Patent Grant
11029632
The present disclosure relates to a fixing apparatus for use with an image forming apparatus, such as a copying machine, a printer, or a facsimile, which includes a function of forming an image on a recording material.
An electrophotographic process using toner has heretofore been widely used for image forming apparatuses such as a copying machine, a printer, and a facsimile. As a fixing apparatus for use with such image forming apparatuses, a fixing apparatus having the following structure is known. That is, the fixing apparatus has a structure in which a ceramic heater provided with a pattern of heat generating resistors on a ceramic substrate is used as a heating member and a fixing film which is a rotatable cylindrical endless belt to be heated by the heating member is used. Specifically, a fixing apparatus that employs a film heating process as described below is known. That is, a recording material is brought into pressure contact by a cylindrical fixing film and a pressure roller, and the recording material bearing an image is nipped and conveyed by a pressure-contact portion (fixing nip portion) while being heated, to thereby fix a toner image onto the recording material as a fixed image.
The fixing apparatus that employs the film heating process as described above has a feature that a ceramic heater and a fixing film with a low heat capacity can be used, and thus the temperature of each of the ceramic heater and the fixing film can be increased to a temperature at which the fixing process can be achieved in a short period of time. Therefore, the fixing apparatus that employs the film heating process has advantages such as a reduction in wait time (quick start property: activation on demand), power saving, and suppression of a temperature rise in the main body of an image forming apparatus.
In the fixing apparatus that employs the film heating process, when a recording material (small-size paper) having a width narrower than that of a recording material (large-size paper) having a maximum width for printing is caused to pass in a longitudinal direction, the temperature gradually rises in a non-sheet-passing area (non-sheet-passing portion temperature rise). This temperature rise in the non-sheet-passing portion increases as the speed of printing increases, which is one of the issues for obtaining high productivity.
As one method for suppressing the temperature rise in the non-sheet-passing portion, a method of improving thermal conductivity in the longitudinal direction by disposing a thermal conductive member in contact with the back surface of a heating member such as a ceramic heater is known (Japanese Patent Application Laid-Open No. 11-84919).
However, one of the issues of a fixing apparatus having a structure in which a thermal conductive member is disposed in contact with the back surface of a heating member is an increase in First Print Out Time (FPOT) in an image forming apparatus using such a fixing apparatus. The FPOT refers to a time period since a print signal is transmitted to a printer until a first recording material is discharged from the printer. To shorten the FPOT, it is necessary to use members having a low heat capacity in the fixing apparatus. However, if the thickness of the thermal conductive member is increased to enhance the effect on the temperature rise in the non-sheet-passing portion, the heat capacity increases by that amount, resulting in an increase in heat capacity of the entire fixing apparatus. Accordingly, heat generated from the heater is easily transferred to the thermal conductive member, which leads to a deterioration in the efficiency of heat supply to the recording material.
The present disclosure has been made in view of the above-described circumstances and is directed to providing a fixing apparatus capable of suppressing a temperature rise in a non-sheet-passing portion without degrading FPOT.
According to an aspect of the present disclosure, a fixing apparatus includes a rotatable cylindrical film, a heater including a first surface in contact with an inner peripheral surface of the film, and a second surface disposed on an opposite side of the first surface, a support member configured to support the heater, and a pressure member configured to form a nip with the heater through the film. The fixing apparatus heats a toner image at the nip, and fixes the toner image onto a recording material. The fixing apparatus also includes a thermal conductive member in contact with the second surface, and a thermal-resistant member disposed between the thermal conductive member and the support member and having a thermal conductivity lower than the thermal conductivity of the thermal conductive member.
Further features and aspects of the present disclosure will become apparent from the following description of example embodiments with reference to the attached drawings.
Example embodiments and various aspects of the present disclosure will be described in detail below.
(Outline of Example Fixing Apparatus)
The fixing apparatus 18 includes a film assembly 31, which is a flexible rotary member including a fixing film 36, and a pressure roller 32 which is a pressure member. The film assembly 31 and the pressure roller 32 are provided substantially in parallel to each other vertically between left and right side plates 34 of an apparatus frame 33.
The pressure roller 32 includes a core metal 32a and an elastic layer 32b which is formed in a roller shape concentrically integral with the core metal 32a and is made of silicone rubber, fluororubber, or the like. On the elastic layer 32b, a release layer 32c which is made of a perfluoroalkoxy alkane (PFA), polytetrafluoroethylene resin (PTFE), tetrafluoroethylene-hexafluoropropylene copolymer resin (FEP), or the like is formed. In the present example embodiment, the pressure roller 32 having a structure in which the elastic layer 32b having a thickness of approximately 3.5 mm is formed on the core metal 32a, which is made of stainless steel and has an outer diameter of 11 mm, by injection molding and the PFA resin tube 32C having a thickness of approximately 40 μm is coated on the silicone rubber layer 32b is used. The outer diameter of the pressure roller 32 is 18 mm. The hardness of the pressure roller 32 is can be in a range from 40° to 70° with a load of 9.8 N by an ASKER-C hardness meter from the standpoint of securing a fixing nip portion N, endurance, and the like. In the present example embodiment, the hardness of the pressure roller 32 is set to 540. The length of a longitudinal rubber surface of the pressure roller 32 is 226 mm. As illustrated in
The film assembly 31 is illustrated in
The heater 37 is a heating member that heats the fixing film 36. The heater holder 38 guides the fixing film 36 from the inside and supports the heater 37. The thermal-resistant sheet 100 is a thermal-resistant member which is disposed on a surface where the heater 37 is not in contact with the fixing film 36. The thermal conductive member 51 is a heat leveling member that is disposed between the thermal-resistant sheet 100 and the heater holder 38. The film assembly 31 has a structure in which the left and right fixing flanges (regulating members) 41 regulate the movement in the longitudinal direction of the pressure stay 40 and the fixing film 36.
In the present example embodiment, the fixing film 36 has an outer diameter of 18 mm in a non-deformed cylindrical state, and has a multi-layer structure in the thickness direction. The fixing film 36 includes layers, such as a base layer for maintaining the strength of the fixing film 36, and a release layer for reducing the adhesion of soiling on the surface of the fixing film 36. The material of the base layer is required to have a heat resistance because the base layer receives heat from the heater 37. The material of the base layer is also required to have a sufficient strength because the base layer and the heater 37 slide against each other. Accordingly, metal, such as stainless steel or nickel, or a heat resistant resin, such as polyimide, may be used. In the present example embodiment, a polyimide resin is used as the material of the base layer of the fixing film 36, and a carbon-based filler for improving the thermal conductivity and strength is added. Heat generated from the heater 37 is more likely to be transferred to the surface of the pressure roller 32 as the thickness of the base layer decreases, while the strength deteriorates due to a decrease in the thickness of the base layer. For this reason, the thickness of the base layer can be approximately 15 μm to 100 μm. In the present example embodiment, the thickness of the base layer is 50 μm.
As the material of the release layer of the fixing film 36, fluorine resins such as PFA, PTFE, and FEP can be used. In the present example embodiment, the PFA having excellent releasability and heat resistance among the fluorine resins is used. As the release layer, a layer coated with a tube may be used, and a layer having a surface coated with coating solution may also be used. In the present example embodiment, the release layer is molded by a coating method excellent in thin molding. Although heat generated from the heater 37 is more likely to be transferred onto the surface of the fixing film 36 as the thickness of the release layer decreases, the endurance deteriorates if the thickness of the release layer is extremely small. Accordingly, the thickness of the release layer can be approximately 5 μm to 30 μm. In the present example embodiment, the thickness of the release layer is 10 μm. Although not used in the present example embodiment, an elastic layer may be provided between the base layer and the release layer. In this case, silicone rubber, fluororubber, or the like is used as the material of the elastic layer.
As illustrated in
As illustrated in
When power is supplied to the heat generating resistors 37b from a feed portion located at an end of the heater 37, the temperature of the heater 37 rapidly rises. Then, the heater temperature is detected by the thermistor 42, and the supply of power to the heat generating resistors 37b from the feed portion is controlled by a control portion (not illustrated) so that the temperature can be controlled at a predetermined temperature.
The pressure stay 40 is a horizontally-long rigid member having a downward U-shaped cross section. In the present example embodiment, stainless steel with a plate thickness of 1.6 mm is used.
As illustrated in
As illustrated in
As illustrated in
Further, a rotary force is transmitted from the drive mechanism portion (not illustrated) to the drive gear G of the pressure roller 32, so that the pressure roller 32 is rotationally driven at a predetermined speed clockwise in
In a state where the fixing film 36 is rotated in accordance with the rotation of the pressure roller 32 and the heater 37 is energized to increase the heater temperature to a predetermined temperature and then the heater temperature is controlled, a recording material P is introduced. An inlet guide 30 has a function of guiding the recording material P so that the recording material P having an unfixed toner image t formed thereon can be accurately guided to the fixing nip portion N.
When the recording material P bearing the unfixed toner image t advances between the fixing film 36 and the pressure roller 32 of the fixing nip portion N, the recording material P is nipped and conveyed together with the fixing film 36 in a state where the toner image bearing surface of the recording material P is in close contact with the outer surface of the fixing film 36. The recording material P is heated by heat from the fixing film 36 which is heated by the heater 37 in the nipping and conveyance process, and the unfixed toner image t formed on the recording material P is heated and pressed onto the recording material P and is then melted and fixed. The recording material P which has passed through the fixing nip portion N is curvature-separated from the surface of the fixing film 36 and is then discharged and conveyed by a discharge roller pair (not illustrated).
The substrate 37a of the heater 37 has a rectangular parallelepiped shape having a longitudinal-direction length of 260 mm, a width-direction length of 5.8 mm, and a thickness of 1.0 mm, and is made of alumina. The longitudinal-direction length of each heat generating resistor 37b on the heater 37 is 222 mm. Also, when the recording material P of a maximum size (having a width of 216 mm in the present example embodiment) that can be used in an image forming apparatus incorporating the fixing apparatus 18 according to the present example embodiment is used, the heater 37 has a width greater than that of the recording material P so that toner can be uniformly fixed onto the recording material P.
Accordingly, in an area outside the width of the recording material P, heat supplied from the heater 37 is not absorbed by the recording material P and the toner thereon, and the heat is accumulated in the components such as the fixing film 36, the heater 37, and the heater holder 38. When paper is used as the recording material P, in an area outside the recording material P (the area is hereinafter referred to as a non-sheet-passing portion), an excessive temperature rise is likely to occur. This phenomenon is referred to as a “non-sheet-passing portion temperature rise”. The temperature at which each member is used has an upper limit. If each member is used at a temperature higher than the upper limit, a problem such as a damage to the member is caused. For this reason, it is necessary to use each member at a temperature lower than or equal to a certain temperature. The “non-sheet-passing portion temperature rise” becomes prominent as the width of the recording material P with respect to the length of each heat generating resistor 37b becomes smaller. Accordingly, some measures, such as reduction of an output speed by increasing intervals between recording materials P, are required to reduce the non-sheet-passing portion temperature rise to a certain temperature or lower. Further, if the “non-sheet-passing portion temperature rise” occurs, a thermal stress is applied to the heater 37 due to a temperature difference between a sheet-passing portion and the non-sheet-passing portion, which may cause a damage to the heater 37.
(Arrangement of Example Thermal-Resistant Sheet and Thermal Conductive Member)
In this case, the thermal conductive member 51 having a thermal conductivity higher than the thermal conductivity of the base material of the heater 37 is disposed on the back surface of the heater 37, thereby obtaining a heat leveling effect in which temperature variations in the longitudinal direction are averaged by transferring heat from the non-sheet-passing portion which is at a high temperature to the sheet-passing portion which is at a relatively low temperature. Specifically, the thermal conductive member 51 having a thermal conductivity higher than the thermal conductivity of 32 W/m·K of the base material of the heater 37 formed of aluminum is used. Thus, heat generated outside the recording material P is also transferred to the sheet-passing portion through the thermal conductive member 51 and is then transmitted to the recording material P, so that the heat can be used more efficiently and the “non-sheet-passing portion temperature rise” can be suppressed.
A heat leveling member using the thermal conductive member 51 as illustrated in
However, if the thickness of a material such as a metal plate is increased, the heat capacity also increases in proportion to an increase in thickness. When the heat capacity of the thermal conductive member 51 is increased, heat generated from the heater 37 is lost to the thermal conductive member 51 at start-up of the fixing apparatus 18, which leads to an increase in time required for the temperature to rise to a temperature at which the fixing film 36 can be fixed.
Accordingly, in the present example embodiment, the thermal-resistant sheet 100 is disposed between the heater 37 and the thermal conductive member 51. Thus, the pressing force to be applied from the heater holder 38 is sequentially transmitted to the thermal conductive member 51, the thermal-resistant sheet 100, and the heater 37, so that the heater 37 can be pressed against the pressure roller 32 through the fixing film 36 and a uniform fixing pressure can be applied. On the other hand, in the structure according to the present example embodiment, the thermal resistance value of the thermal-resistant sheet 100 is increased and the heat capacity is decreased to achieve a high-speed start-up, and the non-sheet-passing portion temperature rise can be suppressed by the heat transport amount of the thermal conductive member 51 with a large cross-sectional area during the occurrence of the non-sheet-passing portion temperature rise.
The structure and advantageous effects of the present example embodiment will be described in detail below. The structure and arrangement of the thermal conductive member 51 and the thermal-resistant sheet 100 will be described with reference to
As illustrated in
In the present example embodiment, the longitudinal-direction length of each of the thermal conductive member 51 and the thermal-resistant sheet 100 is 222 mm, and the width-direction length of each of the thermal conductive member 51 and the thermal-resistant sheet 100 is 5.8 mm. The longitudinal-direction length is set to be equal to the length of each heat generating resistor 37b of the heater 37, thereby obtaining a temperature averaging effect without deficiency or excess. The thermal conductivity and thickness of each of the thermal conductive member 51 and the thermal-resistant sheet 100 according to the present example embodiment will be described in detail below.
As illustrated in
Accordingly, the heater holder 38, the thermal conductive member 51, the thermal-resistant sheet 100, and the heater 37 are not fixed to each other so as to absorb a difference in thermal expansion and bending caused due to the pressing force. The heater holder 38, the thermal conductive member 51, the thermal-resistant sheet 100, and the heater 37 contact each other by the spring property of the holding member and the pressing force generated by the pressure roller 32.
As illustrated in
In the present example embodiment, Kapton® (DU PONT-TORAY CO., LTD.), which is a polyimide film having a high heat-insulating property, is used as the thermal-resistant sheet 100, and the thermal conductivity is set to 0.16 [W/mK]. The specific heat and the density of the thermal-resistant sheet 100 are 1.16 [kJ/kgK] and 2000 [kg/m3], respectively. Pure aluminum is used as the thermal conductive member 51 and the thermal conductivity is set to 237 [W/mK]. The specific heat and the density of the thermal conductive member 51 are 0.905 [kJ/kgK] and 2688 [kg/m3], respectively. These values are merely examples. The thermal-resistant sheet 100 may have any value as long as the thermal conductivity is less than or equal to 2 [W/mK] so as to achieve high-speed start-up, and the thermal conductive member 51 may have any value as long as the thermal conductivity is greater than or equal to 80 [W/mK] so as to suppress the non-sheet-passing portion temperature rise.
The thermal resistance [K/W] of each of the thermal-resistant sheet 100 and the thermal conductive member 51 is obtained by dividing the thickness of each member by the product of the thermal conductivity and the area in the plane direction. The heat capacity [J/Km2] per unit area in the plane direction is obtained by integrating the specific heat, the density, and the thickness.
The present example embodiment has a feature in that the thermal resistance in the thickness direction of the thermal-resistant sheet 100 is higher than that of the thermal conductive member 51, and the heat capacity in the plane direction of the thermal conductive member 51 is higher than that of the thermal-resistant sheet 100.
When the above-described relationships are satisfied, heat generated from the heater 37 at the start-up can be prevented from being lost to the thermal conductive member 51 due to the high thermal resistance of the thermal-resistant sheet 100. Accordingly, the heat capacity of the thermal conductive member 51 can be increased. Since the heat capacity of the thermal-resistant sheet 100 is low during continuous printing in which the non-sheet-passing portion temperature rise occurs, heat is transmitted to the thermal conductive member 51, so that the non-sheet-passing portion temperature rise can be suppressed by the heat transport amount.
Next, advantageous effects of the present disclosure will be described with reference to
As a result, in the comparative example, the fixing start-up time was 6.0 seconds and the maximum temperature of the pressure roller 32 when the temperature rise occurred in the non-sheet-passing portion was 230° C. Based on the results of the comparative example,
When the thickness of the thermal-resistant sheet 100 is 0.3 [mm] and the thermal resistance is 14.6 [K/W], the heat-insulating performance of the thermal-resistant sheet 100 was too high, and thus an improvement in the effect of suppressing the non-sheet-passing portion temperature rise was not confirmed even when the thickness of the thermal conductive member 51 was set to 10 [mm].
On the other hand, when the thickness of the thermal-resistant sheet 100 is in a range from 0.05 to 0.25 [mm], excellent results for both the start-up time and the temperature rise in the non-sheet-passing portion were obtained by optimizing the thickness of the thermal conductive member 51.
In this regard,
As illustrated in
0.09X+2.85<Y<2.55X+2.6[log 10 (J/K·m2)] (A)
In expression (A), the thermal resistance is set to be greater than 2.0 [K/W] so that X [K/W] is set in a range in which no failure occurs due to the non-sheet-passing portion temperature rise, and the thermal resistance is set to be less than 12.5 [K/W] so that X [K/W] is set in a range that does not exceed the upper limit of the start-up time.
Table 2 illustrates a list of measurement results of the start-up time and the non-sheet-passing portion temperature rise when the material and the thermal conductivity of the thermal-resistant sheet 100 are varied. As the thermal-resistant sheet 100, not only Kapton®, but also UPILEX® (UBE INDUSTRIES, LTD.) and a mixture of polyimide and thermal conductive filler such as boron nitride carbon fiber were used. UPILEX® includes polyimide as the main material, just as in the case of Kapton®, and has a thermal conductivity of 0.29 [W/mK]. A mixture of polyimide and thermal conductive filler such as boron nitride carbon fiber, in which the amount of thermal conductive filler was adjusted as needed and the thermal conductivity was 2.0 [W/mK], was used. The measurement was carried out at the same thermal resistance by changing the thickness of the thermal-resistant sheet 100. Each thermal-resistance sheet 100 was evaluated by using 3-mm pure aluminum as the thermal conductive member 51 and by setting the thermal conductivity to 237 [W/mK] and the heat capacity to 3.86 [log 10 (J/K·m2)]. When the thermal-resistant sheets 100 have the same thermal resistance, the values of the start-up time and the non-sheet-passing portion temperature rise were the same even when a heat-insulating member other than Kapton® was used, and the same advantageous effects as those of the present example embodiment were obtained.
Next, Table 3 illustrates a list of measurement results of the start-up time and the non-sheet-passing portion temperature rise when iron and copper, which is metal other than pure aluminum, are used as metal materials of the thermal conductive member 51. Iron has a thermal conductivity of 80 [W/mK], and the specific heat and the density of iron are 0.442 [kJ/kgK] and 7870 [kg/m3], respectively. Copper has a thermal conductivity of 398 [W/mK], and the specific heat and the density of copper are 0.386 [kJ/kgK] and 8880 [kg/m3], respectively. Accordingly, in the present example embodiment, the measurement was carried out at the same heat capacity by changing the thickness of the thermal conductive member 51. The thermal conductive member 51 was evaluated by using Kapton® with a thickness of 150 [μm] as the thermal-resistant sheet 100 and by setting the thermal conductivity to 0.16 [W/mK] and the thermal resistance to 7.3 [K/W].
At the same heat capacity of the thermal conductive member 51, the values of the start-up time and the non-sheet-passing portion temperature rise were the same even when metal other than pure aluminum was used, and the same advantageous effects as those of the present example embodiment were obtained.
The present example embodiment has been described above using the thermal-resistant sheet 100 including polyimide as the main material. However, as the thermal-resistant sheet 100, a material having a low thermal conductivity and a high thermal resistance, such as PFA, PTFE, or FEP can be used.
While the present example embodiment has been described above using pure aluminum, iron, and copper as the material of the thermal conductive member 51, the material is not limited to metal as described above. As long as the heat capacity falls within the range indicated by the expression (A), other metals having a high thermal conductivity and a high heat capacity, such as gold, silver, nickel, and brass, can also be used. As long as the heat capacity falls within the range indicated by the expression (A), the same advantageous effects as those described above can be obtained by using a material other than metal, such as silicone rubber or carbon graphite.
While the present disclosure has been described with reference to example embodiments, it is to be understood that the disclosure is not limited to the disclosed example 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.
This application claims the benefit of Japanese Patent Application No. 2018-088842, filed May 2, 2018, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| JP2018-088842 | May 2018 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20140138372 | Ogura | May 2014 | A1 |
| 20150227091 | Ando | Aug 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| 11-084919 | Mar 1999 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20190339638 A1 | Nov 2019 | US |
