the image forming apparatus 100. The separation roller 230 is a lower roller of the roller pair 210. A driving force acting in a direction opposite a direction in which a driving force is given to the feed roller 220 is given to the separation roller 230 by a drive shaft through a torque limiter.
The separation roller 230 is pressed against the feed roller 220 by a biasing member such as a spring. A clutch transmits the driving force of the feed roller 220 to the sheet feed roller 60. Thus, the sheet feed roller 60 rotates counterclockwise in
The registration roller pair 250 feeds the sheet P, which has contacted the registration roller pair 250, toward a secondary transfer nip between the secondary transfer roller 20 and the drive roller 18, which is illustrated as a transfer nip N in
A post-transfer conveyance path 33 is disposed above the secondary transfer nip between the secondary transfer roller 20 and the drive roller 18. The fixing device 300 is disposed near an upper end of the post-transfer conveyance path 33.
The fixing device 300 includes a fixing belt 310 that is a flexible endless belt and a pressure roller 320 as a pressure rotator that rotates while pressing against the fixing belt 310 with a predetermined pressure.
A post-fixing conveyance path 35 is disposed above the fixing device 300 and branches into a sheet ejection path 36 and a reverse conveyance path 41 at the upper end of the post-fixing conveyance path 35. At this branching portion, a switching member 42 is disposed and pivots on a pivot shaft 42a. At an opening end of the sheet ejection path 36, a pair of sheet ejection rollers 37 is disposed.
The reverse conveyance path 41 begins from the branching portion and converges into the sheet feeding path 2. Additionally, a reverse conveyance roller pair 43 is disposed midway in the reverse conveyance path 41. An upper face of the image forming apparatus 100 is recessed to an inner side of the image forming apparatus 100 and serves as an output tray 44.
A powder container 10 such as a toner container is disposed between the transfer device 15 and the sheet feeder 200. The powder container 10 is removably installed in the main body of the image forming apparatus 100.
Suitable sheet conveyance in the image forming apparatus 100 according to the present embodiment needs a predetermined length from the sheet feed roller 60 to the secondary transfer roller 20. The powder container 10 is disposed in a dead space caused by that distance to keep the entire image forming apparatus compact.
A transfer cover 8 is disposed above the sheet feeder 200 and on a front side in a direction to which the sheet feeder 200 is pulled out. The transfer cover 8 can be opened to check an interior of the image forming apparatus 100. The transfer cover 8 includes a bypass feed roller 45 for bypass sheet feeding and a bypass feeder 46 for the bypass sheet feeding.
Next, a basic operation of the image forming apparatus (illustrated as the laser printer) according to the present embodiment is described below with reference to
First, operations of a simplex or single-sided printing are described.
The sheet feed roller 60 rotates according to a sheet feeding signal from a controller in the image forming apparatus 100. The sheet feed roller 60 separates the uppermost sheet from a bundle of sheets P (also referred to as a sheet bundle) loaded in the sheet feeder 200 and feeds the uppermost sheet to the sheet feeding path 32.
When the leading edge of the sheet P, which has been fed by the sheet feed roller 60 and the roller pair 210, reaches a nip of the registration roller pair 250, the sheet P is slackened and temporarily stopped by the registration roller pair 250. The registration roller pair 250 corrects the skew on the leading-edge side of the sheet P and rotates in synchronization with an optimum timing so that a toner image formed on the intermediate transfer belt 16 is transferred onto the sheet P.
In the case that the sheet P is fed from the bypass feeder 46, sheets P of the sheet bundle loaded on the bypass feeder 46 are fed one by one from the uppermost sheet of the sheet bundle by the bypass feed roller 45. Then, the sheet P passes a part of reverse conveyance path 41 and is conveyed to the nip of the registration roller pair 250. The subsequent operations are the same as the sheet feeding operations from the sheet feeder 200.
As to image formation, operations of the process unit 1K are described as representative, and descriptions of the other process units 1Y, 1M, and 1C are omitted here. First, the charging device 4K uniformly charges the surface of the image bearer 2K to high potential. The exposure device 7 irradiates the surface of the image bearer 2K with laser light L according to image data.
The surface of the image bearer 2K irradiated with the laser light L has an electrostatic latent image due to a drop in the potential of the irradiated portion. The developing device 5K includes a developer hearer to bear a developer including toner and transfers unused black toner supplied from the toner bottle 6K onto the irradiated portion of the surface of the image bearer 2K having the electrostatic latent image, through the developer bearer.
The image bearer 2K to which the toner has been transferred forms (develops) a black toner image on the surface of the image bearer 2K. The black toner image formed on the image bearer 2K is transferred onto the intermediate transfer belt 16.
The photoconductor cleaner 3K removes residual toner remaining on the surface of the image bearer 2K after an intermediate transfer operation. The removed residual toner is conveyed by a waste toner conveyor and collected to a waste toner container in the process unit 1K. The discharger discharges the remaining charge on the image bearer 2K from which the remaining toner is removed by the photoconductor cleaner 3K.
Similarly, toner images are formed on the image bearers 2Y, 2M, and 2C in the process units 1Y, 1M, and 1C for the colors, and color toner images are transferred to the intermediate transfer belt 16 such that the color toner images are superimposed on one on another.
The intermediate transfer belt 16 on which the color toner images are transferred and superimposed travels such that the color toner images reach the secondary transfer nip between the secondary transfer roller 20 and the drive roller 18. The registration roller pair 250 rotates to nip the sheet P contacting the registration roller pair 250 at a predetermined timing and conveys the sheet P to the secondary transfer nip of the secondary transfer roller 20 at a suitable timing such that the toner image on the intermediate transfer belt 16 is transferred onto the sheet P. In this manner, the toner image on the intermediate transfer belt 16 is transferred to the sheet P sent out by the registration roller pair 250.
After the toner image is transferred onto the sheet P, the belt cleaner 21 removes residual toner from the intermediate transfer belt 16. In this case, the residual toner is toner that has failed to be transferred onto the sheet, and therefore remains on the intermediate transfer belt 16. The waste toner conveyor conveys the toner removed from the intermediate transfer belt 16 to the powder container 10, and the toner is collected inside the powder container 10.
The sheet P having the transferred composite toner image is conveyed to the fixing device 300 through the post-transfer conveyance path 33. The sheet P conveyed to the fixing device 300 is nipped by the fixing belt 310 and the pressure roller 320. The unfixed toner image is fixed onto the sheet P under heat and pressure in the fixing device 300. The sheet P, on which the composite toner image has been fixed, is sent out from the fixing device 300 to the post-fixing conveyance path 35.
When the fixing device 300 sends out the sheet P, the switching member 42 is at a position at which the upper end of the post-fixing conveyance path 35 is open, as indicated by the solid line of
Next, a description is given of operations of a duplex or double-sided printing. In the case of double-sided printing, firstly, the toner image is transferred onto the sheet P, and the fixing device 300 fixes the unfixed toner image to the sheet P in the same manner as the single-sided printing. After the fixing device 300 fixes the toner image to the sheet P, the sheet P is sent from the fixing device 300 to the sheet ejection path 36. At a timing at which the trailing edge of the sheet P passes through the switching member 42, the switching member 42 pivots on the pivot shaft 42a as indicated with a dashed line in
The sheet P sent out to the reverse conveyance path 41 reaches the registration roller pair 250 via the reverse conveyance roller pair 43. The registration roller pair 250 temporarily stops the sheet P to correct the leading-edge skew and sends the sheet P to the secondary transfer nip at the optimum timing.
The bias applied at the secondary transfer nip electrostatically transfers the toner image formed by the same operations as above-described image forming operations onto the sheet P. After the toner image is transferred to the sheet P, the sheet P is conveyed to the fixing device 300 through the post-transfer conveyance path 33. The sheet P conveyed to the fixing device 300 is nipped by the fixing belt 310 and the pressure roller 320. The unfixed toner image is fixed onto the sheet P under heat and pressure in the fixing device 300.
The sheet P having the toner images fixed to both front and back sides of the sheet P in this manner is sent out from the fixing device 300 to the post-fixing conveyance path 35. At this time, the switching member 42 is returned to the position at which the upper end of the post-fixing conveyance path 35 is open, as indicated by the solid line of
The sheet P sent out from the fixing device 300 is sent to the sheet ejection path 36 via the post-fixing conveyance path 35. The pair of sheet ejection rollers 37 ejects the sheet P to the output tray 44. Thus, the duplex printing is completed.
Next, a description is given of the fixing device 300 according to the present embodiment of the present disclosure.
Various types of fixing devices 300 to 300C exist as illustrated in
As illustrated in
The fixing belt 310 is a thin endless belt and includes, for example, a tubular base 313 mainly made of polyimide (PI). The tubular base 313 has an outer diameter of 25 mm and a thickness of 40 to 120 μm. The base 313 of the fixing belt 310 may be made of heat-resistant resin such as polyetheretherketone (PEEK) or metal such as nickel (Ni) or stainless steel (Stainless Used Steel (SUS)), in addition to polyimide. In the case that the base 313 is made of metal, a sliding layer made of polyimide, polytetrafluoroethylene (PTFE), or the like may be on the inner circumferential surface of the base 313.
The fixing belt 310 further includes a release layer 314 serving as an outermost surface layer. The release layer 314 is made of fluororesin, such as tetrafluoroethylene-perfluoroalkylvinylether copolymer (PFA) or polytetrafluoroethylene (PTFE) and has a thickness of froth 5 μm to 50 μm to enhance durability of the fixing belt 310 and facilitate separation of the sheet P from the fixing belt 310. Optionally, an elastic layer that is made of rubber or the like and has a thickness in a range of from 50 μm to 500 μm may be interposed between the base 313 and the release layer 314.
The pressure roller 320 having, for example, an outer diameter of 25 mm, includes a core 321 that is a solid iron core, an elastic layer 322 on the outer circumferential surface of the core 321, and a release layer 323 formed on the outer circumferential surface of the elastic layer 322. The elastic layer 322 is, for example, made of foamed rubber and has a thickness of 3.5 mm. The release layer 323 is, for example, made of fluororesin and has a thickness of approximately 40 μm.
A biasing member such as a spring presses the pressure roller 320 against the fixing belt 310 to press the pressure roller 320 against the outer circumferential surface of the fixing belt 310. Thus, a fixing nip SN as a nip is formed between the fixing belt 310 and the pressure roller 320. In other words, the fixing nip SN is formed on a contact portion between the fixing belt 310 and the pressure roller 320.
The stay 350 and the heater holder 340 are disposed inside the loop of the fixing belt 310.
The heater holder 340 holds the heater 330. Since the heater bolder 340 is subject to temperature increase by heat from the heater 330, the heater holder 340 is preferably made of a heat-resistant material. In the case that the heater holder 340 is made of heat-resistant resin having low heat conductivity, such as a liquid crystal polymer (LCP) or polyether ether ketone (PEEK), the heater holder 340 can have a heat-resistant property and reduce heat transfer from the heater 330 to the heater holder 340. As a result, the beater 330 can efficiently heats the fixing belt 310.
The stay 350 supports the heater holder 340. The stay 350 supports a stay side face of the heater holder 340. The stay side face is opposite a nip side face of the heater holder 340 facing the fixing nip SN. Accordingly, the stay 350 prevents the heater holder 340 from being bended by a pressing force of the pressure roller 320. Thus, the fixing nip SN having a uniform width is formed between the fixing belt 310 and the pressure roller 320. The stay 350 is preferably made of an iron-based metal such as steel use stainless (SUS) or steel electrolytic cold commercial (SECC) that is electrogalvanized sheet steel to ensure rigidity.
The heater 330 extends in a longitudinal direction of the fixing belt 310 (that is a sheet width direction intersecting a sheet conveyance direction). In addition, the heater 330 is in contact with the inner circumferential surface or the fixing belt 310 to heat the inner circumferential surface of the fixing belt 310. Optionally, the fixing device may include a beater to heat the pressure roller 320. The heater 330 according to the present embodiment includes a planar substrate 341, a resistive heat generator 370 disposed on a fixing nip side of the substrate 341, and an insulation layer 385 covering the resistive heat generators 370. The fixing nip side of the substrate 341 faces the fixing nip SN. The substrate 341 is made of a material having excellent heat resistance and insulating properties, such as polyimide, glass, mica, or ceramic such as alumina or aluminum nitride. Alternatively, the substrate 341 may be an insulation layer formed on a metal plate made of metal (that is a conductive material) such as steel use stainless (SUS), iron, or aluminum. In particular, the substrate 341 made of a high thermal conductive material such as aluminum, copper, silver, graphite, or graphene improves the thermal uniformity of the heater 330 and image quality. The resistive heat generator 370 is, for example, produced as below. Silver-palladium (AgPd), glass powder, and the like are mixed to make paste. The paste is screen-printed on the surface of the substrate 341. Thereafter, the substrate 341 is subject to firing. Then, the resistive beat generator 370 is produced. The material of the resistive heat generator 370 may contain a resistance material, such as silver alloy (e.g., AgPt) or ruthenium oxide (e.g., RuO2). The insulation layer 385 is made of a material having excellent heat resistance and insulating properties, such as polyimide, glass, mica, or ceramic such as alumina or aluminum nitride.
A thermistor TH as a temperature detector is disposed on the heater 330. The output of the heater 330 is controlled based on temperatures detected by the thermistor TH to maintain the temperature of the fixing belt 310 to be a predetermined temperature. The thermistor TH in the present embodiment is disposed so as to be in contact with the substrate 341 of the heater 330, but the temperature detector that detects the temperature of the heater 330 is not limited to a contact type temperature sensor. The temperature detector may be a non-contact type temperature sensor.
In the fixing device according to the above-described present embodiment of the present disclosure, the heater is in contact with the inner circumferential surface of the fixing belt, and rotations of the pressure roller rotate the fixing belt. As a result, the fixing belt slides on the heater. The fixing belt sliding on the heater may generate abnormal noise, and the fixing belt may wear.
One of countermeasures to prevent the above-described problems is applying lubricant 50 such as grease to a sliding portion between the fixing belt and the heater as illustrated in a partial enlarged view in
However, in the fixing device including the pressure roller as the pressure rotator that includes the elastic layer made of foamed rubber like the fixing device according to the present embodiment, heat tends to deteriorate the lubricant and decrease an amount of the lubricant. Since the pressure roller including a porous elastic body made of foamed rubber or the like has a lower thermal conductivity and a higher thermal insulation property than the pressure roller including the elastic layer made of solid rubber that is not the porous elastic body, passing sheets each having an width smaller than the width of the heater (that is a heat generation width) through the fixing device causes a remarkable temperature increase of the fixing belt in a non-sheet-passing region (that is a non-recording-medium-passing region) through which the sheet does not pass. The remarkable temperature increase reduces viscosity of the lubricant and deteriorates lubricant properly. In addition, the heat vaporizes the lubricant and gradually decreases the amount of lubricant interposed between the fixing belt and the heater. As a result, abrasion of the fixing belt occurs in the non-sheet-passing region. The abrasion generates abrasion powder. The abrasion powder is diffused into a portion of the fixing belt facing a sheet-passing region that is a region through which the sheet passes. The abrasion powder puts minute scratches on the surface of the fixing belt, which may generate an abnormal image.
The present inventors conducted tests each evaluating the abrasion of fixing belt to improve the abrasion resistance of the fixing belt. As a result, the present inventors found that increasing an elastic power of an inner portion having the sliding surface of the fixing belt improves the abrasion resistance of the fixing belt. The following describes the relationship between the elastic power and the abrasion resistance.
Firstly, the elastic power is described.
The elastic power is obtained by taking a relationship between load and displacement of a member to which the load is applied, calculating the amount of work of elastic deformation, and dividing the amount of work of elastic deformation by the total amount of work (that is the sum of the amount of work of elastic deformation and an amount of work of plastic deformation). The elastic power is expressed by the following expression (1). The closer the elastic power is to 1 (100%), the more easily the member is elastically deformed.
Elastic power work of elastic deformation/(work of plastic deformation+work of elastic deformation)×100 (1)
A method for measuring the elastic power is as follows.
The elastic power may be measured by a loading-unloading test (i.e., an indentation test) of a micro surface hardness tester using a diamond indenter. Specifically, as illustrated in
The elastic power is obtained by recording the relationship between the load and the displacement (as illustrated in the graph of
The present inventors measured the elastic powers of the inner portions of the fixing belts in the present embodiment under constant temperature and humidity. Specifically, the present inventors measured the elastic powers under an environmental condition of a temperature of 23° C. and a relative humidity of 50%. The measurement was performed as follows. A Fischer scope HM-2000 ® (manufactured by Fischer Instruments K. K.) and a Vickers's indenter were used. The load was applied under the conditions of a set load 20 mN, a time 30 sec until reaching the maximum load, and a creep time 5 sec. Unloading was performed during 30 sec. However, the measurement may be performed by any device having an equivalent performance.
In the measurements, samples that were fixing belts were closely attached to a metal board to measure the elastic power. Since the elastic power is affected by the spring characteristics of the board, a rigid metal plate, slide glass, or the like is suitable as the board. The set load was adjusted so that the maximum displacement was 1/10 of the thickness of the inner portion to decrease influences due to factors of hardness and elasticity of layer adjacent to the inner portion (for example, the base made of metal in the fixing belt). Preferably, the elastic layer made of rubber and the release layer are removed when the measurement is performed to exclude the influence of the elastic, layer made of rubber and the release layer on the base. The present inventors removed the elastic layer and the release layer from the fixing belt when the measurement was performed.
The present inventors examined grades of wear volume of fixing belts having the inner portions with different elastic powers.
A test to evaluate the wear resistance of the fixing belt was performed as follows. The fixing belt was assembled to the fixing device. The heater heated the fixing belt and was controlled so that the temperature of the fixing belt was a constant temperature (that is a fixing temperature), and the fixing device repeated rotating the fixing belt and stopping the rotation of the fixing belt until the rotation distance of the fixing belt reached the lifetime distance. After the rotation distance of the fixing belt reached the lifetime distance, the present inventors evaluated wear volumes of fixing belts. The fixing device used in this evaluation test was configured by the fixing belt including a polyimide layer as the inner portion having the inner circumferential surface of the fixing belt, the heater as the nip formation pad including a glass layer, the heater holder, and the pressure roller including the elastic layer made of foamed rubber, and the fixing belt slid on the glass layer. The surface hardness of the inner circumferential surface of the fixing belt was about 500 N/mm2, and the surface hardness of the glass layer of the heater was about 3500 N/mm2. The surface hardness was measured by a measurement method in accordance with ISO14577, and the shoved amount of the indenter with respect to the inner circumferential surface of the fixing belt and the glass layer of the heater was set to 1 μm. After each of the evaluation tests, the inner portion of the fixing belt was worn, and large wear volumes caused gloss unevenness such as gross streaks in a solid image. Results of the evaluation tests were expressed by grades of wear volumes 1 to 5 as illustrated in the vertical axis of
Grade 1 means that a large number of gross streaks clearly occurred in the solid image after the evaluation test. Grade 2 means that gross streaks clearly occurred in the solid image after the evaluation test. Grade 3 means that gross streaks slightly occurred in the solid image after the evaluation test. Grade 4 means that the gloss streak was not recognized in the solid image after the evaluation test, in other words, the wear of the fixing belt does not affect the image quality. Grade 5 means that a streak was not found in the inner circumferential surface of the fixing belt after the evaluation test. When the grade of wear volume was grade 3, the fixing belt worn after the evaluation test was evaluated as a practically usable level.
From the test results illustrated in
Based on the above, the present inventors set the elastic power of the inner portion having the sliding surface of the fixing belt to 55%, or more in the fixing device according to the present disclosure. As a result, the above-described setting improves the wear resistance of the inner portion having the sliding surface of the fixing belt and can effectively prevent the occurrence of abnormal noise at the sliding portion over a long period of time. In addition, the present inventors found that setting, the elastic power of the inner portion having the sliding surface of the fixing belt to 62% or more can effectively prevent the occurrence of abnormal noise at the sliding portion over a long period of time and prevent occurrence of abnormal images such as the streak. As a result, high-quality images were provided.
In the above-described evaluation tests, the fixing belt slid on a slide, surface of the heater that is the surface of the glass layer having a larger surface hardness than the inner portion having the sliding surface of the fixing belt. However, the present disclosure is not limited to this surface hardness relationship. Since the relationship between the elastic power and the wear resistance is different from the relationship between the surface hardness of the sliding surface of the fixing belt and the surface hardness of the slide surface of the heater, the relationship between the elastic power and the wear resistance is established regardless of the relationship between the surface hardness of the sliding surface of the fixing belt and the surface hardness of the slide surface of the heater. Accordingly, even in the case that the surface hardness of the slide surface of the heater is smaller than the surface hardness of the inner portion having the sliding surface of the fixing belt, which is opposite to the above-described embodiments, setting the elastic power of the inner portion having the sliding surface of the fixing belt to 55% or more improves the wear resistance of the inner portion having the sliding surface of the fixing belt.
Next, a relationship between the elastic power and friction coefficients is described.
The present inventors performed experiments to examine the relationship between the elastic power and friction coefficients in the fixing belt. The present inventors prepared three types of fixing belt samples having different elastic powers of the inner portions having the sliding surfaces and measured the coefficient of kinetic friction and the coefficient of static friction in each sample using a ring-on tester 400 illustrated in
The coefficient of kinetic friction was measured under the following conditions.
The tip end of the abutment had a contact surface having a circular shape with a diameter of 10 mm.
An amount of the lubricant applied to the tip end of the abutment was 50 mg.
The lubricant was grease HP300 ™ manufactured by Dow Corning Toray Co., Ltd.
Rotational speed of the rotating disk was 250 mm/sec at a contact portion of the abutment.
Contact load of the abutment was 1 kg/cm2. Temperature was maintained to be 23° C. The coefficient of static friction was measured using the abutment having the tip end to which the lubricant was not applied. Other measurement conditions of the coefficient of static friction were the same as the measurement conditions of the coefficient of kinetic friction.
As illustrated in
Then the present inventors performed sensory tests to examine occurrences of the vibration and the abnormal noise and obtained results illustrated in
According to the present embodiment, setting the elastic power of the inner portion including the sliding surface of the fixing belt to 55% or more as described above can effectively improve the wear resistance of the fixing belt. The above-described setting can reduce the wear of the fixing belt over a long period of time even in a configuration in which the pressure rotator includes the porous elastic body, that is, a configuration in which the temperature rise is likely to occur in the fixing belt facing the non-sheet-passing region and causes deterioration of the lubricant and a decrease in the amount of the lubricant due to heat. In addition, the above-described setting according to the present embodiment can effectively reduce the wear of the fixing belt even if the sliding surface of the fixing belt or the slide surface of the heater is made of a material other than polytetrafluoroethylene (PTFE), which increases the degree of freedom in selecting the materials of the fixing belt and the heater. According to embodiments of the present disclosure, it is possible to provide a fixing device excellent in durability and practicability.
The lubricant interposed in the sliding portion between the heater and the fixing belt may include fluorine grease or silicone oil. Interposing such a lubricant in the sliding portion enables maintaining lubricity over a long period of time even in the sliding portion under high temperature and high pressure and reducing the wear of the fixing belt.
The fixing belt including the base, the release layer as the surface layer on the outer circumferential surface of the base does not preferably include the elastic layer such as the rubber layer between the base and the release layer as the surface layer. The fixing belt having no elastic layer has a lower heat insulating property and a higher thermal conductivity from the heater to the surface (outer circumferential surface) of the fixing belt than the fixing belt having the elastic layer. Therefore, the heat generation amount or temperature of the resistive heat generator in the fixing device including the fixing belt having no elastic layer can be set lower than the heat generation amount or temperature of the resistive heat generator in the fixing device including the fixing belt having the elastic layer. Since high temperature generally weakens the strength of the fixing belt and increases the wear of the fixing belt, the fixing device configured by the fixing belt not including the elastic layer enables setting the heat generation amount or temperature of the resistive heat generator to be lower preventing the fixing belt from wearing. In addition, since setting the heat generation amount or temperature of the resistive heat generator to be lower can prevent the deterioration of the lubricant interposed between the fixing belt and the heater, the lubricating function can be maintained over a long period of time. As a result, the fixing belt not including the elastic layer is less likely to be worn, and the life of the fixing belt can be prolonged.
The fixing device including the pressure rotator having the porous elastic body that has the thermal conductivity of 0.15 W/m×k or less according to the embodiments of the present disclosure can be expected to have a particularly large effect. In such a configuration, since the temperature rise in the portion facing the non-sheet-passing region is likely to be significant, deterioration of the lubricating function due to heat is also likely to occur. Applying the above-described setting to the fixing device including the pressure rotator having the porous elastic body with the heat transfer coefficient of 0.15 W/m×k or less effectively reduces the wear of the fixing belt and lengthens the life of the fixing belt. The porous elastic body included in the pressure rotator may be a material other than rubber in addition to the foamed rubber such as sponge rubber, expanded rubber, or soft urethane foam.
A method for measuring the thermal conductivity is as follows.
The thermal conductivity (λ) of the porous elastic body included in the pressure rotator is obtained by the following expression (2) using the density (ρ), the specific heat (C), and the thermal diffusivity (α).
F=μ×N. (2)
Specifically, the present inventors calculated the thermal conductivity (λ) using the density (ρ), specific heat (C), and thermal diffusivity (α) obtained by the following measurement methods.
The present inventors measured the density (ρ) by using a dry automatic densitometer (trade name (TM): AccuPyc 1330 manufactured by SHIMADZU CORPORATION). The present inventors measured the specific heat (C) by using a differential scanning calorimeter (trade name (TM): DSC-60 manufactured by SHIMADZU CORPORATION) and sapphire as a reference material. The present inventors measured the specific heat (C) five times and used an average value at 50° C. The present inventors cut the elastic layer of the pressure roller into pieces having a length of 1 mm or less to prepare a measurement sample and measured the thermal diffusivity (α) by using a thermal diffusivity/conductivity measuring device (trade name (TM): ai-Phase Mobile Iu, manufactured by Ai-Phase co., ltd.).
The following describes difference between the elastic power and a return rate.
There is a return rate as an index similar to the elastic power. The “return rate” is a value expressed by the following expression (3), where h1 is the maximum displacement of a target member to which a load is applied, and h2 is a displacement after the load is removed (see
Return rate (%)=(h1−h2)/h1×100 (3)
In contrast, the elastic power is a value indicating an energy loss when the target member elastically returns the shape of the target member during the unloading process, which means that the elastic power includes information of the return speed. As a result, the elastic powers are different in the target members having the different return lines 1, 2, and 3. The target members having the same return rate may have different elastic powers depending on profiles during the unloading process. The frictional force (that affects a rotational torque) at the sliding portion of the fixing belt may be different depending on the difference in the elastic power. Specifically, increasing the difference in energy loss obtained from the elastic power increases the frictional force (that affects a rotational torque) at the sliding portion of the fixing belt. For this reason, the elastic power that relates to the frictional force in addition to the wear resistance is more useful than the return rate that cannot determine the presence or absence of the frictional force and the magnitude relationship of the frictional force as a characteristic of the sliding surface of the fixing belt or the like.
A description is given of a manufacturing method of the fixing belt.
A main ingredient of the tubular base of the fixing belt according to the embodiment of the present disclosure is polyimide (PI). The polyimide as the main ingredient can increase elastic power of the base. In the case that the base is made of metal, paint containing polyimide may be applied to the inner circumferential surface oldie base.
The following describes a method of manufacturing the fixing belt according to the present embodiments.
Firstly, preparation of coating liquid for the fixing belt is described.
To make the coating liquid, a preparation liquid A was prepared by adding N-methyl-pyrrolidone (NMP) 80 g to the polyimide varnish 100 g and mixing.
As the polyimide varnish, U-imide varnish AR® manufactured by UNITIKA LTD. was used.
NMP was N-methyl-pyrrolidinone special grade manufactured by Kanto Chemical Co., Inc.
As a result, a preparation liquid A was prepared.
Needle-shaped inorganic filler was gradually added to the above-described preparation liquid A while performing blade stirring by a desktop mixer, and kneading was performed.
The needle-shaped inorganic filler 20 g was added to the polyimide varnish 100 g.
The needle-like inorganic filler was gradually added and kneaded over about 10 to 15 minutes so as not to form beads.
As the needle-like inorganic filler, TISMO D® manufactured by Otsuka Chemical Co., Ltd. was used.
As a result, the coating liquid B was prepared.
The coating liquid B was coated to the inner circumferential surface of the fixing belt as follows.
Coating method to coat the coating liquid B to the inner circumferential surface of the fixing belt is generally spray coating or dipping coating.
Present inventors used the spray coating.
The coating liquid B was put into a pumping tank.
The fixing belt as an object to be coated was rotated in order to coat the coating liquid B to the inner circumferential surface of the fixing belt.
The number of rotations of the fixing belt is set in a range of 900 to 1000 rpm.
The number of rotations of the fixing belt was set to 900 rpm.
The present inventors set a coating speed to be 30 mm/s. A coating weight in one coating process of a plurality of coating processes was set to be in a range of 0.7 to 1.2 g.
The coating weight is adjusted by the pressure at which the coating liquid B is pumped.
The present inventors set the pressure to be 125 kPa, and the coating weight in one coating process was 1.0 g.
After coating, preliminary drying was carried out with hot air at 200° C., and the coating process was repeated. The coating process and preliminary drying were repeated three to four times. After completion of each coating process, in order to volatilize NMP, the fixing belt was put into a drying furnace at 260° C. and heat-treated for 30 minutes.
The film thickness of the sliding layer was 8 to 15 μm.
For example, when the coating liquid B 4.2 g was applied, the film thickness was 11 μm.
Subsequently, the fixing belt was fired.
Firing process was carried out in a vertical type far-infrared firing furnace.
The vertical type far-infrared firing furnace included far-infrared heaters laterally disposed. Each of the far infrared heaters had a heating range equal to or longer than the fixing belt. The fixing belt was vertically disposed between the far-infrared heaters.
The temperature of the far-infrared heaters was set so that the fixing belt had a predetermined temperature.
The temperature of the far-infrared heaters was set so that the actual temperature of the fixing belt was 360° C.
Firing time was 30 minutes.
The present inventors measured the elastic power of the inner portion having the sliding surface of the fixing belt manufactured as described above. The elastic power was 70.0% under 23° C. that is an example of a room temperature and 60.2% under 165° C. that is an example of a temperature of fixing belt heated in the fixing device. Thus, the elastic power was 55% or more under the above-described both temperature conditions. As described above, 55% or more of the elastic power is a target for improving the wear resistance of the fixing belt.
Changing firing conditions enables adjusting the elastic power of the fixing belt. The following describes other firing conditions.
One type of fixing belt was tired as follows.
The temperature of the far-infrared heaters was set so that the actual temperature of the fixing belt was 280° C.
Firing time was 30 minutes.
Conditions other than the firing temperature and the firing time are the same as those in the above-described manufacturing method.
The present inventors measured the elastic power of the inner portion having the sliding surface of the fixing belt manufactured under the above-described different firing conditions. The elastic power was 60.4% under 23° C. that is the example of the room temperature and 52.1% under 165° C. that is the example of the temperature of fixing belt heated in the fixing device.
As described above, changing the firing conditions of the fixing belt made of polyimide as the material of the base of the fixing belt enables appropriately adjusting the elastic power of the inner portion having the sliding surface of the fixing belt. In other words, using polyimide as the material of the base of the fixing belt enables easily adjusting the elastic power of the fixing belt to a desired value to improve the wear resistance of the fixing belt. The material of the fixing belt according to the present disclosure is not limited to polyimide. Heat-resistant resin such as PEEK may be used. Alternatively, the base of the fixing belt may be made of a metal material such as nickel or SUS, and polyimide, PTFE, or the like may be applied to the base of the fixing belt.
Other fixing devices are described below.
The fixing device according to the present disclosure is not limited to the fixing device 300 in the embodiment illustrated in
As illustrated in
An auxiliary stay 351 supports the heater 330, and the stay 350 supports the auxiliary stay 351. The auxiliary stay 351 is attached on one side of the stay 350, and a nip formation pad 381 is attached on the other side of the stay 350. The nip formation pad 381 contacts the pressure roller 320 via the fixing belt 310 to form the fixing nip SN.
As illustrated in
As illustrated in
Next, heater configurations are described.
The heater in the fixing device according to the present disclosure may have various types of configurations as illustrated in
The following describes a single type resistive heat generator.
On the other end of the substrate 341, the other ends of the two parallel rows of the resistive heat generator 370 are coupled each other by a power supply line 379b having a small resistance value and extending in the short side direction of the substrate 341. As a result, the resistive heat generator 370 has a form turned back in the longitudinal direction of the substrate 341. The resistive heat generator 370, the electrodes 370c and 370d, and the power supply lines 379a to 379c are formed by, for example, screen-printing with a predetermined line width and thickness.
The surfaces of the resistive heat generator 370 and the power supply lines 379a to 379c are covered with a thin overcoat layer or an insulation layer 385. The insulation layer 385 secures the slidability with the fixing belt 310 and the insulation between the fixing belt 310 and the resistive heat generator 370 and the power supply lines 379a to 379c. The insulation layer 385 made of heat-resistant glass prevents the lubricant on the slide layer of the heater 330 from impregnating into the resistive heat generator 370 and thus prevents oil film shortage at the nip surface.
The following describes a dual type resistive heat generator.
As illustrated in
Coupling the resistive heat generators 370-1 and 370-2 to the electrodes 370e to 370h enables the central resistive heat generator 370-1 and the end resistive heat generators 370-2 to independently generate heat. Specifically, applying a voltage to the electrodes 370e and 370h causes the central resistive heat generator 370-1 to generate heat, applying the voltage to the electrodes 370e and 370f causes the left end resistive heat generator 370-2 to generate heat, and applying the voltage to the electrodes 370e and 370e, causes the right end resistive heat generator 370-2 to generate heat.
Coupling the electrodes 370f and 370g in parallel outside the heater enables the left and right end resistive heat generators 370-2 to simultaneously generate heat. When the fixing device is configured to convey the sheet on the center of the fixing belt, the temperature distribution of the fixing belt is symmetrical with respect to the center in the right and left direction. Therefore, a thermistor may be disposed opposite one of the end resistive heat generators 370-2 without disposing two thermistors opposite the end resistive heat generators 370-2 at both end portions of the substrate 341, thereby reducing the cost.
The following describes a multi-type resistive heat generator.
The PTC elements 371 to 378 are arranged linearly at equal intervals in the longitudinal direction of the substrate 341. On both sides of each of the PTC elements 371 to 378 in the short-side direction of the substrate 341, power supply lines 370a and 370b having small resistance values are linearly arranged in parallel to each other. Both ends of each of the PIC elements 371 to 378 are coupled to the power supply lines 370a and 370b. The PTC elements 371 to 378 are coupled to the electrodes 370c and 370d disposed on both end sides of the heater 330 in the longitudinal direction via the power supply lines 370a and 370b.
The PTC elements 371 to 378 may be formed by, for example, applying the paste prepared by mixing silver-palladium (AgPd), glass powder, or the like to the substrate 341 by screen printing or the like, and then firing the substrate 341. As the material of the PTC elements 371 to 378, a resistance material such as the silver alloy (AgPt) or ruthenium oxide (RnO2) may be used in addition to the materials described above.
Use of the PTC elements 371 to 378 reduces an increase in temperature in the PTC element in which small sheets do not contact when the small sheets pass through the fixing device 300 because the relation of the PTC element (that is a resistance heating element) between resistance and temperature reduces heat generation amount in the PTC element in which the small sheets do not contact. For example, printing sheets smaller than a width corresponding to all the PTC elements 371 to 378, for example, sheets each having a width corresponding to PTC elements 373 to 376, raises temperatures in the PTC elements 371, 372, 377, and 378 disposed outside the sheets because the sheets do not draw heat from the PTC elements 371, 372, 377, and 378. Raising temperatures in the PTC elements 371, 372, 377, and 378 causes increase in resistance values of the PTC elements 371, 372, 377, and 378. Since a constant voltage is applied to the PTC elements 371 to 378, the increase in resistance values relatively reduces outputs of the PTC elements 371, 372, 377, and 378 disposed outside the width of the sheet, thus restraining an increase in temperature in end portions outside the sheets.
Unlike configurations illustrated in
As the temperature increases, the strength of the fixing belt decreases. Therefore, the fixing belt is likely to be worn. Using the multi-type resistive heat generator as illustrated in
The shape of each of the PTC elements 371 to 378 may be a shape having a step portion formed by an L-shaped notch at an end in the longitudinal direction as illustrated in
In
The electrodes 370c and 370d in each of the heaters 330 illustrated in
The shape of each of the PTC elements 371 to 378 is not limited to a block shape (a rectangular shape, a parallelogram shape, or the like) as illustrated in
In the above-described embodiments, the present disclosure is applied to the fixing device that is an example of the belt device. The present disclosure may be applied to other belt devices. For example, in an inkjet type image forming apparatus, the belt device of the present disclosure may be applied to a drying device as the belt device that heats the sheet to dry an ink (that is liquid) on the sheet while the belt conveys the sheet.
In the above-described embodiments, the present disclosure is applied to prevent the occurrence of the abnormal noise and the wear at the sliding portion between the fixing belt and the heater as examples. However, the present disclosure is also applicable to the sliding portion between the nip formation pad 381 and the belt illustrated in
The above-described embodiments are illustrative and do not limit the present invention. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted far each other within the scope of the present invention.
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