Patent Application
20120177393
This patent application is based on and claims priority pursuant to 35 U.S.C. §119 to Japanese Patent Application No. 2011-001841, filed on Jan. 7, 2011 in the Japanese Patent Office, the entire disclosure of which is hereby incorporated by reference herein.
The present invention relates to a fixing device and system and an image formation apparatus.
Image formation apparatuses using electrophotography, such as photocopiers, printers, fax machines, etc., are well known, as disclosed for example in Japanese Patent Application Publication Nos. H10-74023 (JP-H10-74023-A) and H11-52783(JP-H11-52783-A).
To form images, such conventional apparatuses first form an electrostatic latent image on a surface of a photosensitive drum of an image bearer. The latent image is then developed into a visible image using toner as a development agent. The thus-developed image is transferred onto a sheet of recording material and is fixed thereon by a fixing device using heat and pressure to complete the image formation process.
The fixing device includes a fusing rotation member composed of opposed rollers, belts, or a combination of rollers and belts, sandwiches the recording sheet therebetween, and fuses the toner image onto the recording sheet by applying heat and pressure. The fixing device includes a heater, power supplying to which is controlled, to generate heat. The fixing device calculates a duty of electricity (i.e., a power-turn-on time period) supplied to the heater to control the temperature of the fixing device members at each control cycle. The fixing device conducts zero-crossing control based on the duty thus calculated while also performing soft-start control based on phase control to avoid abnormalities such as flicker, etc.
However, supplying a heater with power using soft-start control while gradually increasing a phase angle means that, near duties of 0% and 100%, one of the power-turn-on duties necessarily becomes discontinuous. Consequently, target temperatures cannot be maintained at duties near 0% or 100%, resulting in defective fusing. In recent years, fixing device members having a low heat capacity are used to reduce a warm-up time to save energy. As a result, control is bifurcated for the same product, with a higher duty used to start up quickly while a lower duty used only to maintain heat due to upgrading of thermal efficiency. Such an arrangement aggravates the problem of inability to maintain target temperatures at duties of near 0% and 100% described above.
Accordingly, the present invention provides a novel fixing device that comprises an electric heater supplied with power of an input AC voltage to generate heat based on soft-start control. A temperature of the heater is controlled using multiple different power-turn-on-duty control patterns in accordance with power requirements and an operation mode of the fixing device.
In another aspect, turn on-duty to supply power to the heater is controlled based on detection of a zero-crossing point of an input voltage.
In yet another aspect, the fixing device has a fixing member heated by the heater. A temperature detector is provided to detect temperature of the fixing member. A power-turn-on time period in a duty control cycle for supplying electric power to the heater is calculated based on a relation between the temperature of the fixing member detected by the temperature detector and a target temperature. A soft-start time period for executing the soft-start control is added to the power-turn-on time period in a duty control cycle starting from the zero-crossing point of the input AC voltage when one of the multiple different control patterns is practiced. The soft-start time period is neglected when the sum of the soft-start time period and the power-turn-on time period exceeds the duty control cycle.
In yet another aspect, the soft-start time period is included in the power-turn-on time period in the duty control cycle.
In yet another aspect, the heater control includes on/off control and PID control, and the soft-start time period is added to the power-turn-on time period when the on/off control type is used.
In yet another aspect, the soft-start time period is included in the power-turn-on time period when the PID control type is used.
In yet another aspect, the type of control is switched when the operating mode is changed.
In yet another aspect, the fixing device has a flexible endless fixing member having a low heat capacity. A pipe-shaped metal heat conductor is provided in a housing in the vicinity of an inner surface of the flexible endless fixing member. A temperature detector is provided to detect the temperature of the flexible endless fixing member. The flexible endless fixing member is freely rotatable through the metal heat conductor.
In yet another aspect, there is provided an image forming apparatus having an image forming device to form a toner image and the fixing device.
In yet another aspect, there is provided a method of controlling the temperature of a fixing device comprising the steps of supplying electric power to the heater included in the fixing device by turning on/off electricity supplied thereto in a prescribed manner, and changing the electricity activation control pattern to another when the operating mode of the fixing device is changed in accordance with the electric power requirements for a given operating mode.
A more complete appreciation of the present invention and many of the attendant advantages thereof will be more readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views thereof and in particular to FIG. 1, a cross-sectional diagram shows the main parts of a fixing device according to various embodiments of the present invention.
Specifically, a fixing unit 10 in this figure includes a fixing belt 21, a metal pipe 22 arranged close to an inner circumferential surface of the fixing belt 21, and around which the fixing belt 21 rotates, a heater 23, and a pressure rotor 31 (in this example, a pressing roller) or the like in a fixing device housing, which is not illustrated. In the present embodiment, the heater 23 is a Halogen heater that heats the fixing belt 21 through the metal pipe 22. A temperature detector 26 is arranged near the fixing device 21.
Also held by a supporter 24 (in this example, a metal pipe) inside of a loop of the fixing device 21 is a nip formation member 25 in direct sliding contact with the inner surface of the belt 21 or indirectly sliding contact therewith via a sliding sheet (not shown).
A pressure roller 31 is pressed against and contacts the nip formation member 25 through the belt fixing device 21 and forms a fixing nip therebetween. As shown in
The pressure roller 31 as a pressure rotor is composed of a hollow metal roller covered by a silicone layer and a mold releasing layer (for example, a PFA or PTFE; layer) overlying the surface of the layer to obtain better releasing ability. The pressure roller 31 is driven and rotates receiving a driving force from a driving source, such as a motor, etc., through a gear, not shown, each installed in the image forming apparatus. Further, the pressure roller 31 is biased by a spring or the like, not shown, and is pressed against the belt fixing device 21, so that the rubber layer is crushed to transform and form a given nip width there. Although the pressure roller can be a solid roller, it is preferably hollow due to its required smaller heat capacity.
Optionally, the pressure roller 31 can include a heater such as a halogen heater, etc. Further, solid rubber can be used as the silicone layer. However, if the pressure roller has no heater internally, sponge rubber can be employed, because the heat insulation increases due to the sponge rubber, and heat becomes less deprived from the belt fixing device.
The belt fixing device 21 is an endless belt (or a film) made of metal, such as nickel, SUS (stainless steel), etc., or resin, such as polyimide, etc. The surface of the fixing belt has a releasing layer of a PFA or PTFE layer or the like with releasing characteristics so that toner does not adhere thereto. Between a substrate of the fixing belt and the PFA or PTFE layer, an elastic layer made of silicone rubber may be disposed. The heat capacity of the fixing belt becomes smaller if no silicone layer exists thereby improving a fixing performance. However, a slight unevenness of the belt surface is transferred putting an orange peel skin mark on a solid image when an unfixed toner image is fixed being crushed. To solve this problem, the silicone rubber layer preferably has more than 100 μm. Specifically, the silicone layer deformation absorbs the slight unevenness suppressing the orange peel skin mark image put there.
The hollow metal pipe 22 is made of metal, such as aluminum, steel, stainless steel, etc. The illustrated example of the hollow metal pipe 22 shows the pipe as circular in cross-section, although other shapes are acceptable. The pipe shaped metal body 22 may also include a supporter to support a nip section from within the pipe 22. A metal supporter 24 is disposed as shown here. At this time, when the supporter 24 is also heated by radiant heat emitted from the heater 23 of the halogen heater, surface treatment is applied to prevent such heating and suppress wasteful energy consumption. A heater 23 heating the metal pipe 22 as the metal hollow heat conduction member may be one of a halogen heater, a heating device using an IH system, a heating element, and a carbon heater or the like.
The belt fixing device 21 is rotated by an external roller. In the present embodiment, a pressure roller 31 is rotated by a driving source, which is not illustrated, and a driving force is transmitted to the belt fixing device 21 at the nip section thereby rotating the fixing belt 21. The fixing belt 21 is sandwiched and is circulated in the nip section. The Metal body 22 guides the fixing belt 21 at outside of the nip section not to separate the fixing belt 21 far from the thermal conductor (i.e., a metal pipe 22) more than a certain distance. On a boundary between the belt fixing device 21 and the metal pipe 22, lubricant, such as silicone oil, fluorinated grease, etc., is disposed. A difference in diameter between the fixing belt 21 and the pipe 22 may be within 1 mm.
Hence, with these inexpensive configurations, since warm-up is quickly completed, because the pipe shaped metal member 22 spreads and uniformly provides heat over the entire fixing belt 21, a fixing device capable of stabilizing temperature over the entire belt fixing device 21 is realized.
A fixing device having a heater 23 provided with electricity from an AC power source to generate heat (a halogen heater, in the example of
In
In such a configuration, an electricity turn on time Tn defined by hatching in
Electricity turn on (i.e., energizing) time Tn of heater 23 in n/2th cycle after power is turned on is represented by the following formula: Tn=(½πf)arc sin(I0·Rh (tn)/V0), wherein F represents frequency of AC voltage, Vo repress amplitude of AC voltage, and Rh (tn) represents resistance of a heat source 23 at a time tn when amplitude of AC voltage becomes Vo level after power is turned on while the heater 23 is not controlled.
Hence, by detecting the zero-crossing point of the AC voltage when the heater 23 is energized (i.e., power is supplied thereto), the time Tn elapsing after the zero-crossing points is increased per half cycle, and thereby gradually increasingly flowing safe heater current i(t) into the heater 23. Such a soft-start control is executed until the heater current i(t) becomes a rating current (±I0). When such current flow becomes stable at the rating current (±I0), the temperature detection instrument 26 detects temperature of the heater 23 and the temperature control circuit 6 drives the switch element 7 based on the output of the temperature detection instruments 26 to set the temperature of heater 23 to a fixing possible level.
Such a phase control system used in this electricity turn on control for the heater 23 can reduce inrush current generally flown thereto and fluctuation of a voltage of the power supply occurring instantly when power is initially supplied. For the same reason, the electronic switching element 7 can only handle a small rating current, so that the control device 8 can be downsized.
Now, one of distinctive manners of controlling a heater of a fixing device of one embodiment of the present invention is described. When a heater 23, such as halogen heater, etc., is used as a heating source of a fixing device, PID control or turn on/off control is selectively executed by a controller, such as a control circuit 6, etc., described later at a prescribed power-turn-on duty (i.e., a percentage of turning on a heater 23 in a prescribed cycle) to reach a target temperature. Specifically, a power-turn-on time period (or, a power-turn-on percentage) to supply power to the heater 23 is calculated based on a relationship between the target temperature and current temperature of the fixing device (i.e., the fixing belt 21) detected by a temperature detector 26. Then, soft start is executed to turn on the heater 23 for the purpose of suppressing inrush current. Such soft start is executed in first and second control patterns different from each other as described below with reference to
In executing these control patterns, power is differently supplied to the heater 23 in accordance with various situations (i.e., conditions) as described below, wherein one turn-on cycle is represented by 1 s and the maximum soft-start time period (A) is 0.3 s.
For example, when a turn on time period (B) calculated based on the above-described relation is 0 s as a first situation, the heater 23 is not supplied with any power in executing each of the control patterns as shown in the up most part in the draw. When a turn on time period (B) is less than soft-start time period (A) as a second situation, the heater 23 is supplied with power at a turn on rate of about 100% for the turn on time period B of about 0.2 s in a half wave after the soft-start time period (0.3 s) is over in executing the first control pattern as shown in the second left part from the top. By contrast, the soft-start time period (A) terminates at a time 0.2 s in executing the second control pattern as shown on the second right side from the top.
When an amount of heat outputted during a control cycle of the heater, which corresponds to an area in the drawing, in executing the first situation, and that in executing the second situation are compared with each other, it is noted that a difference therebetween is greater in the first control pattern than that in the second control pattern. Thus, with the second control pattern, the amount of output heat can be continuously changed on the lower duty side due to the smaller difference.
When an inequality (A<B) is met as a third situation, the heater 23 is supplied with power at a turn on rate of about 100% for the turn on time period B of about 0.5 s in the half wave after the soft-start time period (0.3 s) is over in executing the first control pattern as in the second situation as shown in the third left part from the top. The turn on time period B of about 0.5 s for executing the second control pattern is the sum of a soft-start time period and a time period for tuning on power at the turn on rate of about 100% as shown in the third right part.
As shown in the fourth left part from the top, when the inequality (A<B) and an equality (A+B=D) are met as a fourth situation, the heater 23 is supplied with power until right the end of the control cycle in executing the first control pattern.
When an inequality (A+B>D) is met as a fifth situation, the heater 23 is supplied with power for the turn on time period B with a priority to a soft-start time period, and the soft start is executed for a remaining time period as shown in the fifth left part from the top. Specifically, an initial stage of the soft start is omitted as shown by a controller. When inequalities (A+B>D) and (B<<D) are met, the heater 23 is supplied with power for the turn on time period B with a priority to a soft-start time period, and the soft start is executed for the remaining time period in executing the first control pattern as in the fifth situation as shown in the sixth left part from the top. Accordingly, the turn on rate becomes near 100% in such a situation. For this reason, with the first control pattern, the amount of output heat can be continuously changed on the high duty side.
When an equality (B=D) is met, since the output heat changes sharply from the fifth to sixth situations in executing the second control pattern as shown in the lower most part, the amount of output heat cannot be continuously changed on the high duty side.
In any way, the above-described turn on time period B is calculated at every start of a new phase (e.g. every 1 s in
Specifically, a first control pattern can continuously change an output on the side of high Duty. By contrast, an output is suddenly lost when it is less than or equal to a prescribed level on the low Duty side, so that temperature control is difficult due to its discontinuity. In a second control pattern, the output can be continuously changed on the low duty side, and temperature control is difficult on the high Duty side due to its discontinuity. Therefore, one of two control patterns is optionally chosen in accordance with a range so that temperature control can be easily performed in this embodiment. Specifically, the first control pattern is adopted during the turn on/off control, such as a standby mode, a start-up mode, etc., in which precise control is needed on the high Duty side. Whereas, the second control pattern of the soft-start option is adopted during the PID control, such as a sheet feed mode, etc., in which exactly precise control is needed on the low-Duty-side.
A difference between these control patterns in this situation is shown below in
As noted from the table 1, a warm-up time period required for the first control pattern is quickly stabilized. Whereas, a variation goes on the second control pattern depending on the duty. In addition, a change in temperature is suppressed during the sheet passage in the second control pattern, whereas temperature ripple grows depending on the duty in the first control pattern.
Accordingly, when it is intended to control power supply in a power-turn-on duty of around 0% for a mode only requiring small energy, such as a sheet passage mode (i.e., a copying mode), etc., a second control pattern incorporating a soft-start time period within an power-turn-on time period is used, and the soft-start for heating the heater 23 is executed. As a result, electrical power is continuously supplied in such an electric power area due to the soft start during power supply control at the low-power-turn-on rate. As a result, temperature of fixing device member can be controlled as aimed not affected by temperature control.
Further, when it is intended to control in a power-turn-on rate of near 100% for a mode requiring great electric power, such as a standby mode, a start-up mode, etc., a first control pattern that adds the soft-start time period to the power-turn-on time period is used. Hence, electrical power is continuously supplied in an electric power area of the high duty. As a result, temperature of fixing device member can be controlled as aimed not affected by the temperature control.
Hence, the warm-up time period is quickly settled reducing temperature ripple during passage of a sheet. That is, conflicting requests (i.e., decrease in warm-up time period and reduction of temperature ripple) can be realized at the same time.
It is preferable that both control patterns are switched and one of the turn on/off control and the PID control is optionally used per mode, such as a copy mode, a standby mode, etc., when changed. Further, it is preferable that a power-turn-on duty of the previous cycle used in feeding back calculation is stipulated from a difference between the target and the current temperature degrees when a control manner is switched to the PID control from the turn on/off control. Hence, control disturbance can be suppressed and a temperature of the heater 23 (i.e. a fixing member) can be highly precisely controlled as aimed. Accordingly, a stable and high image quality can be obtained.
As discussed heretofore, according to the present invention, as a soft-start pattern executed when the heater 23 is supplied with power, a different power-turn-on control is used depending on an amount of power necessary for each of control modes (operating modes) of the fixing device. Consequently, heater 23 control is optimized and temperature of the fixing member can be highly precisely controlled regardless of the control mode. Further, stable image quality can be obtained preventing fixing malfunction at power-turn-on duties near 0% and 100% when executing phase control.
With reference to
The image formation unit 110 employs a tandem system arranging four image formation unit 101 (a, b, c, d) almost at the center thereof to form a full-color image. Each of the image formation units 101 (a, b, c, d) forms a component color image of yellow, magenta, cyan, and black. Each of the image forming units 101 (a, b, c, d) is arranged parallel to each other along a lower running side of an intermediate transfer belt 107. The Intermediate transfer belt 107 is wound around supporting rollers 108a and 108b and is circulated counter clockwise in the drawing. At an outside of the left side supporter 108a, a cleaning unit 109 is located to clean the intermediate transfer belt 107. Above the intermediate transfer belt 107, there is provided multiple toner bottles 113 (a, b, c, d) to accommodate respective color for particles to be replenished to developing devices of the image formation units.
Each image formation unit 101 (a, b, c, d) has the same configuration employing different color toner to handle. Herein below, various devices in the image formation unit 101 are described omitting the suffixes of a, b, c, and d. The image formation unit 101 includes a photoconductive drum 102 as an image bearer. Around the photoconductive drum 102, a developing device 104, a cleaning device 105, and a charging device 103 or the like are disposed. Further, a transfer roller 106 is disposed opposed to the photo-conductive drum 102 at inside of a loop of the intermediate transfer belt 107 as a primary transfer device. Each of the image formation units 101 is detachably attached to an apparatus body as a process cartridge.
Below the four image formation units 101, an optical writing apparatus 100 is disposed. The optical writing device 100 emits a laser light as a scanning light to each of surfaces of the photoconductive drums 102 of the color image formation units.
Below the image formation unit 110, a sheet feeding unit 120 of a sheet feed tray 12 loading multiple sheets is disposed. A sheet feed roller 122 is disposed on the right side of the sheet tray 121 and sends out sheets loaded in the tray one by one.
A pair of conveyance rollers 123 and a pair of registration rollers 124 are disposed downstream of the sheet feed roller 122 in a sheet transport direction. Further, above the pair of registration rollers 124, a roller transfer roller 111 as a secondary transfer device is disposed being opposed to a belt support roller 108b serving as a transfer opposed roller.
Above a secondary transfer section, the fixing unit 10 is located. The fixing unit 10 fuses a not-fixed toner image transferred onto a sheet at the secondary transfer section by applying heating and pressure thereto. Above the fixing device 10, a sheet ejection roller 114 is disposed to eject a sheet with a fixed toner image thereon onto a sheet exit tray 115 of the inner sheet ejection unit 150.
Above the image formation unit 110, a reading unit 130 is located across the inner sheet ejection unit 150. The reading unit 130 includes a first carriage member 132 having a manuscript lighting use light source and a first mirror, and a second carriage 133 having second and third mirrors to read a manuscript (not shown) loaded on a contact glass 131. Image information obtained from the document by scanning with the first and second carriage members 132 and 133 is subsequently read by a CCD 135 located behind a lens 134 as an image signal and is digitized by applying image processing. In accordance with the image signal subjected to the image processing, the light source of the optical scanning device 100 emits and scans light and forms a latent image on the surface of the photoconductor 102.
An automatic manuscript feeding device (ADF) 140 is mounted on a reading unit 130. The ADF 140 sends manuscripts set on a manuscript tray one by one. The first and second carriages 132 and 133 stopping at prescribed sections scan and read the manuscript being conveyed in the reading unit 130. Beside the image formation based on the information read from the manuscript in the reading unit 130, an image can be formed based on image information transmitted from external devices, such as personal computers, etc.
Now, an image formation behavior of a copier with the above-described device is briefly described. The photoconductive drum 102 of the above described image formation unit 101 is driven and rotated clockwise in the drawing by a driving device not illustrated. Then, the surface of the photoconductive drum 102 is uniformly charged by a charging device 103 with a given pole. The thus charged photosensitive surface receives a laser light from the optical writing device 100 thereby forming a latent image thereon. When a color image is formed, image information included in exposure light emitted to each photoconductive drum 102 is decomposed color information of yellow, magenta, cyan, and black monochromatic image information pieces. Each color toner is supplied from the developing device 104 to latent electrostatic images thus formed, so that the latent images are visualized as toner images.
Further, the intermediate transfer belt 107 is driven and circulated counterclockwise in the drawing. Then, each color toner image is transferred and overlaid on the intermediate transfer belt 107 from each of the photoconductive drums 102 by a function of each of the primary transfer rollers 106 one by one in each of the image formation units 101. Consequently, the intermediate transfer belt 107 bears the full-color toner image surface thereon.
Further, a monochromatic image can be formed only using one of image formation units 101 or dual or a triple color image also can be formed. When a black and white print is generated, only the rightmost side Bk unit (101d) in the figure is used among the four process cartridges. Subsequently, residual toner adhering to the surface of the photoconductive drum after the transferring process transferring the toner images is removed therefrom.
Then, the surface of the photoconductive drum is initialized by a static electricity eliminator and prepares for the next image formation.
On the other hand, a sheet fed from the sheet tray 121 is conveyed by a pair of registration rollers 124 toward the secondary transfer section synchronizing with a toner image borne on the intermediate transfer belt 107. The toner image on the surface of the intermediate transfer belt is transferred onto the sheet at once by a function of the secondary transfer roller 111. The toner image on the sheet is fused and fixed thereon when passing through the fixing unit 10 by heat and pressure. The sheet with the fused toner image is then ejected onto the exit tray 115 by the exit roller 114.
The present invention is not limited to the above-described various examples. For example, the fixing device is not limit to the belt fixing device type and can optionally employ a heat roll system. Further, the heater 23 is not limited to the halogen Heater and can employ a heating device employing an IH system, a carbon heater, and a heat resistance or the like. A sheet feed direction of the fixing device is not limit to a vertical one. A fixing device control device can employ an appropriate configuration as well.
Further, the configuration of the image formation device is optionally chosen. Further, an order of arrangement of respective color process cartridges in the tandem state may be optionally determined. Further, it is not limited to just the tandem system and can employ a system, in which several developing devices are disposed around one photosensitive body, or a revolver developer apparatus as well. Further, the present invention is also applied to a full-color machine using a triple color toner particles, a multi-color presses using twin color toner, and a black and white color machine as well. Of course, the image forming apparatus is not limited to just a copier and a multifunction printer, facsimile, or a multiple functional machine combining these functions can be employed.
According to the fixing device, the image forming apparatus, and the control system of the fixing device of one embodiment of the present invention, since the heater 23 of the fixing apparatus is controlled in accordance with an amount of power needed to an operating mode, the heater 23 can be excellently controlled regardless of the control mode while highly precisely controlling temperature of a fixing member. The embodiment can also prevent fixing malfunction at power-turn-on duties near 0% and 100% when phase control is executed, thereby high quality and stable image can be obtained.
According to another aspect, inrush current can be reduced with zero-crossing control, so that the heater 23 can prolong its life. According to yet another aspect, temperature control can be precise even on the high Duty side.
According to yet another aspect, temperature control can be again precise on the low Duty side. Further, soft-start control can be optimized and temperature control can be highly precise during the turn on/off control in which the high Duty side control is expected to be highly precise.
According to yet another aspect, soft-start control can be optimized and temperature control can be highly precise during the PID control in which the low Duty side control is expected to be highly precise.
According to yet another aspect, stable temperature control is obtained by switching the control pattern when an operation mode is changed. According to yet another aspect, even when heat capacity of the fixing member is small and is sensitive to a change in electricity turn on duty, deterioration of members can be prevented by enabling high-precision temperature control.
Numerous additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-001841 | Jan 2011 | JP | national |
