The present disclosure relates to fixing apparatuses installed in image forming apparatuses, such as electrophotographic copying machines and electrophotographic printers.
Examples of the fixing apparatuses installed in electrophotographic printers and the like include a fixing apparatus that include a cylindrical film (also referred to as “belt”) including a resistance heating layer and that passes a current through the resistance heating layer to cause the film to generate heat. Japanese Patent Laid-Open No. 2011-253085 discloses a fixing apparatus that includes an electric contact at an end of the film and that passes a current through the film in the direction of the rotation axis of the film to cause the film to generate heat. Japanese Patent Laid-Open No. 2014-26267 discloses an induction heating fixing apparatus that includes an energizing coil and a magnetic core in the internal space of the film and that causes the film to generate a current flowing in the circumferential direction of the film by electromagnetic induction.
A detector for detecting the temperature of the film may be disposed in the internal space of the film because a recording material may wind around the film to hinder correct measurement of temperature. Japanese Patent Laid-Open No. 2015-210203 discloses a temperature sensor disposed in contact with the film and including a thermistor element.
A film that comes into contact with a toner image on a recording material is so thin that it has low heat capacity. If the fixing apparatus is in normal operation, the film generates heat while rotating in contact with a pressure roller, which causes the heat to be sequentially removed by the member in the film, the pressure roller, and so on. Thus, the rate of temperature rise of the film is decreased by the amount of heat removed. For this reason, the temperature sensor that detects the temperature of the film tends to follow the rate of temperature rise of the film.
However, in case of an abnormality, such as when the film slips and does not rotate, the heat removed by the pressure roller and so on decreases, thereby significantly increasing the rate of temperature rise of the film. In such a case, the response of the temperature sensor falls behind the temperature rise of the film, which may cause a delay in activating the safety mechanism of the apparatus.
According to an aspect of the present disclosure, a fixing apparatus to fix a toner image formed on a recording material to the recording material includes a rotatable member including a heat generation layer, a power supply circuit configured to supply electrical power to the rotatable member, and a control unit configured to control supply of electrical power to the rotatable member and to detect a change rate of electrical resistance of the heat generation layer, wherein the heat generation layer generates heat by the electrical power supplied to the rotatable member, and the toner image on the recording material is fixed to the recording material by the heat from the heat generation layer, and wherein, if the change rate of the electrical resistance to the supplied electrical power is higher than a predetermined threshold, the control unit stops the supply of electrical power to the rotatable member.
Further features of the present disclosure will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
1. Description of Printer
First, a printer, which is an image forming apparatus, will be described with reference to
The recording materials P in the cassette 2 are separated one by one by a separation roller 3 and are fed to registration rollers 4. The printer 1 includes image forming units 5Y, 5M, 5C, and 5K corresponding to yellow, magenta, cyan, and black, respectively. The image forming unit 5Y includes a photosensitive member 6Y and a charging unit 7Y that charges the surface of the photosensitive member 6Y uniformly. The photosensitive member 6Y charged by the charging unit 7Y is scanned with a laser beam according to image information, emitted from a scanner unit 8. Thus, an electrostatic latent image according to the image information is formed on the photosensitive member 6Y. The electrostatic latent image is developed by toner supplied from a developing unit 9Y. The toner image on the photosensitive member 6Y is transferred to an electrostatic transfer belt 10 at a primary transfer portion 11Y. Also in the other image forming units 5M, 5C, and 5K, a toner image is formed, and a four-color toner image superposed on the electrostatic transfer belt 10 is transferred to the recording material P at a secondary transfer portion 12. The toner image transferred to the recording material P is fixed to the recording material P by a fixing unit A. Thereafter, the recording material P is discharge to a stacking unit 14 through a conveying portion 13.
2. Description of Fixing Apparatus (Fixing Unit)
The fixing apparatus A is an electromagnetic induction heating fixing apparatus.
A cylindrical fixing film (rotatable member) 20 includes a base layer 20a, a heat generation layer 20b, an elastic layer 20c, and a releasing layer 20d. The material of the base layer 20a is an insulating heat-resistant resin, such as polyimide, polyamidoimide, polyetheretherketone (PEEK), or polyethersulfone (PES), having an inside diameter of 30 mm, a length of 240 mm, and a thickness of about 50 μm. The material of the heat generation layer 20b is iron, copper, silver, aluminum, nickel, chrome, tungsten, or an alloy containing them, such as SUS304 (stainless steel) or nichrome. Other example materials include electrical conductors, such as carbon fiber reinforced plastic (CFRP) and carbon nanotube resin, whose absolute value of the temperature coefficient of resistance may be large. Examples of a method for forming the heat generation layer 20b include coating, plating, sputtering, and depositing. The heat generation layer 20b of this embodiment is formed of copper with a thickness of about 2 μm by electrolytic plating. The material of the elastic layer 20c may have high heat resistance and heat conductivity, such as silicone rubber, fluorine-containing rubber, or fluorosilicone rubber. The elastic layer 20c of this embodiment is made of silicone rubber with a thickness of about 200 μm. The material of the releasing layer 20d may have high releasing properties and heat resistance, such as perfluoroalkoxy (PFA), polytetrafluoroethylene (PTFE), or fluorinated ethylene propylene (FEP). In this embodiment, the releasing layer 20d is formed of a PFA resin tube with a thickness of about 15 μm. The inner surface of the fixing film 20 is in contact with a film guide member 25 formed of a heat-resistant resin, such as polyphenylene sulfide (PPS).
A pressure roller 21 includes a metal core 21a and an elastic layer 21b that coats the metal core 21a concentrically in a roller shape and further includes a releasing layer 21c on the surface layer. The elastic layer 21b may be made of a heat-resistant material, such as silicone rubber, fluorine-containing rubber, or fluorosilicone rubber.
The opposite ends of the metal core 21a are held by a side plate (not shown) which is part of the chassis of the fixing apparatus A via a conductive bearing. Pressure springs 24a and 24b are respectively disposed between the opposite ends of a metal stay 22 for providing the fixing apparatus A with sufficient rigidity and spring bearings 23a and 23b of the chassis so that the stay 22 is pressed toward the pressure roller 21. The fixing apparatus A of this embodiment applies a pressing force of about 100 to 300 N (about 10 to 30 kgf) in total to the stay 22. Thus, a fixing nip portion N is formed between the film guide member 25 and the pressure roller 21, with the fixing film 20 therebetween. The pressure roller 21 id driven by a motor (not shown), and the fixing film 20 is rotated with the rotation of the pressure roller 21.
A magnetic core 26 passes through the inner space of the stay 22 with a U-shaped cross section.
The magnetic core 26 has a columnar shape with ends and is disposed roughly in the radial center of the fixing film 20. Thus, the fixing film 20 houses the energizing coil 27 wound so as to form a helical portion whose helical axis is substantially parallel to the axis of the fixing film 20 and also houses the magnetic core 26 with ends disposed in the helical portion. The magnetic core 26 has a role in inducing the magnetic line (magnetic flux) of an alternating magnetic field generated by the energizing coil 27 to form a path (magnetic path) for the magnetic line. The material of the magnetic core 26 may be a material with small hysteresis loss and high relative magnetic permeability, for example, a ferromagnetic substance with high magnetic permeability, such as calcined ferrite or ferrite resin. The cross-sectional shape of the magnetic core 26 may be any shape that can be housed in the inner space of the fixing film 20 and may be as large as possible although not have to be circular. The magnetic core 26 of this embodiment is 10 mm in diameter and 280 mm in length. The energizing coil 27 is made of a copper wire (single conducting wire) having a diameter of 1 to 2 mm coated with heat-resistive polyamidoimide and is wound around the magnetic core 26 into a helical shape. The winding number is 20. The helical axis of the energizing coil 27 is parallel to the axis of the magnetic core 26. Passing a high-frequency current through the energizing coil 27 causes an inductive current to flow through the heat generation layer 20b to cause the heat generation layer 20b to generate heat on the basis of the principle described below.
The temperature of the fixing film 20 is detected by a temperature sensor 30. The temperature sensor 30 includes a leaf spring 30a fixed to the stay 22 at one end, a thermistor (temperature detection element) 30b disposed at the other end of the leaf spring 30a, and a sponge 30c interposed between the leaf spring 30a and the thermistor 30b. The surface of the thermistor 30b is covered with a polyimide tape 50 μm in thickness to provide electrical insulation. The sponge 30c functions as a heat insulator for the thermistor 30b and also has the function of fitting the thermistor 30b softly to the fixing film 20 to be measured.
The thermistor 30b covered with the polyimide tape is brought into contact with the inner surface of the fixing film 20 by the spring force of the leaf spring 30a. The output (voltage value) of the thermistor 30b is converted from analog to digital and is input to a control circuit (control unit) 100 (see
3. Description of Principle of Heating
Thus, the fixing apparatus A includes the fixing film 20 including the heat generation layer 20b, a power supply circuit (
4. Description of Method for Detecting Stop-Heated State
Next, a method for detecting a stop-heated state will be described. The electrical energy (electrical power) supplied from the power source is finally converted to thermal energy by Joule's heat generated from the heat generation layer 20b of the fixing film 20. When electrical power is supplied to the energizing coil 27 while the fixing film 20 is normally rotating, the Joule's heat generated by the orbital current flowing around the heat generation layer 20b raises the temperature of the pressure roller 21 and the film guide member 25 in addition to the fixing film 20 itself.
In contrast, electrical power is supplied while the fixing film 20 is not rotating, most of the thermal energy generated from the heat generation layer 20b raises only the temperature of the fixing film 20. In this case, the rate of temperature rise of the fixing film 20 increases significantly because the heat capacity of the fixing film 20 is small.
Employing a material that changes in electrical resistance according to the temperature as a material for the heat generation layer 20b allows for determining whether the fixing film 20 is in an abnormal state in principle. However, if the absolute value of the temperature coefficient of resistance is low, the change rate of the electrical resistance is also low, which requires high detection accuracy for a unit for detecting the change rate of the electrical resistance. Accordingly, it is preferable that the change rate of the electrical resistance be about 10%. If the temperature coefficient of resistance is 550×10−6/° C., the change rate of the electrical resistance in the case of the temperature rise from 20° C. to 200° C. is about 10%. If the temperature coefficient of resistance is 1100×10−6/° C. or higher, its change rate is about 20%, which is more preferable. This embodiment employs copper plating for the heat generation layer 20b, and the temperature coefficient of resistance is about 1,500×10−6/° C.
Next, a method for finding the change rate of electrical resistance to the suppled electrical power will be described.
To find the electrical resistance of the fixing film 20, the film voltage and the film current applied to the fixing film 20 have to be obtained. However, a voltage detection circuit and a current detection circuit cannot be connected to the fixing film 20. However, even if the film voltage and the film current are not measured directly, the change rate of the electrical resistance of the fixing film 20 can be found if the supply voltage and the supply current can be measured.
Disposing a current detection circuit at the GND end of the power supply circuit, as shown in
Another method for calculating the supply voltage is calculation using a voltage detection circuit disposed at another position (the position in
Another method for changing the output voltage is changing the duty cycle of the square wave.
Next, another method for calculating the supply voltage will be described.
For this reason, the control unit 100 detects the change rate of the electrical resistance of the heat generation layer 20b, and if the change rate of electrical resistance to the supplied electrical power is higher than a threshold, the control unit 100 determines that the fixing film 20 is in the stop-heated state and reduces or stops the supply of electrical power to the fixing film 20.
If the electrical power supplied to the fixing film 20 is always constant, it can be determined whether the fixing film 20 is in the rotation-heated state or the stop-heated state by determining whether the change rate of the electrical resistance to the electrical power is less than a predetermined threshold. However, it is rare that constant electrical power is constantly supplied. For example, the electrical resistance value of the heat generation layer 20b increases with a change in temperature even at a constant voltage, which decreases consumed electrical power. For this reason, after finding the accumulated value of power for a predetermined time and calculating the average of the power, it may be determined whether the fixing film 20 is in the rotation-heated state or the stop-heated state from the change rate of electrical resistance with respect to the average electrical power.
Alternatively, a sequence of constant power supply may be provided. For example, in adjusting the temperature of the fixing apparatus A to a predetermined temperature at the start of printing, by supplying a fixed amount of electrical power only for a predetermined time, and finding the rate of change in electrical resistance in the period, it can be determined whether the fixing apparatus A is in the rotation-heated state or the stop-heated state.
If the sequence of supplying constant electrical power is provided, it is necessary to pay attention to the amount of power to be supplied.
For example, if the electrical power to be supplied during the period PA is set to the maximum power, there is no issue when the fixing apparatus A is cool at the start of power supply. However, if the fixing apparatus is warm, the temperature of the fixing film 20 during constant power supply can become higher than the target temperature for fixing processing. In contrast, if the electrical power supplied during the period PA is excessively decreased, the rate of change in resistance also decreases, which causes an issue in detection accuracy. The higher the temperature coefficient of resistance, the easier the detection, as described above. Accordingly, if the absolute value of the temperature coefficient of resistance is 550×10−6/° C., the constant electrical power value is not decreased significantly. However, if the absolute value of the temperature coefficient of resistance is 1100×10−6/° C., sufficient detection accuracy can be provided even if the constant electrical power value is decreased to about half of the maximum electrical power. Thus, abnormal temperature rise during stop-heated can also be detected while avoiding the temperature of the fixing film 20 from becoming excessively higher than the target temperature for fixing processing.
The method for determining whether the fixing film is in the rotation-heated state or the stop-heated state is effective not only for the fixing apparatus that generates heat by non-contact power supply using electromagnetic induction but also for a fixing apparatus that generates heat by contact power supply.
While the present disclosure has been described with reference to exemplary embodiments, it is to be understood that the disclosure 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.
This application claims the benefit of Japanese Patent Application No. 2021-060822 filed Mar. 31, 2021, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2021-060822 | Mar 2021 | JP | national |
Number | Name | Date | Kind |
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20110222876 | Yuasa | Sep 2011 | A1 |
20160062285 | Yonekubo | Mar 2016 | A1 |
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20220317603 A1 | Oct 2022 | US |