FIXING MEMBER, FIXING DEVICE HAVING FIXING MEMBER, AND METHOD FOR MANUFACTURING FIXING MEMBER

FIELD OF THE INVENTION AND RELATED ART

The present invention relates to a fixing member, a fixing device having a fixing member, and a method for manufacturing a fixing member. This rotational heating member and an image heating device having the rotational heating member are employable by an image forming apparatus such as a printing machine, a copying machine, and the like.

As an example of image heating device, a fixing device for fixing an unfixed toner image formed on recording medium, a glossing device for improving in gloss an image fixed to recording medium, by heating the toner image, and the like can be listed.

As a fixing device to be installed in an image forming apparatus, there is an apparatus which is provided with a rotational heating member such as a roller having an electrically conductive layer, which is supplied with electric power to generate Joule's heat, being therefore shorter in the length of startup time, and also, smaller in energy consumption. For example, there is disclosed in Japanese Laid-open Patent Application No. 2013-97315, a fixing member as a rotational heating member having: a heat generation layer made of a compound concocted by dispersing carbon filler in heat resistant resin; an electrically insulative elastic layer formed on the heat generation layer; and an electrically insulative release layer formed on the elastic layer. In the case of this fixing device, heat is generated by directly supplying the electrically resistant heat generating layer, which is a part of the rotational member, with electrical power, in order to reduce the length of time necessary for warm up.

By the way, the electrically insulative layer of a fixing member such as the above-described one, which comprises an elastic layer, a release layer, etc., is not sufficient in strength. That is, it is easily scarred by the friction which occurs between itself and recording medium, and/or foreign substances that enter the fixing device from outside the apparatus. These scars possibly reach the electrically resistant heat generating layer. Further, it is possible that a user will scar the electrically resistant heat generating layer with a tweezer, a cutter, and/or the like. If the electrically resistant heat generating layer is scarred, the portion of the heat generating layer, which is adjacent to the scarred portion increase in electric current density, making it possible that this portion will abnormally heat up.

Next, this phenomenon is described in greater detail with reference to FIG. 12, which is a schematic drawing of a fixing device. The fixing device employs a cylindrical fixation film 1, as a fixing member, which has a heat generating layer formed of an electrically resistant substance. The drawing shows the manner in which the electric current which flows through the heat generating resistant layer concentrates in the adjacencies of the end portions of a scar, or crack C, as the crack C develops across a part of the electrically resistant heat generating layer. The lengthwise end portions of the fixation film 1 are provided with a pair of electrically conductive layers 1b, which extend in the circumferential direction of the fixation film 1. The fixation film 1 is made to generate heat by placing a pair of power supplying members 3a and 3b in contact with the pair of electrically conductive layers 1b, one for one, to cause electric current to flow through the fixation film 1 with the use of an alternating current source 10.

A referential code 4 stands for a pressure roller, as a pressure applying rotational member, which is rotationally driven. The pressure roller 4 forms a nip N (fixation nip), in cooperation with the fixation film 1. The fixation film 1 is rotated by the rotation of the pressure roller 4. A sheet of recording medium, on which an unfixed toner is borne is introduced into the nip N, and is conveyed through the nip N while remaining pinched by the fixation film 1 and pressure roller 4. As the sheet P is conveyed through the nip N, the sheet and the toner image on the sheet, are heated and pressed. Consequently, the unfixed toner image becomes fixed to the sheet.

Referential codes 11-14 stand for electric currents which are flowing through the electrically resistant heat generating layer of the fixation film 1. Since the fixation film 1 is provided with the pair of electrically conductive layers 1, electric current uniformly flows through the electrically resistant heat generating layer in the lengthwise direction of the fixation film 1, and therefore, the heat is uniformly generated in the fixation film 1.

However, as the crack C occurs in the electrically resistant heat generating layer, it interferes with the flow of the electric current I2 and I3, causing the electric currents I2 and I3 to divert to the adjacencies A and B of the end portions of the crack C. Consequently, the areas A and B are increased in electric current density, generating therefore an abnormally larger amount of heat, which in turn makes these areas A and B extremely high in temperature compared to the other areas of the electrically resistant heat generating layer, making it possible for the fixation film 1 to suffer from thermal damages and/or for the image forming apparatus to output unsatisfactory images.

As one of the means for preventing the abnormally large amount of heat generation in the electrically resistant heat generating layer, which is attributable to the occurrence of the abovementioned crack C in the electrically resistant heat generating layer, it is possible to design the heat generating layer as shown in FIG. 13, which shows a referential example of a fixation film. That is, it is possible to construct the fixation film so that a preset number of strips 1e of electrically resistant heat generating substance extend in parallel on the substrative layer 1a of the fixation film 1, with the presence of preset intervals in terms of the circumferential direction of the fixation film 1. The electrically conductive layers 1b and 1b are formed on the lengthwise end portions of the substrative layer 1a so that they encircle the substrative layer 1a, and also, so that they contact each of the heat generating strips 1e. By constructing the fixation film 1 so that it is provided with multiple heat generating strips 1e which are positioned so that they extend in parallel to the lengthwise direction of the fixation film 1, with the presence of a preset amount of interval between the adjacent two strips 1e, it is possible to prevent the problem that as the electrically resistant heat generating layer cracks in the circumferential direction of the fixation film 1, the adjacencies of the lengthwise ends of the crack fixation film 1 increase in electric current density due to the electric current concentration.

The electrically resistant heat generating strips 1e are formed by printing, on the cylindrical insulative substrative layer 1a of the fixation film 1. The greater the number of the heat generating strips 1e in terms of the circumferential direction of the fixation film 1, the smaller the amount by which electric current flows through each strips 1e, and therefore, the less likely for electric current to concentrate to specific portions of the fixation film 1. This solution, however, suffers from the following problem. That is, in a case where a substantial number of heat generating strips 1e are formed by printing on the substrative layer 1a of the fixation film 1 so that they extend in the lengthwise direction of the fixation film 1, with the presence of the preset amount of interval between the adjacent two strips 1e, the heat generating strips 1e to be printed on the area of the substrative layer 1a, which corresponds in position to the printing junction where printing is started and ended are likely to be disturbed during the printing.

Next, this problem is described in greater detail with reference to a case where the electrically resistant heat generating strips 1e are printed by screen printing, for example. Referring to part (a) of FIG. 14 which shows an example of how the electrically resistant heat generating strips 1e are formed by screen printing, while the cylindrically formed substrative layer 1a (substrative layer of fixation film 1) is rotated on one of the surfaces of the screen 8 so that it moves in the direction indicated by an arrow mark in the drawing, a squeegee 9 supplied with electrically resistant heat generating paste H is moved along the other surface of the screen 8 in the direction indicated by another arrow mark in the drawing. Thus, the electrically resistant heat generating paste H passes through the minute openings M of the screen 8, and forms the preset number of electrically resistant heat generating strips 1e in the preset pattern on the substrative layer 1a. That is, the electrically resistant heat generating strips 1e are printed on the substrative layer 1a.

part (b) of FIG. 14 is a schematic top view of a combination of the substrative layer, and the screen 8 having the pattern for printing the electrically resistant heat generating strips 1e, and pair of electrically conductive layers 1b. The areas 1b′ of the screen 8 form the electrically conductive layers 1b, and the areas 1e′ of the screen 8 form the electrically resistant heat generating strips 1e. A referential code h1 stands for the heat generating strip (which may be referred to as first heat generating strip) to be printed first by the areas 1e′, and a referential code h2 stands for the heat generating strip (which may be referred to as second heat generating strip) to be printed last. Thus, the area h1′ of the screen 8 forms the heat generating strip 1h, and the area h2′ of the screen 8 forms the electrically resistant heat generating strip h2.

Hereafter, the area of the substrative layer 1a, between the area on which the first heat generating strip h1 is formed and the area on which the last heat generating strip h2 is formed after a full rotation of the substrative layer 1a after the formation of the first electrically resistant heat generating strip h1, are going to be referred to as “printing junction”. If the distance between the first and last electrically resistant heat generating strips h1 and h2, respectively, on the printing junction is small, the first electrically resistant heat generating strip h1, or the heat generating strip printed first, comes into contact with the screen 8. At this stage of the screen printing, the printed heat generating strips 1e have not been sintered, being therefore “wet”. Thus, the first electrically resistant heat generating strip h1 comes into contact with the screen 8 while it is “wet”. Therefore, parts of the first electrically resistant heat generating strip h1, which is a wet strip of electrically resistant heat generating paste, adhere to the screen 8. Consequently, the first electrically resistant heat generating strip h1, or the heat generating strip 1e printed first, becomes partially thinner.

The thinned portions of the first electrically resistant heat generating strip h1 are higher in electrical resistance; they might have become noncontiguous sometimes. Therefore, the thinned electrically resistant heat generating layer h1 is smaller in the amount by which electric current is allowed to flow, being therefore smaller in the amount of heat generation, or may be zero in the amount of electric current flow. Thus, the fixation film 1 manufactured with the use of the above-described method suffered from the problem that it caused an image forming apparatus to output defective images, the defects of which are repetitive and synchronous in occurrence with the rotational cycle of the fixation film 1.

By the way, in addition to screen printing, various other printing methods such as flexographic printing and inkjet printing are usable. However, as long as multiple electrically resistant heat generating strips 1e are printed in parallel, with the presence of a preset interval between the adjacent two strips 1e, on an endless substrative layer 1a, a problem similar to the above-described one will occur.

Thus, the primary object of the present invention, which is related to a rotational heating member having a preset number of printed electrically resistant heat generating strips, is to provide: a rotational heating member, which does not suffer from the problem that its portion which corresponds in position to the “printing junction” is insufficient in the amount of heat generation, and therefore, it fails to properly heat; and an image heating fixing device employing the rotational heat generating member.

SUMMARY OF THE INVENTION

According to an aspect of the present invention, there is provided a fixing member for a fixing device, said fixing member comprising a cylindrical base layer; and a plurality of heat generating resistors extending in a longitudinal direction of said fixing member on said base layer and arranged with intervals in a circumferential direction of said base layer, wherein heat generating resistors have volume resistivities lower than that of said base layer, said heat generating resistors include a first heat generating resistor and a second heat generating resistor adjacent to each other in the circumferential direction, and said first heat generating resistor and said second heat generating resistor are at least partly overlapped in the circumferential direction.

According to another aspect of the present invention, there is provided a fixing member for a fixing device, said fixing member comprising a cylindrical base layer; and a plurality of heat generating resistors extending in a longitudinal direction of said fixing member on said base layer and arranged with intervals in a circumferential direction of said base layer, wherein heat generating resistors have volume resistivities lower than that of said base layer, said heat generating resistors include a first heat generating resistor and a second heat generating resistor, a interval between said first heat generating resistor and said second heat generating resistor in the circumferential direction is the largest of the intervals between adjacent heat generating resistors, and a width, measured in the circumferential direction, of at least one of said first heat generating resistor and said second heat generating resistor is the largest of the widths, measured in the circumferential direction, of the heat generating resistors.

According to a further aspect of the present invention, there is provided a fixing device for fixing an image on a recording material, said fixing device comprising a rotatable heating member contactable to the image; a cylindrical base layer; a plurality of heat generating resistors extending in a longitudinal direction of said fixing member on said base layer and arranged with intervals in a circumferential direction of said base layer, wherein heat generating resistors have volume resistivities lower than that of said base layer, said heat generating resistors include a first heat generating resistor and a second heat generating resistor adjacent to each other in the circumferential direction, and said first heat generating resistor and said second heat generating resistor are at least partly overlapped in the circumferential direction; and a voltage application member configured to apply a voltage between longitudinal end portions of heat generating resistors.

According to a further aspect of the present invention, there is provided a fixing device for fixing a image on a recording material, said fixing device comprising a rotatable heating member contactable to the image; a cylindrical base layer; a plurality of heat generating resistors extending in a longitudinal direction of said fixing member on said base layer and arranged with intervals in a circumferential direction of said base layer, wherein heat generating resistors have volume resistivities lower than that of said base layer, said heat generating resistors include a first heat generating resistor and a second heat generating resistor, a interval between said first heat generating resistor and said second heat generating resistor in the circumferential direction is the largest of the intervals between adjacent heat generating resistors, and a width, measured in the circumferential direction, of at least one of said first heat generating resistor and said second heat generating resistor is the largest of the widths, measured in the circumferential direction, of the heat generating resistors; and a voltage application member configured to apply a voltage between longitudinal end portions of heat generating resistors.

According to a further aspect of the present invention, there is provided a method for manufacturing a fixing member for a fixing device, said method comprising a step of printing, on a cylindrical base layer, a plurality of heat generating resistors elongated in a longitudinal direction of said fixing member with intervals in a circumferential direction of said base layer, said heat generating resistors including a first heat generating resistor first printed on said base layer and a second heat generating resistor last printed on said base layer, wherein a width, measured in the circumferential direction, of at least one of said first heat generating resistor and said second heat generating resistor is the largest of the widths, measured in the circumferential direction, of the heat generating resistors, wherein said second heat generating resistor is printed in said printing step so that the interval between said first heat generating resistor and said second heat generating resistor is the largest of the intervals between adjacent heat generating resistors.

Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of the fixation film, as a rotational heating member, in the first embodiment of the present invention, as seen from the front side of the fixation film. It is for describing the positioning of the electrically resistant heat generating strips.

part (a) of FIG. 2 is a schematic cross-sectional view of the one of the lengthwise end portions of the fixation film, at a line D1-D1 in FIG. 1, and part (b) of FIG. 2 is a schematic cross-sectional view of the center portion of the fixation film, at a line D2-D2 in FIG. 1.

FIG. 3 is a schematic, vertical, and partial sectional view of the fixation film at a line D3-D3 in FIG. 3, which is parallel to the lengthwise direction of the fixation film.

FIG. 4 is a schematic top view of a combination of the substrative layer of the fixation film, and the screen used for printing the electrically resistant heat generating strips.

FIG. 5 is an enlarged schematic sectional view of the portion of the fixation film, where the first and last electrically resistant heat generating strips overlap.

FIG. 6 is a schematic drawing of the essential portions of the fixing device in the first embodiment of the present invention.

FIG. 7 is an enlarged schematic sectional view of the portion of the fixation film, in the modified version of the first embodiment, where the first and last electrically resistant heat generating strips overlap.

FIG. 8 is a schematic side view of the fixation film, as a rotational heating member, in the first embodiment, as seen from the front side of the fixing device. It is for describing the positioning of the electrically resistant heat generating strips.

part (a) of FIG. 9 is a schematic cross-sectional view of one of the lengthwise end portions of the fixation film, at a line D1-D1 in FIG. 8, and part (b) of FIG. 9 is a schematic cross-sectional view of the center portion of the fixation film, at a line D2-D2 in FIG. 8.

FIG. 10 is a schematic, vertical, partial, and sectional view of the fixation film at a line D3-D3 in FIG. 8.

FIG. 11A is a schematic top views of a combination of the substrative layer of the fixation film, and the screen used for the printing of the electrically resistant heat generating strips.

Parts (a) and (b) of FIG. 11B are schematic cross sectional views of an example of rotational heating member which is in the form of a roller.

FIG. 12 is a schematic drawing of the essential portions of a referential fixing device which employs a rotational heating member having a electrically resistant heat generating layer.

FIG. 13 is a schematic drawing of a referential fixation film having multiple electrically resistant heat generating strips.

FIG. 14 is a schematic drawing for describing the process of screen printing.

FIG. 15 is a schematic drawing of a fixation film, which is for showing the thinning which occurred to the electrically resistant heat generating strip printed first on the printing junction portion of the substrative layer of the fixation film.

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, the rotational heating member which is in accordance with the present invention, and an example of image forming apparatus employing the rotational heating member, are described. By the way, in the following description of the rotational heating member and image forming apparatus, the “lengthwise direction” means the direction which is parallel to the generatrix of the rotational heating member. The “circumferential direction” means the direction which is parallel to the direction in which the rotational heating member rotates. The “thickness direction” means the direction which is parallel to the diameter direction of the rotational heating member.

Embodiment 1

Next, the first embodiment of the present invention is described with reference to FIGS. 1-7. To begin with, a fixation film 1 (fixing member), as a rotational heating member, is described about its structure. Then, a fixing device (image heating apparatus) which employs the fixation film 1 is described.

[Fixation Film]

Referring to FIGS. 1-3, the fixation film 1 in this embodiment is described about its structure. The fixation film 1 has: cylindrical substrative layer 1a; and a preset number of electrically resistant heat generating strips 1e (heat generating strip), which are formed on the substrative layer 1a by printing in such a manner that they extend in the lengthwise direction, with the presence of a preset interval between the adjacent two strips 1e, and which are smaller in volume resistivity than the substrative layer 1a. Further, the fixation film 1 has a pair of electrically conductive layers 1b, which are formed on the lengthwise end portions of the substrative layer 1a, one for one, in such a manner that they encircle the substrative layer 1a in connection (physically and electrically) to the above mentioned preset number of electrically resistant heat generating strips 1e, and which are smaller in volume resistivity than the substrative layer 1a. Further, one of the characteristic features of this fixation film 1 is that the two of the above-described preset number of electrically resistant heat generating strips 1e, more specifically, the electrically resistant heat generating strip h1 (first electrically resistant heat generating strip) and the electrically resistant heat generating strip h2 (second electrically resistant heat generating strip) at least partially overlap in terms of the direction parallel to the circumferential direction of the substrative layer 1a.

FIG. 1 is a schematic drawing of the fixation film 1 as seen from its front side. It is for describing the positioning of the electrically resistant heat generating strips 1e. Part (a) of FIG. 2 is a schematic cross-sectional view of the one of the lengthwise end portions of the fixation film, at a line D1-D1 in FIG. 1, and part (b) of FIG. 2 is a schematic cross-sectional view of the center portion of the fixation film, at a line D2-D2 in FIG. 1, in terms of the lengthwise direction. FIG. 3 is a schematic, vertical, and partial sectional view of the fixation film at a line D3-D3 in FIG. 1, which is parallel to the lengthwise direction of the fixation film.

The fixation film 1 has the substrative layer 1a, pair of electrically conductive layers 1b, electrically resistant heat generating strips 1e, elastic layer 1c, and release layer 1d. The fixation film 1 is flexible. If it is left unattended, it remains roughly cylindrical because of its own elasticity. FIG. 1 does not show the elastic layer 1c and release layer 1d.

The substrative layer 1a is a cylindrical member, which is dielectric or high in electrical resistance. It is a base layer which provides the fixation film 1 with such mechanical properties as torsional rigidity and smoothness. It is formed of such resin as polyimide (PI), polyamideimide (PAI), polyether-ether-ketone (PEEK). In this embodiment, it is made of polyimide, and is 18 mm in external diameter, 240 mm in length, and 60 μm in thickness.

In order to supply the electrically resistant heat generating strips 1e with electric power from the outward side of the fixation film 1, the fixation film 1 is provided with the pair of electrically conductive layers 1b, which are formed of silver paste, on the lengthwise end portions, one for one, of the substrative layer 1a in such a pattern that are 10 mm in width in terms of the lengthwise direction of the fixation film 1, and also, that encircle the entirety of the lengthwise end portions of the substrative layer 1a in the circumferential direction of the substrative layer 1a. In this embodiment, silver paste which was 4×10⁻⁵Ω·cm in volume resistivity was used as the material for the pair of electrically conductive layers 1b for power supply. The silver paste is a compound formed by dispersing microscopic particles of silver in polyimide resin, with the use of solvent. It was sintered after its deposition on the substrative layer 1a.

The electrically resistant heat generating strips 1e are formed on the substrative layer 1a. Each heat generating strip 1e is electrically in connection to the electrically conductive layers 1b and 1b by its lengthwise ends, one for one. That is, it is in connection to the electrically conductive layers 1b and 1b so that electric current is allowed to flow through the electrically resistant heat generating strips 1e, which are between the electrically conductive layers 1b and 1b. In this embodiment, silver paste which was 2×10⁻³Ω·cm in volume resistivity was used as the material for the electrically resistant heat generating strips 1e. It was coated on the peripheral surface of the substrative layer 1a by screen printing.

FIG. 4 is a schematic top view of a combination of the substrative layer of the fixation film, and the screen used for printing the electrically resistant heat generating strips, in this embodiment. The area 1b′ of the screen 8 forms the electrically conductive layer 1b, and the area 1e′ of the screen 8 forms the heat generating strip 1e. Among the preset number of electrically resistant heat generating strips 1e, the one printed first is referred to as an electrically resistant heat generating strip h1, and the one printed last is referred to as a heat generating strip h2. In this case, the area h1′ of the screen 8 forms the electrically resistant heat generating strip h1, and the area h2′ forms the heat generating strip h2.

With the use of this screen 8, a preset number of strips of silver paste, which are 1 mm in width (dimension in terms of circumferential direction), roughly 10 μm in thickness, and are the same in volume resistivity, are printed in parallel in the lengthwise direction, with the placement of preset interval d of 1 mm between the adjacent two strips 1e(pitch of 2 mm), in such a manner that as the substrative layer 1a is rotated once, the heat generating strip h2 is overlaid on the electrically resistant heat generating strip h1 or the electrically resistant heat generating strip printed first. By the way, it is desired that the electrically resistant heat generating strips 1e are no less than 0.20 mm and no more than 2.0 mm in width (in terms of circumferential direction), and the interval between the adjacent two electrically resistant heat generating strips 1e is no less than 0.20 mm and no more than 2.0 mm.

FIG. 5 is an enlarged sectional view of the portion of the fixation film 1, on which the electrically resistant heat generating strip h1, which was printed first during a process in which the fixation film 1 in this embodiment was manufactured, and the heat generating strip h2, which was printed last during the process, are present. After the completion of this process, the substrative layer 1a and the strips of silver paste on the substrative layer 1a are sintered to remove the moisture, binding agents, etc., in the strips to yield the electrically resistant heat generating strips 1e and electrically resistant heat generating strip if (h1+h2). The electrically resistant heat generating strips 1e are roughly 10 μm in thickness. However, the heat generating strip 1f, which resulted as the heat generating strip h2 was printed on the electrically resistant heat generating strip h1 is roughly 20 μm in thickness.

By the way, after the formation of the pair of electrically conductive layers 1b on the substrative layer 1a as described above, the electrical resistance between the pair of electrically conductive layers 1b was 15.7Ω. The total number of electrically resistant heat generating strips 1e, inclusive of the electrically resistant heat generating strip 1f, is 28. The electrical resistance between the lengthwise ends of the electrically resistant heat generating strip if is roughly 230Ω. The electrical resistance between the lengthwise ends of each heat generating strip 1e is roughly 460Ω.

In this embodiment, the electrically resistant heat generating strips 1e and 1f, the material for which is silver paste which is 2×10⁻³Ω·cm in volume resistivity, and the electrically conductive layers 1b and 1b, the material for which is 4×10⁻⁵Ω·cm in volume resistivity, are formed at the same time by screen printing with the use of the screen 8. However, the manufacturing process may be altered so that either the electrically resistant heat generating strips 1e and 1f, or the pair of electrically conductive layers 1b, are formed first by screen printing and sintered, and then, the others are formed by screen printing and sintering.

The elastic layer 1c is formed of a compound made by dispersing thermally conductive filler in silicone rubber. It is 170 μm in thickness. The release layer 1d is formed of PFA. It is formed by being coated on the elastic layer 1c. It is roughly 15 μm in thickness. The elastic layer 1c and release layer 1d are dielectric. They cover the electrically resistant heat generating strips 1e and if and their intervals, leaving the pair of electrically conductive layers 1b exposed across their peripheral surface.

[Fixing Device]

Next, referring to FIG. 6, the fixing device in this embodiment, which is an image heating apparatus, is described about its structure. Part (a) of FIG. 6 is a schematic cross-sectional view of the lengthwise center portion of the essential portion of the fixing device 50 in this embodiment. Part (b) of FIG. 6 is a schematic drawing of the essential portion of the fixing device 50 as seen from a direction which is diagonal to the lengthwise direction.

This fixing device 50 is an apparatus for thermally fixing a toner image T formed on a sheet P of recording medium with the use of an ordinary electrophotographic image forming method, to the sheet P. The sheet P bearing the toner image T is conveyed to the fixing device 50 by a conveying means (unshown) from the left side of part (a) of FIG. 6, and is introduced into the fixing device 50. As the sheet P is conveyed through the fixing device 50, the toner image on the sheet P is thermally fixed to the sheet P.

The fixing device 50 in this embodiment has: the cylindrical fixation film 1 as a rotational heating member; and a film guide 2 inserted in the hollow of the fixation film 1 to support the fixation film 1. It has also an elastic pressure roller 4, as a pressure applying member (nip forming member), which forms a nip N (fixation nip) in cooperation with the fixation film 1. The pressure roller 4 is rotatably supported by it lengthwise end portions, by the frame (unshown) of the fixing device 50, with the placement of a pair of bearings between the pressure roller 4 and frame. In the case of the apparatus in this embodiment, this pressure roller 4, as a rotationally drivable member, is rotationally driven at a preset peripheral velocity in the clockwise direction indicated by an arrow mark in part (a) of FIG. 6 by a driving mechanism portion 101 which is controlled by a control portion 100 (CPU).

The film guide 2 is formed of such heat resistant resin as liquid polymer, PPS and PEEK. Its lengthwise ends engage with a fixation stay 5, which is held by the frame (unshown) of the apparatus. The lengthwise end portions of the fixation stay 5 are under the pressure generated by a pair of compression springs (unshown) as a pressure applying means. Thus, the film guide 2 remains pressured toward the pressure roller 4 with the presence of the fixation film 1 between itself and the pressure roller 4.

In order to ensure that the pressure which the fixation stay 5 received by its lengthwise end portions is uniformly applied to the film guide 2 in terms of the lengthwise direction, rigid material such as iron plate, stainless steel plate, Zinc-coated steel plate, and the like are used as the material for the fixation stay 5. Further, in order to increase the fixation stay 5, the fixation stay 5 is formed so that its cross-section becomes U-shaped. Thus, the film guide 2 is pressed against the pressure roller 4 without being made to warp by the elasticity of the pressure roller 4 with the presence of the fixation film 1 between itself and pressure roller 4. Thus, a fixation nip N, which is uniform in width in terms of the lengthwise direction of the pressure roller 4, is formed between the fixation film 1 and pressure roller 4.

In this embodiment, liquid polymer was used as the material for the film guide 2. As the material for the fixation stay 5, a piece of zinc-coated steel plate was used. The amount of pressure applied to the pressure roller 4 is 160 N, which forms the fixation nip N which is roughly 6 mm in dimension in terms of the direction perpendicular to the lengthwise direction.

The fixing device 50 is provided with a temperature detection element 6, which is attached to the film guide 2 in a manner to remain in contact with the inward surface of the fixation film 1. The information about the temperature detected by the temperature detection element 6 is inputted into the control portion 100, which controls the amount by which electric power is supplied to the fixation film 1 from an AC power source 10 (power supplying portion), based on the information about the temperature of the fixation film 1 inputted from the temperature detection element 6, so that the temperature of the fixation film 1 increases to a preset level and remains at the preset level.

The pressure roller 4 is made up of a metallic core 4a, an elastic layer 4b, and a release layer 4c. The material for the metallic core 4a is iron, aluminum, or the like. The material for the elastic layer 4b is silicone rubber or the like. The material for the release layer 4c is PFA, or the like. In order to ensure that the fixation nip N formed by the pressure roller 4 is wide enough for satisfactory fixation, and also, that the pressure roller 4 is satisfactory in durability, it is desired that the hardness of the pressure roller 4 measured with the use of a ASKER-C hardness gauge under a load of 9.8 N is desired to be in a range of 40° to 70°. In this embodiment, the silicon rubber layer 4b was formed on the peripheral surface of the iron core 4a to a thickness of 3.5 mm. Then, the combination was covered with a piece of dielectric PFA tube, which is 40 μm in thickness. It is 56° in hardness, and 18 mm in external diameter. Both the elastic layer 4b and release layer 4c are 240 mm in length.

The power supplying members 3a and 3b are in connection to an AC power source 10 through AC cables 7. They are in contact with the peripheral surface of each of the pair of electrically conductive layers 1b which are parts of the lengthwise end portions of the fixation film 1. Employed as the power supplying members 3a and 3b are a brush formed of bundles of fine gold wires or the like, a leaf spring, a pad, or the like.

In this embodiment, it was a combination of a carbon chip and a stainless leaf spring that was used as each of the power supplying members 3a and 3b (voltage applying members). The carbon chip is pressed on the exposed portion of the peripheral surface of the electrically conductive layer 1b by the resiliency of this leaf spring, whereby alternating voltage is applied to the electrically conductive layer 1b from the AC voltage source 10 through the AC cable 7. Thus, voltage is applied between the pair of electrically conductive layers 1b, whereby the electrically resistant heat generating strips 1e of the fixation film 1 are supplied with electric power. In this embodiment, the pair of electrically conductive layers 1b are disposed on the lengthwise end portions of the substrative layer 1a of the fixation film 1, one for one, making it possible for all the electrically resistant heat generating strips 1e and if to be always supplied with electric power even while the fixation film 1 is rotated.

The operation of the fixing device 50 is as follows: The pressure roller 4 is rotationally driven at a preset speed in the clockwise direction indicated by an arrow mark in part (a) of FIG. 6. As the pressure roller 4 is rotationally driven, the friction between the pressure roller 4 and fixation film 1 acts on the fixation film 1 in such a direction to cause the fixation film 1 to rotate, in the fixation nip N. Thus, the fixation film 1 is rotated by the rotation of the pressure roller 4 around the film guide 2 in the counter clockwise direction indicated by another arrow mark, sliding on the film guide 2, with its inward surface remaining in contact with the film guide 2.

As the fixation film 1 is rotated by the rotation of the pressure roller 4, and is supplied with electric power, it is controlled in temperature by the combination of the temperature detection element 6 and control portion 100 so that the temperature of the fixation film 1 increases to the preset level and remains at the preset level. Then, a sheet P of recording medium bearing an unfixed toner image T is introduced into the fixation nip N, and is conveyed through the fixation nip N along with the fixation film 1, remaining pinched between the pressure roller 4 and fixation film 1, with the toner image bearing surface of the sheet P remaining in contact with the fixation film 1.

While the sheet P bearing the unfixed toner image T is conveyed through the fixation nip N, the sheet P and the unfixed toner image T thereon are heated by the heat from the fixation film 1 and pressed. Thus, the unfixed toner image T melts, and becomes fixed (welded) to the sheet P as it cools down. As the sheet P is conveyed through the fixation nip N, the sheet P is separated from the surface of the fixation film 1 by the curvature of the fixation film (film guide 2). Then, it is conveyed further by a pair of discharge rollers (unshown).

In the case of the fixation film 1 in this embodiment, the electrically resistant heat generating strip if is formed of the electrically resistant heat generating strip h1, which was printed first, and the heat generating strip h2 which was printed last in a manner to be overlaid on the electrically resistant heat generating strip h1, being therefore twice in thickness compared to the other electrically resistant heat generating strips 1e. Further, the electrically resistant heat generating strip if and the adjacent electrically resistant heat generating strips 1e are connected in parallel by their lengthwise end portions, by the pair of electrically conductive layers 1b. Therefore, the amount by which electric current is allowed to flow through the electrically resistant heat generating strip if is roughly twice the amount by which electric current is allowed to flow through each of the electrically resistant heat generating strips 1e.

Thus, even if the heat generating strip 1e which was printed second happened to be thinner or noncontinuous, as shown in FIG. 5, due to the transfer of the silver paste, of which each of the electrically resistant heat generating strips is made, which occurred during the manufacturing of the fixation film 1, the electrically resistant heat generating strip if can compensate for the second heat generating strip 1e in the amount of heat generation, because it is twice in the amount of heat generation. Therefore, it does not occur that the portion of the fixation film 1, which corresponds in position to the printing junction, is insufficient in the amount of heat generation. Therefore, it does not occur that unsatisfactory fixation occurs in synchronism with the rotation of the fixation film 1.

By the way, it is unnecessary that the heat generating strip h2, that is, the one printed last, perfectly overlaps with the electrically resistant heat generating strip h1, that is, the one printed first. That is, it may be partially that the heat generating strip h2 overlaps with the electrically resistant heat generating strip h1. Shown in FIG. 7 is a modified version of this embodiment. Part (a) of FIG. 7 shows the heat generating strip 1f, which resulted when the process for manufacturing the fixation film 1 was set up so that the heat generating strip h2 begins to overlap with the electrically resistant heat generating strip h1 after it is partially printed. In this case, the trailing end portion of the electrically resistant heat generating strip h1 in terms of the rotational direction of the substrative layer 1a is thinned. However, the area where the overlapping occurs, and therefore, is greater in the amount of heat generation is next to the area where the thinning occurs. Therefore, it is possible to prevent the problem that the image forming apparatus 100 forms defective images, the defects of which corresponds in position to the printing junction.

part (b) of FIG. 7 shows the heat generating strip 1f, which resulted when the process for manufacturing the fixation film 1 was set up so that the heat generating strip h2 begins to be printed to partially overlap with the electrically resistant heat generating strip h1 after the first heat generating electrically resistant strip h2 moved past the screen 8 for the second time after it was printed. In this case, the leading end portion of the electrically resistant heat generating strip h1 in terms of the rotational direction of the substrative layer 1a, and the heat generating strip 1e which was printed second are thinned as illustrated. However, there is the portion of the substrative layer 1a, on which the heat generating strips overlapped as in the case illustrated in part (a) of FIG. 7, being therefore greater in the amount of heat generation. Therefore, it is unlikely for the unsatisfactory fixation caused by the portion of the fixation film, which corresponds in position to the printing junction.

By the way, in a case where the electrically resistant heat generating strips are divided into several groups, and each group is separately printed from the others, the printing junction occurs during every printing process. In such a case, an effect similar to the above-described on can be obtained by setting up the printing process so that the heat generating strip which is to be printed first in the second run is laid on the heat generating strip to be printed last during the first run.

As described above, by printing the electrically resistant heat generating strips 1e so that the heat generating strip h2 at least partially overlaps with the electrically resistant heat generating strip h1, it is possible to compensate the printing junction for the insufficiency in the amount of heat generation. Therefore, it is possible to prevent the unsatisfactory fixation (unsatisfactory heating) which is caused by the portion of the fixation film 1, which corresponds in position to the printing junction.

Embodiment 2

The second embodiment is different from the first embodiment in the pattern of the heat generating strips which are printed on the portion of the substrative layer 1a, which corresponds in position to the printing junction. Referring to FIGS. 8-10, the structure of the fixation film 1 in the second embodiment is described.

FIG. 8 is a schematic side view of the fixation film, as a rotational heating member, in the second embodiment, as seen from the front side of the fixing device. It is for describing the positioning of the electrically resistant heat generating strips. Part (a) of FIG. 9 is a schematic cross-sectional view of one of the lengthwise end portions of the fixation film, at a line D1-D1 in FIG. 8, and part (b) of FIG. 9 is a schematic cross-sectional view of the center portion of the fixation film, at a line D2-D2 in FIG. 8. FIG. 10 is a schematic, vertical, partial, and sectional view of the fixation film at a line D3-D3 in FIG. 8. Like FIG. 1, FIG. 8 does not show the elastic layer 1c and release layer 1d.

Like the fixation film 1 in the first embodiment, the fixation film 1 in the second embodiment also has a cylindrical substrative layer 1a. It has also a preset number of electrically resistant heat generating strips 1e formed on the substrative layer 1a by printing. The electrically resistant heat generating strips 1e are smaller in volume resistivity than the substrative layer 1a. Further, it has a pair of electrically conductive layers 1b formed on the lengthwise ends of the substrative layer 1a. The pair of electrically conductive layers 1b extend in the circumferential direction of the substrative layer 1a, in contact with the electrically resistant heat generating strips 1e, having thereby electrical connection with the electrically resistant heat generating strips 1e. They are smaller in volumetric resistivity than the substrative layer 1a.

The characteristic of the fixation film 1 in this embodiment is that the interval d(a) between the electrically resistant heat generating strips 1g and 1h, which are adjacent to each other, is greater than the other intervals d(b) among the electrically resistant heat generating strips 1e, and also, that at least one of the electrically resistant heat generating strips 1g and 1h, the interval between which is greater than the intervals among the other electrically resistant heat generating strips 1e, is greater in width (dimension in terms of circumferential direction of fixation film 1).

More concretely, the interval d(a) between the electrically resistant heat generating strip 1g, which was printed first, and the electrically resistant heat generating strip 1h which was printed last is greater than the interval d(b) between the adjacent two of the other electrically resistant heat generating strips 1e, and the electrically resistant heat generating strip 1g and electrically resistant heat generating strip 1h are greater in width than the other electrically resistant heat generating strips 1e.

FIG. 11A is a top views of a combination of the substrative layer 1a of the fixation film, and the screen 8 used in the second embodiment 2. The areas 1b′ of the screen 8 form the pair of electrically conductive layers 1b. The areas 1e′ form the electrically resistant heat generating strips 1e. The area 1g′ of the screen 8 forms the electrically resistant heat generating strip 1g, which is printed first among the electrically resistant heat generating strips 1e. The area 1h′ forms electrically resistant heat generating strip 1h, which is printed last.

First, the electrically resistant heat generating strip 1g which is 2 mm in dimension in terms of the circumferential direction of the fixation film 1 is printed with the use of this screen 8. Then, a preset number of electrically resistant heat generating strips 1e which are the same in volumetric resistivity as the electrically resistant heat generating strip 1g, and are 1 mm in dimension (width W=1 mm) in terms of the circumferential direction of the fixation film 1, are formed in parallel to the lengthwise direction, with the placement of intervals d(b) (2 mm pitch). Lastly, the electrically resistant heat generating strip 1h which is 2 mm in width (dimension in terms of circumferential direction of substrative layer 1a) is printed. The screen 8 is provided with such a pattern that after the completion of the printing process, the interval d(a) between the electrically resistant heat generating strip 1g which is printed first, and the electrically resistant heat generating strip 1h which is printed last, will be 3 mm (d(a)=3 mm). Therefore, it does not occur that the electrically resistant heat generating strip 1g comes into contact with the screen 8 after it is printed first.

After the printing of these electrically resistant heat generating strips, the moisture and binding components in the silver paste are removed by sintering to yield the actual electrically resistant heat generating strips 1e, 1g and 1h. The electrically resistant heat generating strips 1e, 1g and 1h are all roughly 10 μm in thickness. After the formation of the pair of electrically conductive layers 1b on the substrative layer 1a, the electrical resistance between the pair of electrically conductive layers 1b is 15.7Ω. The number of the electrically resistant heat generating strips 1e (inclusive of 1g and 1h) is 26. The electrical resistance between the lengthwise ends of each of the electrically resistant heat generating strips 1g and 1h is roughly 220Ω. The electrical resistance between the lengthwise ends of each of the other electrically resistant heat generating strips 1e is roughly 440Ω.

In the second embodiment, the electrically resistant heat generating strip 1g which was printed first, and the electrically resistant heat generating strip 1h which was printed last, are twice the other electrically resistant heat generating strips 1e in the width (dimension in terms of circumferential direction of substrative layer 1a). The electrically resistant heat generating strips 1e, 1h, and 1g are connected in parallel with the pair of electrically conductive layers 1b printed on the lengthwise end portions of the substrative layer 1a, one for one. Further, the electrically resistant heat generating strips 1g and 1h are twice the electrically resistant heat generating strip 1e in width, being therefore twice in the amount of heat generation compared to the heat generating strip 1e.

Further, the interval d(a) between the electrically resistant heat generating strip 1g which was printed first, and the electrically resistant heat generating strip 1h which was printed last is 3 mm, which is three times the interval d(b) between the adjacent two of the other electrically resistant heat generating strips 1e. Thus, it does not occur that the electrically resistant heat generating strip 1g comes into contact with the screen 8 when the electrically resistant heat generating strip 1h is printed. Therefore, it does not occur that the precursor (silver paste strip) of the electrically resistant heat generating strip 1g is thinned by the screen 8.

Although the interval d(a) between the electrically resistant heat generating strips 1g and 1h is greater that the interval d(b) between the adjacent two among the other electrically resistant heat generating strips 1e, the electrically resistant heat generating strips 1g and 1h are twice the other electrically resistant heat generating strips 1e, in the amount of heat generation. Therefore, it does not occur that the portion of the fixation film 1, which corresponds in position to the printing junction, becomes insufficient in the amount of heat generation. Therefore, it does not occur that the unsatisfactory fixation (insufficient heating) occur in synchronism with the rotation of the fixation film 1. By the way, it is desired that the heat generating strips 1e are no less than 0.2 mm and no more than 2.0 mm in width (dimension in terms of circumferential direction of fixation film 1), and also, that the interval between the adjacent two electrically resistant heat generating strips 1e is no less than 0.20 mm and no more than 2.0 mm.

By the way, in this embodiment, both the electrically resistant heat generating strip 1g which is printed first, and the electrically resistant heat generating strip 1h which is printed last, are made greater in width than the other electrically resistant heat generating strips 1e. However, it may be only one of the electrically resistant heat generating strips 1g and 1h that is made greater in width. By adjusting in width at least one of the electrically resistant heat generating strips 1g and 1h, which are printed first and last, respectively, it is possible to increase the interval between the electrically resistant heat generating strips 1g and 1h so that the electrically resistant heat generating strip 1g which is printed first does not come into contact with the screen 8.

Further, in a case where the electrically resistant heat generating strips are divided into a preset number of groups which are separately printed, the printing junction occurs each time a group of electrically resistant heat generating strips is printed after the preceding group. In such a case, effects similar to the above-described one can be obtained by printing the first electrically resistant heat generating strip in the following group, with the provision of a greater interval from the last electrically resistant heat generating strip in the preceding group of electrically resistant heat generating strips than the normal interval, and increasing both or one of the two strips in width.

As described above, the interval d(a) between the electrically resistant heat generating strips 1g and 1h which correspond in position to the printing junction, is made greater than the interval d(b) between any adjacent two among the other electrically resistant heat generating strips 1e, and at least one of the two electrically resistant heat generating strips 1g and 1h separated by the interval d(a) is made greater in width (dimension in terms of circumferential direction of fixation film 1) than the other electrically resistant heat generating strips 1e. Thus, it is possible to compensate the portion of the fixation film 1, which corresponds in position to the printing junction, for the insufficiency in the amount of heat, and therefore, it is possible to prevent the problem that the unsatisfactory fixation is caused by the portion of the fixation film 1, which corresponds in position to the printing junction.

That is, by laying one electrically resistant heat generating strip upon another in the printing junction, or increasing one of the two electrically resistant heat generating strips to be printed on the printing junction portion of the substrative layer 1a in the amount of heat generation, as in the first and second embodiments, it is possible to compensate for the insufficient amount of heat generation by the portion of the fixation film 1, which corresponds in position to the printing junction, and therefore, it is possible to prevent the insufficient heating which is caused by the portion of the fixation film 1, which corresponds in position to the printing junction.

In the first and second embodiments described above, the rotational heating member was the fixation film 1 (member formed of heat generating film). However, the preceding embodiments are not intended to limit the present invention in scope. That is, the present invention is applicable to any rotational heating member, as long as the rotational heating member is made by forming electrically resistant heat generating strips on a cylindrical substrative layer by printing. For example, effects similar to those described above can be obtained by applying the present invention to a fixation belt, a fixation roller, and a pressure roller, which are provided with a printed heat generation layer.

Each of parts (a) and (b) of FIG. 11B is a cross-sectional view of an example of rotational heating member 1A which is in the form of a roller. These rotational heating members 1A have: a metallic roller 11 as a rotational shaft, and an elastic layer 12 formed on the metallic roller 11. Further, they have: a substrative layer 1a on which electrically resistant heat generating strips 1e and electrically conductive layers (1b) are formed; and a release layer 1d which is formed on the substrative layer 1a and electrically resistant heat generating strips 1e. By the way, the present invention is also applicable to a rotational heating member structured so that the elastic layer 1c is placed immediately under the release layer 1d.

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

This application claims the benefit of Japanese Patent Application No. 2016-106010 filed on May 27, 2016, which is hereby incorporated by reference herein in its entirety.

FIXING MEMBER, FIXING DEVICE HAVING FIXING MEMBER, AND METHOD FOR MANUFACTURING FIXING MEMBER

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