Patent Application
20130272757
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2012-090685 filed Apr. 12, 2012.
1. Technical Field
The present invention relates to fixing devices and image forming apparatuses.
2. Summary
According to an aspect of the invention, there is provided a fixing device including an endless belt that rotates, a heating source that heats the belt, a pad member having a sliding surface that abuts on an inner surface of the belt, and a pressure roller that presses an outer surface of the belt toward the sliding surface and rotates so as to rotate the belt. The pressure roller works together with the belt so as to fix an unfixed toner image onto a medium that bears the unfixed toner image by allowing the medium to enter between the pressure roller and the belt. Assuming that the sliding surface is divided into an upstream region and a downstream region in a moving direction of the belt moving along the sliding surface, the upstream region and the downstream region both have recessed curved surfaces in the moving direction. Moreover, a first curved surface corresponding to the upstream region has an average curvature that is larger than that of a second curved surface corresponding to the downstream region.
An exemplary embodiment of the present invention will be described in detail based on the following figures, wherein:
An exemplary embodiment of the present invention will be described below with reference to the drawings.
An image forming apparatus 1 shown in
Because the four image forming units 10Y, 10M, 10C, and 10K substantially have the same configuration, the image forming unit 10Y corresponding to yellow will be described here as a representative of the units. The image forming unit 10Y includes a photoconductor drum 11Y, a charging unit 12Y, an exposure unit 13Y, a developing device 14Y, a first-transfer unit 15Y, and a photoconductor cleaner 16Y.
The photoconductor drum 11Y is provided with a photoconductor layer over a surface of a cylindrical base, and rotates in a direction indicated by an arrow A around an axis of the cylinder while bearing an image formed on the surface. The charging unit 12Y, the exposure unit 13Y, the developing device 14Y, the first-transfer unit 15Y, and the photoconductor cleaner 16Y are arranged around the photoconductor drum 11Y in that order in the direction of the arrow A.
The charging unit 12Y electrostatically charges the surface of the photoconductor drum 11Y. The charging unit 12Y is a charging roller that is in contact with the surface of the photoconductor drum 11Y. The charging unit 12Y receives a voltage with the same polarity as that of the toner in the developing device 14Y so as to electrostatically charge the surface of the photoconductor drum 11Y in contact therewith. The exposure unit 13Y radiates exposure light onto the surface of the photoconductor drum 11Y. The exposure unit 13Y emits laser light according to an image signal supplied from outside the image forming apparatus 1 and scans the laser light across the photoconductor drum 11Y. The developing device 14Y develops an image on the surface of the photoconductor drum 11Y by using a developer. The developing device 14Y is supplied with the toner from the toner cartridge 18Y. The developing device 14Y stirs the developer having a mixture of a magnetic carrier and the toner so as to electrostatically charge the toner and the magnetic carrier, and develops the image on the surface of the photoconductor drum 11Y by using the electrostatically-charged toner. The first-transfer unit 15Y is a roller that is opposed to the photoconductor drum 11Y with an intermediate transfer belt 30 interposed therebetween. When voltage is applied to the photoconductor drum 11Y, the first-transfer unit 15Y transfers a toner image on the photoconductor drum 11Y onto the intermediate transfer belt 30. The photoconductor cleaner 16Y cleans the surface of the photoconductor drum 11Y by removing unwanted matter therefrom, such as the toner remaining in an area of the surface of the photoconductor drum 11Y having undergone the transfer process by the first-transfer unit 15Y.
The image forming apparatus 1 also includes the intermediate transfer belt 30, a fixing device 60, a sheet transport unit 80, and a controller 1A. The intermediate transfer belt 30 is an endless belt wrapped around belt support rollers 31 to 35. The intermediate transfer belt 30 rotates in a direction indicated by an arrow B via the image forming units 10Y, 10M, 10C, and 10K and a second-transfer unit 50. Toner images of the respective colors are transferred onto the intermediate transfer belt 30 from the image forming units 10Y, 10M, 10C, and 10K. The intermediate transfer belt 30 moves while bearing these toner images.
The second-transfer unit 50 is a roller that rotates while nipping the intermediate transfer belt 30 and a sheet P together with a backup roller 34, which is one of the belt support rollers 31 to 35. The second-transfer unit 50 receives a voltage having a reversed polarity relative to the charge polarity of the toners so as to transfer the toner images on the intermediate transfer belt 30 onto the sheet P. Accordingly, the toner images are transferred onto the sheet P from the image forming units 10Y, 10M, 10C, and 10K. The combination of the image forming units 10Y, 10M, 10C, and 10K, the intermediate transfer belt 30, and the second-transfer unit 50 corresponds to an example of an image forming section according to an exemplary embodiment of the present invention.
The fixing device 60 fixes the toner images onto the sheet P. The fixing device 60 nips the sheet P and allows the sheet P to pass between a belt and a roller so as to heat and press the toners, thereby fixing the toner images onto the sheet P. The configuration of the fixing device 60 will be described later.
The sheet transport unit 80 transports the sheet P along a sheet transport path R that extends through the second-transfer unit 50 and the fixing device 60. The sheet transport unit 80 includes a feed roller 81, transport rollers 82, a registration roller 84, a transport belt 85, and an output roller 86. The feed roller 81 feeds a sheet P accommodated in a sheet container T, and the transport rollers 82 transport the fed sheet P. The registration roller 84 transports the sheet P to the second-transfer unit 50, and the output roller 86 outputs the sheet P to the outside.
With regard to the basic operation of the image forming apparatus 1 shown in
The intermediate transfer belt 30 rotates in the direction of the arrow B. Similar to the image forming unit 10Y, the image forming units 10M, 10C, and 10K corresponding to the remaining colors, excluding yellow, form toner images corresponding to the respective colors. The toner images are superposed and transferred onto the intermediate transfer belt 30.
The sheet P is fed from the sheet container T by the feed roller 81. The sheet P is transported toward the second-transfer unit 50 in a direction indicated by an arrow C along the sheet transport path R by the transport rollers 82 and the registration roller 84. The registration roller 84 sends the sheet P to the second-transfer unit 50 on the basis of a timing at which the toner images are transferred onto the intermediate transfer belt 30. The second-transfer unit 50 transfers the toner images on the intermediate transfer belt 30 onto the sheet P. The sheet P having the toner images transferred thereon is transported by the transport belt 85 from the second-transfer unit 50 to the fixing device 60 where the toner images transferred on the sheet P are fixed thereto. Accordingly, an image is formed on the sheet P. The sheet P having the image formed thereon is output to the outside of the image forming apparatus 1 by the output roller 86. After the transfer process by the second-transfer unit 50, the toners remaining on the intermediate transfer belt 30 are removed therefrom by a belt cleaner 70.
Fixing Device
The fixing device 60 shown in
The endless belt 61 is wrapped around the tension roller 62, the two positioning rollers 63, and the pad member 65. The endless belt 61 is formed of a base material coated with a rubber layer and a mold-release layer. For example, the base material is composed of polyimide, and the rubber layer is composed of silicone rubber. The mold-release layer is composed of fluorine-based resin, such as perfluoroalkoxy alkane (PFA). The endless belt 61 corresponds to an example of a belt according to an exemplary embodiment of the present invention.
The external heating roller 64 is pressed against the outer surface of the endless belt 61. Roller heaters 67 that heat the endless belt 61 are provided within the tension roller 62 and the external heating roller 64. A belt temperature sensor 69 that detects the temperature of the endless belt 61 is provided at a position facing the outer surface of the endless belt 61. The controller 1A controls the amount of heat generated by the roller heaters 67 on the basis of the temperature detected by the belt temperature sensor 69.
The cleaning roller 68 is provided at a position opposed to one of the positioning rollers 63 with the endless belt 61 interposed therebetween. The cleaning roller 68 removes foreign matter from the endless belt 61 after the toner-image fixing process.
The pad member 65 is disposed so as to abut on the inner surface of the endless belt 61. The pad member 65 is composed of, for example, a metallic material and substantially has a rectangular parallelepiped shape extending longitudinally along the rotation axes of the external heating roller 64 and the pressure roller 66. One of the side surfaces of the pad member 65 that faces the pressure roller 66 serves as a sliding surface 65a that abuts on the inner surface of the endless belt 61. The pad member 65 corresponds to an example of a pad member according to an exemplary embodiment of the present invention.
A pad heater 651 that heats the pad member 65 is provided inside the pad member 65. Furthermore, inside the pad member 65, a first pad temperature sensor 652 is provided between the pad heater 651 and the sliding surface 65a, and a second pad temperature sensor 653 that detects the temperature is provided opposite the sliding surface 65a with the pad heater 651 interposed therebetween.
The first pad temperature sensor 652 detects the temperature in an area between the pad heater 651 and the sliding surface 65a in the pad member 65. The second pad temperature sensor 653 detects the temperature in an area opposite the sliding surface 65a with the pad heater 651 interposed therebetween in the pad member 65.
The fixing device 60 has two kinds of heat sources, namely, first heating sources and a second auxiliary heating source. The first heating sources correspond to the roller heaters 67 built within the tension roller 62 and the external heating roller 64 and are used for heating the endless belt 61. The second auxiliary heating source corresponds to the pad heater 651 built within the pad member 65 and heats the endless belt 61 via the pad member 65. The pad heater 651 heats the pad member 65 so as to prevent the pad member 65 from absorbing heat from the endless belt 61. Furthermore, the pad heater 651 increases an apparent heat capacity of the endless belt 61 (including the heat capacity of the pad member 65) so as to suppress a sudden temperature decrease in the endless belt 61.
The controller 1A includes a central processing unit (CPU) 101 that performs arithmetic processing, a memory 102 as a storage medium that stores data and programs to be executed by the CPU 101, and an interface (IF) 103 that exchanges signals with the components in the fixing device 60. The controller 1A controls the amount of heat generated by the roller heaters 67 on the basis of the temperature detected by the belt temperature sensor 69, and also controls the amount of heat generated by the pad heater 651 on the basis of the temperatures detected by the two pad temperature sensors 652 and 653. The controller 1A is connected to a setting reception unit 1B that receives information indicating the type of sheet to be supplied to the fixing device 60 from the sheet transport unit 80. The setting reception unit 1B is, for example, a touch-screen operable by an operator.
The fixing device 60 will be described below with reference to
The pressure roller 66 is rotationally driven by a driving mechanism (not shown) in a direction indicated by an arrow D in the state where the nip N is formed. The rotation of the pressure roller 66 causes the endless belt 61 to rotate. Specifically, when the pressure roller 66 rotates, the endless belt 61 rotates in a direction indicated by an arrow E in accordance with the rotation of the pressure roller 66. During the rotation of the endless belt 61, the endless belt 61 slides on the sliding surface 65a of the pad member 65.
The sheet P transported in the direction of the arrow C enters the nip N formed between the pressure roller 66 and the endless belt 61, and the pressure roller 66 applies pressure onto the sheet P together with the endless belt 61. While the sheet P passes through the nip N in a moving direction F, the unfixed toner images on the sheet P become fixed onto the sheet P due to the heat and the pressure applied thereto from the endless belt 61 and the pressure roller 66.
The sliding surface 65a of the pad member 65 according to this exemplary embodiment has a recessed surface in conformity to the cylindrical peripheral surface of the pressure roller 66 so as to ensure a sufficient length for the nip N. Specifically, assuming that the sliding surface 65a is divided into an upstream region and a downstream region in the moving direction F, a first curved surface 65u in the upstream region and a second curved surface 65d in the downstream region both are recessed surfaces in the moving direction F of the endless belt 61. In this exemplary embodiment, the average curvature of the first curved surface 65u in the upstream region is larger than that of the second curved surface 65d in the downstream region.
Shape of Sliding Surface
When the pressure roller 66 rotates, the endless belt 61 receives a driving force in the extending direction, that is, the moving direction F, of the endless belt 61 at the nip N. Because the endless belt 61 is pressed against the sliding surface 65a of the pad member 65 by the pressure roller 66, a shearing force is generated in the endless belt 61 in the moving direction F thereof due to the friction between the endless belt 61 and the sliding surface 65a. The endless belt 61 becomes distorted by expanding and contracting in the moving direction F at the nip N.
If the sliding surface 65a is a curved surface having a single curvature, the endless belt 61 is driven so as to be pulled in the moving direction F by the pressure roller 66 at the upstream side in the moving direction F, resulting in a relatively larger amount of expansion. Because the expansion of the endless belt 61 is elastic deformation, the amount of expansion decreases as the endless belt 61 moves. At the downstream side in the moving direction F, contraction occurs since the expansion, which is elastic deformation, occurring at the upstream side is released. When the expansion and contraction of the endless belt 61 at the nip N exceed the limit of a frictional force between the endless belt 61 and the sheet P, the endless belt 61 slips relative to the sheet P, possibly resulting in the occurrence of smearing or blurriness of the toner images on the sheet P or creases in the sheet P.
The amount by which the endless belt 61 contracts due to the driving of the pressure roller 66 varies depending on the curvature of the sliding surface 65a. Specifically, the larger the curvature of the sliding surface 65a, the larger the amount of contraction (distortion). In contrast, the smaller the curvature of the sliding surface 65a, the smaller the amount of contraction (distortion).
In the sliding surface 65a of the pad member 65, the first curved surface 65u in the upstream region has an average curvature that is larger than that of the second curved surface 65d in the downstream region. More specifically, the first curved surface 65u at the upstream side has a substantially circular-arc shape with a curvature radius Ru, whereas the second curved surface 65d at the downstream side has a substantially circular-arc shape with a curvature radius Rd. The curvature radius Ru at the upstream side is smaller than the curvature radius Rd at the downstream side. The first curved surface 65u is connected to the second curved surface 65d by sharing a common tangential plane Q with the second curved surface 65d.
Based on a comparison between the first curved surface 65u and the second curved surface 65d, an average amount of contraction in the first curved surface 65u is relatively large due to having a large curvature. In contrast, an average amount of contraction in the second curved surface 65d is relatively small.
The distortion shown in the graph in
Because the first curved surface 65u and the second curved surface 65d in the sliding surface 65a according to this exemplary embodiment are connected to each other by having the common tangential plane Q, a local slippage of the endless belt 61 at the boundary between the first curved surface 65u and the second curved surface 65d may be reduced, as compared with a case where the common tangential plane Q is not provided.
Furthermore, since the first curved surface 65u and the second curved surface 65d according to this exemplary embodiment both have a substantially circular-arc shape, the shape of the sliding surface 65a of the pad member 65 is simple, as compared with a case where the curved surfaces do not have a circular-arc shape. Therefore, the manufacturing process and the curvature setting process for reducing distortion of the belt are simplified, as compared with a case where the curved surfaces have shapes other than the circular-arc shape.
Shape Maintaining Control
A change in the shape of the pad member 65 will now be described with reference to
The sliding surface 65a of the pad member 65 is in surface contact with the endless belt 61. Therefore, the temperature of an area including the sliding surface 65a of the pad member 65 is susceptible to the heat from the endless belt 61. More specifically, the temperature of the area including the sliding surface 65a of the pad member 65 increases as the temperature of the endless belt 61 is increased by being heated by the roller heaters 67, and decreases as the temperature of the endless belt 61 is decreased due to the sheet P passing through the nip N. On the other hand, an area opposite the sliding surface 65a with the pad member 651 interposed therebetween is relatively less susceptible to the temperature of the endless belt 61. More specifically, the temperature of this area is based on the amount of heat supplied from the pad heater 651 and the amount of heat released toward the upper surface.
The pad member 65 changes in shape due to thermal expansion in accordance with a temperature change in each area. With regard to the shape of the pad member 65, the aforementioned shape of the sliding surface 65a is preset based on the temperature distribution during a standard fixing process. If a temperature difference between the area including the sliding surface 65a and the area opposite thereto fluctuates due to a temperature change in the area including the sliding surface 65a, the pad member 65 changes in shape, resulting in a change in the preset shape of the sliding surface 65a.
In the fixing device 60 according to this exemplary embodiment, the amount of heat generated by the pad heater 651 as a second auxiliary heating source is controlled on the basis of the temperature detected by the first pad temperature sensor 652 provided inside the pad member 65 and the temperature detected by the second pad temperature sensor 653.
The operation of the image forming apparatus 1 including the fixing device 60 is controlled by the controller 1A. First, in step S11, the controller 1A reads, from the setting reception unit 1B, the settings for the type of sheet to be supplied to the fixing device 60. In step S12, the controller 1A detects the temperature of the endless belt 61 on the basis of a detection result of the belt temperature sensor 69. In step S13, the controller 1A performs belt temperature control so that the endless belt 61 reaches a target temperature set in accordance with the type of sheet. Specifically, the controller 1A controls the percentage of a time period during which the roller heaters 67 are turned on in accordance with a difference between the target temperature and the temperature of the endless belt 61, so as to adjust the amount of heat generated by the roller heaters 67. By repeating steps S12 and S13, the temperature of the endless belt 61 approaches the target temperature set in accordance with the type of sheet.
In step S14, the controller 1A determines whether or not a target temperature setting timing for the pad member 65 is reached. The target temperature setting timing is set at a longer interval than the repeating interval of the flow shown in
If the target temperature setting timing is reached (YES in step S14), the controller 1A detects the temperature of an area between the sliding surface 65a and the pad heater 651 in the pad member 65 on the basis of a detection result of the first pad temperature sensor 652 in step S15. Then, the controller 1A reads the settings for the type of sheet in step S16 and performs a target temperature setting process for the pad member 65 in step S17. In this target temperature setting process, the controller 1A sets a target temperature on the basis of the temperature detected by the first pad temperature sensor 652.
If the sheet P is plain paper, which is thinner than thick paper, the controller 1A sets the target temperature to a preset temperature different from, e.g., 30° C. higher than, the temperature detected by the first pad temperature sensor 652. However, if the detected temperature is higher than or equal to an upper limit temperature (e.g., 200° C.) for the pad member 65, the target temperature is maintained at the upper limit temperature. Although the target temperature setting process is performed by, for example, reading data from a memory that preliminarily stores the correspondence relationship shown in
Next, in step S18, the controller 1A detects the temperature of the area of the pad member 65 (see
Subsequently, in step S21, the controller 1A controls each component of the image forming apparatus 1 so as to perform a process for image formation.
In the fixing device 60 according to this exemplary embodiment, temperature-difference control is performed in steps S18 and S19 described above. Therefore, a change in the shape of the pad member 65 due to thermal expansion thereof during the fixing process may be reduced so that fluctuations in the shape of the sliding surface 65a may also be reduced, as compared with a case where the aforementioned temperature-difference control is not performed. Furthermore, in the fixing device 60 according to this exemplary embodiment, the target temperature setting process is performed in steps S15 and S17 described above. Therefore, fluctuations in the shape of the sliding surface 65a may be reduced, while the temperature of the pad member 65 may comply with the temperature change in the endless belt 61, unlike a case where the aforementioned target temperature setting process is not performed.
If the sheet P set in the sheet settings is thick paper having a thickness greater than a predetermined thickness, the fixing device 60 sets a target temperature that is higher than that for plain paper. Specifically, if the sheet P is thick paper, the controller 1A sets the target temperature to a temperature higher than the temperature detected by the first pad temperature sensor 652 by 50° C., as shown in the table in
In the exemplary embodiment described above, the fixing device 60 having the endless belt 61 wrapped around the tension roller 62, the positioning rollers 63, and the pad member 65 is described as an example of a fixing device according to an exemplary embodiment of the present invention. Alternatively, for example, a configuration in which the belt 61 is wrapped around the pad member 65 but not around the rollers such that tension is not applied to the belt 61 may be permissible.
In the exemplary embodiment described above, the pad member 65 against which the endless belt 61 is directly pressed is described as an example of a pad member according to an exemplary embodiment of the present invention. Alternatively, for example, the pad member may include a sliding sheet that intervenes the pad member and the belt 61. Furthermore, in the exemplary embodiment described above, the pad member 65 composed of a metallic material is described as an example of a pad member according to an exemplary embodiment of the present invention. Alternatively, for example, the pad member itself may be composed of a resinous material.
In the exemplary embodiment described above, a tandem-type color printer is described as an example of an image forming apparatus. Alternatively, the image forming apparatus according to the exemplary embodiment of the present invention may be, for example, a monochrome printer that does not have an intermediate transfer belt.
In the exemplary embodiment described above, a printer is described as an example of an image forming apparatus. Alternatively, the image forming apparatus according to the exemplary embodiment of the present invention is not limited to a printer, but may be, for example, a copier or a facsimile apparatus.
The foregoing description of the exemplary embodiment 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 embodiment was 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 be defined by the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-090685 | Apr 2012 | JP | national |
