Patent Application
20190094772
The present invention relates to a film used in a fixing device mounted on an image forming apparatus, such as a printer or copier, and also relates to a fixing device including the film.
As a film used in a fixing device mounted on a copier or printer, one that includes electrode layers formed at both ends of the film in the longitudinal direction and a heating layer interposed between the electrode layers in such a manner as to be connected thereto is known (see, e.g., Japanese Patent Laid-Open No. 2011-253141). A fixing device including this film enables the film to generate heat by using Joule heat which is generated by bringing an electrode member, such as a conductive brush, into contact with each electrode layer so as to pass current through the heating layer. Using this film, which is capable of generating heat, can contribute to energy saving and reduced warm-up time for the fixing device.
With this configuration, however, mechanical stress produced in the film may damage the connecting portion between each electrode layer and the heating layer.
A first aspect of the present invention is a fixing member used for a fixing device. The fixing member includes a tubular base layer; an electrode portion formed on the base layer; a heat generating portion formed by a plurality of thin linear layers extending in a longitudinal direction of the fixing member and spaced from one another along a circumferential direction of the fixing member, the heat generating portion being formed on the base layer in such a manner as to be positioned next to the electrode portion in the longitudinal direction of the fixing member and electrically connected to the electrode portion; and an overcoat layer formed on the heat generating portion in such a manner as to extend over a boundary between the heat generating portion and the electrode portion in the longitudinal direction of the fixing member.
A second aspect of the present invention is a fixing device that fixes an image onto a recording material and includes a fixing member and a power supply member. The fixing member includes a tubular base layer; an electrode portion formed on the base layer; a heat generating portion formed by a plurality of thin linear layers extending in a longitudinal direction of the fixing member and spaced from one another along a circumferential direction of the fixing member, the heat generating portion being formed on the base layer in such a manner as to be positioned next to the electrode portion in the longitudinal direction of the fixing member and electrically connected to the electrode portion; and an overcoat layer formed on the heat generating portion in such a manner as to extend over a boundary between the heat generating portion and the electrode portion in the longitudinal direction of the fixing member. The fixing member is configured to come into contact with the image. The power supply member is configured to supply power through the electrode portion to the heat generating portion. The fixing member generates heat as current flows through the heat generating portion, and a toner image is fixed onto the recording material by the heat of the fixing member.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
A film (fixing member) and a fixing device using the film will now be described in detail on the basis of embodiments. In the following description of a device configuration, the term “longitudinal direction” refers to the longitudinal direction of the film, the term “circumferential direction” refers to the circumferential direction of the film, and the term “thickness direction” refers to the thickness direction of the film.
A first embodiment will be described with reference to
A configuration of a fixing film 1 according to the present embodiment will now be described using
A base layer 1a is a foundation layer having mechanical characteristics of the fixing film 1, such as torsional strength and smoothness. The base layer 1a is made of resin, such as polyimide (PI), polyamide-imide (PAI), or polyether ether ketone (PEEK).
The base layer 1a used in the present embodiment is a tubular polyimide layer having an outside diameter of 18 mm, a length of 240 mm in the longitudinal direction, and a thickness of 60 μm. The base layer 1a is an insulating layer.
The base layer 1a has electrode layers 1b formed thereon in 10-mm-long regions at both ends thereof in the longitudinal direction of the fixing film 1. The electrode layers 1b serve as an electrode portion for feeding power from the outer surface of the fixing film 1 to the resistive heat generating layers 1e. The electrode layers 1b are annular layers each extending in the circumferential direction of the fixing film 1. The electrode layer 1b is a 10-μm-thick layer of silver paste. The silver paste used to form the electrode layer 1b of the present embodiment has a volume resistivity of 4×10−5 Ω·cm. This silver paste is obtained by dispersing fine silver particles in polyimide resin using a solvent. The electrode layer 1b is formed by applying the silver paste to the base layer 1a and firing the applied silver paste.
The resistive heat generating layers 1e form a heat generating portion. The resistive heat generating layers 1e are thin linear layers extending in the longitudinal direction of the fixing film 1 and spaced from one another along the circumferential direction of the fixing film 1. On the base layer 1a, the resistive heat generating layers 1e are positioned next to the electrode layers 1b in the longitudinal direction of the fixing film 1 and are electrically connected to the electrode layers 1b. The resistive heat generating layers 1e of the present embodiment are formed on the base layer 1a by screen printing using silver paste having a volume resistivity of 2×10−3 Ω·cm. The resistive heat generating layers 1e measure 220 mm long, 1 mm wide, and 10 μm thick. As illustrated in
The electrode layers 1b are disposed at both ends of the base layer 1a in the longitudinal direction of the fixing film 1, and the resistive heat generating layers 1e are disposed in the center of the base layer 1a in the longitudinal direction of the fixing film 1 in such a manner that they are electrically connected to the electrode layers 1b at both ends thereof.
In the present embodiment, as illustrated in
Although the electrode layers 1b and the resistive heat generating layers 1e are formed by printing the silver pastes in the present embodiment, the electrode layers 1b and the resistive heat generating layers 1e may be formed by other means, such as metal plating or sputtering.
A configuration of a fixing device according to the present embodiment will now be described with reference to
The fixing device is designed to heat and fix a toner image formed by an electrophotographic image forming technique on a recording material. From the left-hand side in
The fixing device of the present embodiment includes the fixing film 1 having a tubular shape and serving as a heating rotator, a film guide 2 configured to hold the fixing film 1, and a pressure roller 4 serving as a pressure member that forms a fixing nip N between itself and the fixing film 1.
The film guide 2 is made of a heat-resistant resin, such as liquid crystal polymer, polyphenylene sulfide (PPS), or PEEK. The film guide 2 is engaged with a stay 5 held by a device frame at both ends thereof in the longitudinal direction. When pressure springs (not shown) serving as pressure means apply pressure to both ends of the stay 5 in the longitudinal direction, the film guide 2 is pressed against the pressure roller 4. For the stay 5 to uniformly transmit, across the length of the film guide 2, the pressure received at both ends thereof in the longitudinal direction, the stay 5 is made of a stiff material, such as iron, stainless steel, or electro galvanized steel sheet. The stiffness of the stay 5 is enhanced by forming the stay 5 into a U shape in cross section. This enables uniform formation of the fixing nip N with a predetermined width across the length of the pressure roller 4, without causing significant warpage of the film guide 2. The film guide 2 is provided with a temperature detecting element 6, which is in contact with the inner surface of the fixing film 1. In accordance with the temperature detected by the temperature detecting element 6, a central processing unit (CPU) (not shown) controls the application of current to the fixing film 1.
In the present embodiment, liquid crystal polymer is used to form the film guide 2, and an electro galvanized steel sheet is used to form the stay 5. A pressure of 160 N is applied to the pressure roller 4, and this forms the fixing nip N of about 6 mm wide.
The pressure roller 4 includes a metal core 4a made of iron, aluminum, or the like, an elastic layer 4b made of silicone rubber or the like, and a mold release layer 4c made of PFA or the like. To ensure durability and form the fixing nip N having a width that ensures fixing performance, the hardness of the pressure roller 4 preferably ranges from 40° to 70° when measured with a durometer ASKER-C under a load of 9.8 N.
In the present embodiment, the pressure roller 4 is produced by forming a silicone rubber layer with a thickness of 3.5 mm onto an 11-mm-diameter iron core and covering the silicone rubber layer with an insulating PFA tube with a wall thickness of 40 μm. The pressure roller 4 has a hardness of 56° and an outside diameter of 18 mm. The elastic layer 4b and the mold release layer 4c are 218 mm long in the longitudinal direction. As illustrated in
Feeding members 3a are wired by an alternating-current (AC) cable 7 extending from an AC power supply 50. The feeding members 3a are in contact with the respective outer surfaces of the electrode layers 1b at both ends of the fixing film 1. For example, the feeding members 3a are leaf springs, pads, or brushes each formed by a bundle of fine gold wires.
In the present embodiment, the feeding members 3a are each provided as a power supply member that supplies power through the corresponding electrode layer 1b to the resistive heat generating layers 1e. The feeding member 3a is composed of a carbon chip and a leaf spring of stainless steel. By the biasing force of the leaf spring, the carbon chip is pressed against the exposed outer surface of the electrode layer 1b. By applying an AC voltage from the AC power supply 50 through the AC cable 7, power is fed to the resistive heat generating layers 1e of the fixing film 1 through the feeding members 3a.
In the present embodiment, where the fixing film 1 includes the electrode layers 1b at both ends of the base layer 1a, power can be constantly fed to the resistive heat generating layers 1e even during rotation of the fixing film 1. Since current from each feeding member 3a passes through the corresponding electrode layer 1b and flows into the resistive heat generating layers 1e uniformly in the circumferential direction, all the resistive heat generating layers 1e having the same volume resistivity uniformly generate heat.
Then, by a rotational force transmitted from a drive mechanism (not shown) to a drive gear (not shown) of the pressure roller 4, the pressure roller 4 is rotationally driven at a predetermined speed in the clockwise direction in
By the rotation of the pressure roller 4, the fixing film 1 is rotated, energized, heated to a predetermined temperature, and started to be temperature-controlled by the temperature detecting element 6. Then, the recording material P bearing the toner image T in an unfixed state thereon is introduced into the fixing nip N, through which the surface of the recording material P bearing the toner image T thereon is conveyed while being sandwiched between the fixing film 1 and the pressure roller 4. In this process of conveyance, the recording material P is heated by the heat of the fixing film 1. By being subjected to heat and pressure, the unfixed toner image T on the recording material P is fused and fixed onto the recording material P. After passing through the fixing nip N, the recording material P is self-stripped off the surface of the fixing film 1, discharged, and conveyed by a discharge roller pair (not shown).
Accordingly, the present embodiment aims to prevent such mechanical stress from damaging the resistive heat generating layers 1e that are formed as a thin linear pattern on the base layer 1a of the fixing film 1. Specifically, in the present embodiment, forming the overcoat layer 100 over the resistive heat generating layers le can reduce the amount of bend of the resistive heat generating layers 1e at the end of the fixing nip N. Moreover, since the overcoat layer 100 is formed to extend over the boundary K between each electrode layer 1b and the resistive heat generating layers 1e, the torsional mechanical stress applied to the resistive heat generating layers 1e outside the fixing nip N can be relieved.
To confirm the advantageous effect of the present embodiment, a test was performed to observe how the fixing film 1 generated heat. In the test, the controlled temperature of the fixing film 1 was kept at 200° C., the rotational speed of the pressure roller 4 was set at 150 mm/s, and the fixing device continued to run idle without passing any sheet (recording material P) therethrough. It was confirmed by the test that even after rotation of the fixing film 1 for 250 hours, there was no occurrence of abnormal heating of the resistive heat generating layers 1e and the fixing film 1 continued to uniformly generate heat without stoppage of heat generation caused by breakage of the resistive heat generating layers 1e.
To explain the advantageous effect of the present embodiment, the same test as that for the present embodiment was performed for a comparative example. The configuration of the fixing film 1 according to the comparative example will be described with reference to
Except for the fixing film 1, the configuration of the fixing device of the comparative example is the same as that of the fixing device of the first embodiment. The elastic layer 4b and the mold release layer 4c of the pressure roller 4 are 218 mm long in the longitudinal direction. As in
In the comparative example, as illustrated in
For the comparative example, a test was performed to observe how the fixing film 1 generated heat. Again, the controlled temperature of the ixing film 1 was kept at 200° C., the rotational speed of the pressure roller 4 was set at 150 mm/s, and the fixing device continued to run idle without passing any sheet (recording material P) therethrough. After 15 hours, the resistive heat generating layers 1e partly began to crack and the resulting increase in resistance at the cracks and abnormal heating were observed. After the continuous endurance test for 20 hours, part of the resistive heat generating layers 1e completely broke and stopped generating heat. Then after 30 hours, all the resistive heat generating layers 1e completely broke and heat generation in the entire fixing film 1 stopped.
The tests performed for comparison, as described above, reveal that the connecting portions between each electrode layer 1b and the resistive heat generating layers 1e of the fixing film 1 according to the present embodiment are more resistant to damage than those of the fixing film 1 according to the comparative example.
The present embodiment can thus provide a fixing film in which the connecting portion between the electrode portion and the heat generating portion is resistant to damage.
In the present embodiment, where the electrode layers 1b have a volume resistivity lower than the resistive heat generating layers 1e, the electrode layers 1b are made of a material different from that for the resistive heat generating layers 1e. This is to make the amount of heat generation in the electrode layers 1b smaller than that in the resistive heat generating layers 1e, because the electrode layers 1b are located outside the region through which the recording material P passes. However, the configuration is not limited to this. That is, the electrode layers 1b and the resistive heat generating layers 1e may be made of the same material. For example, the resistive heat generating layers 1e and the electrode layers 1b may be simultaneously formed as a continuous layer by screen printing over the base layer 1a.
Although the heat generating portion of the present embodiment is formed by a plurality of thin linear layers extending in the longitudinal direction of the fixing film, the configuration is not limited to this. The heat generating portion may have any configuration as long as the total length of all the thin linear layers forming the heat generating portion is 1/10 to ¾ of the entire length of the base layer in the circumferential direction of the fixing film.
A second embodiment will now be described with reference to
The configuration of the fixing film 1 of the present embodiment is the same as that of the fixing film 1 of the first embodiment. In the present embodiment, the elastic layer 4b and the mold release layer 4c of the pressure roller 4 are 226 mm long in the longitudinal direction. The elastic layer 4b and the mold release layer 4c are equal in length to the overcoat layer 100 of the fixing film 1 and are aligned therewith at both ends in the longitudinal direction. The other configurations are the same as those of the first embodiment.
As illustrated in
A third embodiment will now be described with reference to
In the four different configurations illustrated in
As in the second embodiment, the elastic layer 4b and the mold release layer 4c of the pressure roller 4 in the present embodiment are 226 mm long in the longitudinal direction. That is, as illustrated in
In the configurations illustrated in
Although the overcoat layer 100 including the elastic layer 1c is used in the first, second, and third embodiments, the configuration of the overcoat layer 100 is not limited to this. That is, the overcoat layer 100 may be made of any material that has a lower Young's modulus than the base layer 1a. As described, the overcoat layer 100 is in contact with the electrode layers 1b at both ends of the fixing film 1. Therefore, to prevent current from flowing into the overcoat layer 100, the overcoat layer 100 preferably has a higher electrical resistance than the resistive heat generating layers 1e. The overcoat layer 100 is preferably an insulating layer. The elastic layer 1c of the overcoat layer 100 may be, for example, a layer of silicone rubber containing a thermally conductive filler with high electrical resistance, or an insulating thermally conductive filler, dispersed therein. Similarly, when the overcoat layer 100 is made of metal, the inner surface of the overcoat layer 100 of metal needs to be insulated to prevent a short circuit through the overcoat layer 100 between the electrodes at both ends.
For the reasons described above, it is preferable that the overcoat layer 100 include an elastic layer made of silicone rubber, such as that described in the first, second, and third embodiments. Alternatively, the overcoat layer 100 may include the mold release layer 1d alone.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-109285 | May 2016 | JP | national |
This application is a Continuation of International Patent Application No. PCT/JP2017/019556, filed May 25, 2017, which claims the benefit of Japanese Patent Application No. 2016-109285, filed May 31, 2016, both of which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2017/019556 | May 2017 | US |
| Child | 16201875 | US |
