Patent Application
20150251450
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2014-043243 filed on Mar. 5, 2014.
The present invention relates to a drying device and an image forming apparatus.
According to an aspect of the invention, there is provided a drying device comprising: a drying unit comprising: a heating space having a heating unit; a drying space that has a conveyance path of a recording medium and in which the recording medium is dried by radiation heat produced by the heating unit; and a partition member that separates the heating space and the drying space from each other in such a manner that gas can move between them; a first supply unit that supplies gas to the drying unit in a direction that is opposite to a conveying direction of the recording medium; and a second supply unit that supplies gas to the drying unit in a direction from the heating unit to the partition member.
As shown in
Another mechanism is possible in which a motor is attached to the sheet supply roller 16 or the relay rollers 18 to make it or them a drive roller(s) and a paid-out part of the recording medium 12 is taken up while tension of a part of the recording medium 12 between each pair of adjoining rollers is adjusted. In this case, position sensors or tension sensors for detecting loosening of the recording medium 12 may be provided and the rotation speed (and the rotation direction) of the drive roller(s) may be controlled by a feedback control.
As shown in
Inkjet heads 27Y, 27M, 27C, and 27K of Y (yellow), M (magenta), C (cyan), and K (black) are arranged in the image forming unit 24 and may be referred to generically as an inkjet head(s) 27 below. Ink that is stored in an ink cassette, for example, is brought into each ink head 27 and ink droplets are ejected out of nozzles toward a part of the recording medium 12 opposed to the nozzles by a pressure control, an ultrasonic control, or the like.
In the image recording apparatus 10 according to the exemplary embodiment, the nozzles are arranged so as to cover the entire length of the recording medium 12 in the main scanning direction and the inkjet heads 27 of the respective colors are arranged in the auxiliary scanning direction of the recording medium 12. Ink droplets of amounts corresponding to image data are ejected out of the nozzles of each inkjet head 27 in synchronism with conveyance of the recording medium 12. The manners of arrangement of the nozzles and the inkjet heads 27 are not limited to the above ones; a configuration is possible in which each inkjet head 27 is moved in the main scanning direction.
In the drying unit 26, a part of the recording medium 12 on which an image has been formed by the image forming unit 24 is conveyed downward (as viewed in
In the following description of the exemplary embodiment, the orientation of the drying unit 26 varies depending on the drawing. Therefore, in the following, the bottom plate, top plate, left plate, and right plate of the main frame body 28 as viewed in
Two drying wind inlets 34 and 36 are formed through the first wall 28A so as to communicate with the inside space (drying space 32 and heating space 30 (described later)) of the main frame body 28. The drying wind inlets 34 and 36 extend in the longitudinal direction of the first wall 28A and shaped like slits. The drying wind inlets 34 and 36 are provided with ducts (not shown) through which to supply gas (air) independently. Therefore, gas can be supplied to the inside space through the inlets 34 and 36 at different flow speeds.
Two gas outlets 38 and 40 are formed through the second wall 28B so as to communicate with the inside space of the main frame body 28. The outlets 38 and 40 extend in the longitudinal direction of the second wall 28B and shaped like slits. The outlets 38 and 40 are provided with ducts (not shown) for gas discharge. The ducts are provided independently for the outlets 38 and 40 and a suction pump (not shown) is attached to them. However, in calculations, natural opening may be similar in performance to pump suction. Although the exemplary embodiment actually employs pump suction rather than natural opening, the term “natural opening” includes a case that natural opening is employed in a calculation. The outlets 38 and 40 can be opened or closed selectively.
A net member (in the exemplary embodiment, a wire gauze 42) which is a partition member is disposed in the main frame body 28 so as to partition its inside space. The dimensions of the wire gauze 42 correspond to the inner dimensions of the main frame body 28, and its circumferential edges are fixed to the inner surfaces of the main frame body 28 (i.e., the inner surfaces of the first to fourth walls 28A-28D). No limitations are imposed on the method for fixing the wire gauze 42; it may be any of various fixing methods such as fitting into grooves formed in the inner surfaces of the main frame body 28, fixing via brackets, and fixing with adhesive.
The wire gauze 42 is required to be heat-resistant and it is preferable that it be made of a metal such as aluminum, stainless steel, iron, or gold. Although no limitations are imposed of the metal material, to prevent overheating of a sheet not being conveyed, metals that produce less radiation heat are preferable. The partition member may be a metal plate through which holes are formed, in place of the wire gauze 42.
The wire gauze 42 serves to divide the inside space (i.e., the space between the confronting openings) of the main frame body 28. The deep-side one (see
On the other hand, the view's-side divisional space (see
As shown in
Because of the structure of the wire gauze 42, objects that are larger than the holes of the wire gauze 42 cannot move between the heating space 30 and the drying space 32 but gas can move between them. In other words, whereas gas can flow from the heating space 30 to the drying space 32, no part of the recording medium 12 can move from the drying space 32 to the heating space 30.
As shown in
Nine backside fans 54 which are axial flow fans are attached to the base member 50. Each backside fan 54 has a structure that blades are attached to a rotary shaft and rotated by driving the rotary shaft by a motor. In the exemplary embodiment, the blade diameter is equal to 100 mm. Each backside fan 54 is attached to the base member 50 in such a manner that its rotary shaft coincides with the center of the blowing hole 52 (circular hole). The nine blowing holes 52 serve as blowing holes for drying winds when the backside fans 54 are driven.
As shown in
The backside fans 54 are not limited to axial flow fans, and the number of backside fans 54 need not always be equal to nine. Gas flows may be produced at another place and guided to the base member 50 by ducts. each gas blowing hole 52 need not always be circular and may have any of other shapes such as a slit and meshes.
In the exemplary embodiment, a first object of using gas that flows inside the drying unit 26 is to cool, that is, prevent overheating of, the inside of the drying unit 26 (described later in detail). A second object is to remove humid gas from around a target part of the recording medium 12 to assist drying of that part of the recording medium 12 by radiation heat of the heater unit 44. Therefore, in the following, the gas flow will be referred to as a “drying wind.”
The drying unit 26 has, as inlets for drying winds, the inlets 34 and 36 which are formed through the first wall 28A and blowing holes 52 which are formed in the backside fan unit 48. On the other hand, the drying unit 26 has, as outlets for drying winds, the outlets 38 and 40 which are formed through the second wall 28B.
In the drying unit 26 according to the exemplary embodiment, drying winds that are supplied through the inlets 34 and 36 and the blowing holes 52 are blown over an image-formed surface portion of the recording medium 12 being conveyed. As a result, gas containing water vapor that has been evaporated from this part of the recording medium 12 by drying by radiation heat is removed from it.
Main streams of drying winds are formed by drying winds that are supplied through the inlets 34 and 36 and flow parallel with an image-formed surface portion of the recording medium 12 in the direction opposite to the conveying direction of the recording medium 12, and humid gas produced by drying is discharged through the outlets 38 and 40. Since drying winds flow in the direction opposite to the conveying direction of the recording medium 12, their relative flow speeds are increased and hence their ability to remove humid gas is enhanced.
In the drying unit 26 according to the exemplary embodiment in which the heating space 30 and the drying space 32 are separated from each other by the wire gauze 42 is higher in drying efficiency than a radiation heating type drying device in which the heating space 30 and the drying space 32 are separated by a glass plate or a metal plate because thermal energy generated by the heater unit 44 can be used without being wasted partially. In addition, drying winds increase the ability to remove humid gas per unit time.
On the other hand, the fact that drying winds can move between the heating space 30 and the drying space 32 means that paper powder produced from the recording medium 12 in the drying space 32 may go into the heating space 30 while drying is performed. In the exemplary embodiment, this problem is solved by attaching the backside fan unit 48. That is, the backside fan unit 48 sends necessary drying winds from behind the heater unit 44 through the blowing holes 52, and thereby stops air flows that would otherwise move from the drying space 32 through the wire gauze 42 and prevents paper powder from reaching the heating space 30.
Drying winds (air flows) produced by the backside fan unit 48 flow to reach the heater unit 44, the wire gauze 42, and the recording medium 12 in this order. Therefore, in an emergency such as a stop of conveyance of the recording medium 12, drying winds exercise their cooling function, that is, cool the heater unit 44 and the wire gauze 42 and prevent overdrying of a target part of the recording medium 12 due to overheating.
Workings of the drying unit 26 according to the exemplary embodiment will be described below.
(Condition 1) The flow speed of a drying wind supplied through the drying-space-32-side inlet 34 is 10 m/s.
(Condition 2) The flow speed of a drying wind supplied through the heating-space-30-side inlet 36 is 5 m/s.
(Condition 3) The flow speed of drying winds supplied through the blowing holes 52 of the backside fan unit 48 is 1 m/s.
(Condition 4) The drying-space-32-side outlet 38 is in a natural opening state in terms of calculation.
(Condition 5) The heating-space-30-side outlet 40 is closed.
In the drying unit 26P of Comparative Example, the flow speed of a drying wind supplied through the drying-space-32P-side inlet 34P is 10 to 20 m/s. The heating-space-30-side inlet 34 is open to the ambient air. The two outlets 38P and 40P are in a natural opening state in terms of calculation.
In
Table 1 shows evaluation results, that is, results of comparison between the preferable mode according to the exemplary embodiment shown in
As seen from Table 1, in the preferable mode in which the backside fan unit 48 is provided, no circulating flows occur and drying winds do not flow from the drying space 32 to the heating space 30. Therefore, paper powder produced from the recording medium 12 in the drying space 32 is prevented from going into the heating space 30 being carried by drying winds.
Since the backside fan unit 48 produce downward flows (as viewed in
When the recording medium 12 undergoes an emergency stop, there may occur an event that stagnant drying winds are heated gradually even if the heater unit 44 is turned off, resulting in overheating of a target part of the recording medium 12. In the exemplary embodiment, such overheating of a target part of the recording medium 12 is prevented because drying winds produced by the backside fans 54 cool the heater unit 44 and the wire gauze 42.
Experiment 1 is to check gas flow characteristics in the drying unit 26 for three patterns of combinations of conditions on the drying wind supply side and discharge side. Whether or not paper power goes into the heating space 30 is judged on the basis of presence/absence of drying winds flowing toward the heating space 30. “Natural opening” is a term of calculation.
In Experiment 1, the degree of stagnation of drying winds decreases in order of Pattern 1, Pattern 2, and Pattern 3. One cause of circulating flows is stagnation of drying winds.
As seen from
As shown in
On the other hand, as shown in
In Experiment 1, the degree of stagnation of drying winds (gas) which occurs mainly in the heating space 30 varies depending on the number of inlets and outlets used. It is preferable that drying wind supply be made to both of the heating space 30 and the drying space 32 and drying wind discharge be made only from the drying space 32.
When a drying wind is supplied through the heating-space-30-side inlet 36, the function of the backside fan unit 48 is utilized sufficiently, as a result of which no circulating flows occur and paper powder is prevented from going into the heating space 30.
It is concluded that the most preferable mode of Experiment 1 is Pattern 3.
Experiment 2 is to check drying wind (gas) flow characteristics in the drying unit 26 (heating space 30 and drying space 32) for three patterns in which the flow speed at the heating-space-30-side (second supply side) inlet 36 is different. A temperature variation of the wire gauze 42 and whether or not paper power produced in the drying space 32 goes into the heating space 30 are judged. “Natural opening” is a term of calculation.
As shown in
As shown in
As shown in
Experiment 2 shows that the temperature of the wire gauze 42 can more likely be made lower than the desired temperature as the flow speed at the heating-space-30-side inlet 36 increases, and that circulating flows occur (due to shear flows) near the inlets 34 and 36 if the flow speed is too high. It is seen that the flow speed at the heating-space-30-side inlet 36 has an allowable upper limit and lower limit. It is concluded that the most preferable mode of Experiment 2 is Pattern 2.
Experiment 3 is to check drying wind (gas) flow characteristics in the drying unit 26 (heating space 30 and drying space 32) for four patterns in which the flow speed in the backside fan unit 48 is different. A temperature variation of the wire gauze 42 and whether or not paper power produced in the drying space 32 goes into the heating space 30 are judged. “Natural opening” is a term of calculation.
As shown in
In each of Patterns 1-4, the temperature of the wire gauze 42 is lower than the prescribed temperature and no circulating flows occur that causes paper powder to go into the heating space 30.
The flow speed of the backside fans 54 is not a major factor in causing circulating flows. The efficiency of cooling of the heater unit 44 and the wire gauze 42 (including suppression of circulating flows) increases as the flow speed of the backside fans 54 becomes higher. Since the cooling efficiency increases at a lower rate as it comes closer to the upper limit (100%), it is not necessary to be set to an unnecessarily a large value. The cooling efficiency does not vary much in a flow speed range that is higher than 1 m/s. Therefore, the most preferable mode of Experiment 3 is Pattern 1.
The flow speeds of drying winds of the drying unit 26 according to the exemplary embodiment shown in
That is, in the drying unit 26 according to the exemplary embodiment, the flow speeds of a drying wind supplied through the drying-space-32-side inlet 34, a drying wind supplied through the heating-space-30-side inlet 36, and drying winds supplied through the backside fans 54 are set to 10 m/s, 5 m/s, and 1 m/s, respectively. The heating-space-30 outlet 40 is closed and drying winds are discharged through the drying-space-32-side outlet 38 (natural opening in terms of calculation). As a result, as shown in Table 1, paper powder is prevented from going into the heating space 30 unlike in Comparative Example. And the effect of cooling the heater unit 44 (heating body) and the wire gauze 42 and the effect of removing humid air (i.e., drying efficiency) are made higher than in Comparative Example.
Although Experiments 1-3 are experiments carried out in such a manner that the conditions other than the one to be checked are set to fixed values, experiments may be done using plural conditions as variables.
In the exemplary embodiment, circulating flows which may cause paper powder to go into the heating space 30 are suppressed with the assumption that the drying-space-32-side opening is fully closed by a target part of the recording medium 12. However, in the case of a recording medium 12S which is narrower than the drying unit 26, a target part of it may be dried in a state that the drying-space-32-side opening is not fully closed.
As seen from
The foregoing description of the embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention defined by the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-043243 | Mar 2014 | JP | national |
