Patent Application
20090175664
1. Field of the Invention
The present invention relates to an image forming apparatus provided with a fixing unit for heating and melting unfixed toner and fixing it to a sheet bearing a toner image while permitting the sheet to pass a nip between a pair of rollers heated or between a heating belt and a roller.
2. Description of the Related Art
In recent years, attention has been focused on belt-type image forming apparatuses, in which a smaller heat capacity can be set, due to demands of shortening a warm-up time and saving energy in a fixing unit (see, for example, Japanese Unexamined Patent Publication No. H06-318001). Attention has been also focused on an electromagnetic induction heating method (IH) with a possibility of quick heating and high efficiency heating in recent years, and many products as a combination of electromagnetic induction heating and the employment of a belt have commercialized in light of saving energy upon fixing a color image. In the case of combining the employment of a belt and electromagnetic induction heating, an electromagnetic induction device is often arranged at an outer side of the belt due to merits that a coil can be easily laid out and cooled and further the belt can be directly heated (so-called external IH).
In the above electromagnetic induction heating method, various technologies have been developed to prevent an excessive temperature increase in a sheet non-passage area in consideration of a sheet width (paper width) passed through the fixing unit. Particularly, the following prior arts are known as size switching means in the external IH (for example, Japanese Unexamined Patent Publication No. 2003-107941, Publication of Japanese Patent No. 3527442).
A first prior art (Japanese Unexamined Patent Publication No. 2003-107941 (FIGS. 2 and 3)) discloses that a magnetic member is divided into a plurality of pieces, which are arranged in a sheet width direction, and some of the magnetic member pieces are moved toward or away from an exciting coil in accordance with the size of a sheet to be passed (paper width). In this case, heating efficiency decreases by moving the magnetic member pieces away from the exciting coil in sheet non-passage areas, and the amount of heat generation is thought to be less than in an area corresponding to a sheet with a minimum paper width.
A second prior art (Publication of Japanese Patent No. 3527442 (FIG. 10)) discloses that other conductive members are arranged outside a minimum paper width in a heating roller and the positions thereof are switched between those inside and outside the extent of a magnetic field. According to this prior art, the conductive members are first located outside the extent of the magnetic field to heat the heating roller by electromagnetic induction. If the temperature of the heating roller rises to the vicinity of a Curie temperature, the conductive members are moved to the extent of the magnetic field, thereby causing magnetic fluxes to leak from the heating roller outside the minimum paper width for the prevention of excessive temperature increases.
In the above first and second prior arts, an excessive temperature increase suppressing effect better than before is necessary to improve productivity more than at present. In other words, even if magnetism is shielded outside the paper passage area in the case of passing a small-size sheet, the temperatures of the heating roller and the like increase by the leaking magnetic field and eventually reach excessive temperature increases if the magnetic field (magnetic fluxes) leaks little by little from there. As means for preventing this, a method for making, for example, the area of a magnetic shielding plate larger than at present can be thought.
However, if the area of the shielding plate is excessively enlarged, the magnetic field is influenced even if the shielding plate is retracted. For example, even if the shielding plate is retracted when induction heating is necessary over the entire width of the heating roller, induction heating becomes insufficient, which is not suitable, if the magnetic field is shielded by the influence of the shielding plate at the retracted position. Therefore, there is a natural limit in enlarging the area of the shielding plate even if the excessive temperature increase suppressing effect is improved more than at present.
An object of the present invention is to provide an image forming apparatus having a fixing unit capable of obtaining an excessive temperature increase suppressing effect in end areas of a heating roller and the like without excessively enlarging the areas of a shielding plate and the like and also capable of making it least likely to be influenced by the shielding plate and the like with the shielding plate and the like retracted.
In order to accomplish this object, the present invention is directed to an image forming apparatus which includes an image forming unit for transferring a toner image to a sheet, and a fixing unit having a heating member and a pressing member and adapted to convey the sheet while holding the sheet between the heating member and the pressing member and to fix the toner image to the sheet by heat at least from the heating member in a conveying process. The heating member has a first area where a sheet does not come into contact with the heating member when the sheet being conveyed by the fixing unit passes the heating member, and a second area where the sheet comes into contact with the heating member when the sheet being conveyed by the fixing unit passes the heating member. The first area and the second area are set according to the size of the sheet. The fixing unit further includes a coil for forming a magnetic field by generating magnetism for induction heating the heating member, a core made of a magnetic material to form a magnetic path near the coil, a magnetism adjusting member made of a nonmagnetic material, arranged on the magnetic path and having a closed frame, and a switcher capable of switching the magnetism adjusting member between a first state where the magnetism adjusting member generates an induction current resulting from the magnetic field to shield the magnetism in the first area, and a second state where the magnetism adjusting member generates no induction current and the magnetism is not shielded in the first area.
Hereinafter, embodiments of the present invention are described in detail with reference to the accompanying drawings.
The image forming apparatus 1 shown in
A sheet cassette 5 for storing sheets is arranged at the bottom in the interior of the apparatus main body 2, a stack tray 6 for manually feeding a sheet is arranged in an intermediate part, and an image forming station 7 is arranged in an upper part. The image forming station 7 forms (transfers) a toner image on a sheet based on image data such as characters and pictures transmitted from the outside of the apparatus.
A first conveyance path 9 for conveying a sheet dispensed from the sheet cassette 5 to the image forming station 7 is arranged in a left part of the apparatus main body 2 in
The sheet cassette 5 enables the replenishment of sheets by being withdrawn toward the outside (e.g. toward front side in
The stack tray 6 can be opened and closed relative to an outer surface of the apparatus main body 2, and sheets to be manually fed are placed one by one or a plurality of sheets are placed on a manual feeding portion 19. Sheets placed on the manual feeding portion 19 are picked up one by one by a pickup roller 20 and separation rollers 21 and transported toward the second conveyance path 10.
The first conveyance path 9 and the second conveyance path 10 join before registration rollers 22. A sheet fed to the registration rollers 22 temporarily waits on standby here and is conveyed toward a secondary transfer unit 23 after a skew adjustment and a timing adjustment. A full color toner image on an intermediate transfer belt 40 is secondarily transferred to the conveyed sheet in the secondary transfer unit 23. Thereafter, the sheet having the toner image fixed in the fixing unit 14 is reversed in a fourth conveyance path 12 if necessary, so that a full color toner image is secondarily transferred also to the opposite side of the sheet in the secondary transfer unit 23. After the toner image on the opposite side is fixed in the fixing unit 14, the sheet is discharged to the sheet discharging unit 3 by discharge rollers 24 through the third conveyance path 11.
The image forming station 7 includes four image forming units 26, 27, 28 and 29 for forming toner images of black (B), yellow (Y), cyan (C) and magenta (M) and an intermediate transfer unit 30 for bearing the toner images of the respective colors formed in the image forming units 26 to 29 in a superimposed manner.
Each of the image forming units 26 to 29 includes a photosensitive drum 32, a charger 33 arranged to face the circumferential surface of the photosensitive drum 32, a laser scanning unit 34 arranged downstream of the charger 33 for emitting a laser beam to a specific position on the circumferential surface of the photosensitive drum 32, a developing device 35 arranged to face the circumferential surface of the photosensitive drum 32 downstream of the laser beam emission position from the laser scanning unit 34 and a cleaning device 36 arranged downstream of the developing device 35 to face the photosensitive drum 32.
The photosensitive drum 32 of each of the image forming units 26 to 29 is rotated in a counterclockwise direction in
The intermediate transfer unit 30 includes a drive roller 38 arranged at a position near the image forming unit 26, a driven roller 39 arranged at a position near the image forming unit 29, the intermediate transfer belt 40 tensioned between the drive roller 38 and the driven roller 39, and four transfer rollers 41 arranged in opposed relation with the photosensitive drums 32 of the respective image forming units 26 to 29. The respective transfer rollers 41 are arranged at positions downstream of the developing devices 35 of the corresponding image forming units 26 to 29 such that they can be pressed into contact with the photosensitive drum 32 via the intermediate transfer belt 40.
In this intermediate transfer unit 30, the toner images of the respective colors are transferred in a superimposition manner on the intermediate transfer belt 40 at the positions of the transfer rollers 41 of the respective image forming units 26 to 29. As a result, a full color toner image is finally formed on the intermediate transfer belt 40.
The first conveyance path 9 conveys a sheet dispensed from the sheet cassette 5 toward the intermediate transfer unit 30. The first conveyance path 9 includes a plurality of conveyor rollers 43 arranged at specified positions in the apparatus main body 2 and the registration rollers 22 arranged before the intermediate transfer unit 30 for timing an image forming operation and a sheet feeding operation in the image forming station 7.
The fixing unit 14 fixes an unfixed toner image to a sheet by heating and pressing the sheet having the toner image transferred thereto in the image forming station 7. The fixing unit 14 includes a pair of heating rollers comprised of a pressure roller 44 (pressing member) and a fixing roller 45. The pressure roller 44 is a metallic roller, and the fixing roller 45 is comprised of a metallic core material, an outer layer (e.g. silicon sponge) made of elastic material and a mold releasing layer (e.g. PFA). Further, a heat roller 46 is disposed adjacent to the fixing roller 45, and a heating belt 48 (heating member) is mounted on this heat roller 46 and the fixing roller 45. Alternatively, a heating belt as a heating member may be wound around the outer circumferential surface of the fixing roller 45. A detailed structure of the fixing unit 14 is described later.
Conveyance paths 47 are arranged upstream and downstream of the fixing unit 14 in a sheet conveying direction. A sheet conveyed through the intermediate transfer unit 30 is introduced to a nip between the pressure roller 44 and the fixing roller 45 (heating belt 48) via the upstream conveyance path 47. The sheet having passed the nip between the pressure roller 44 and the fixing roller 45 is guided to the third conveyance path 11 via the downstream conveyance path 47.
The third conveyance path 11 conveys the sheet finished with the fixing process in the fixing unit 14 to the sheet discharging unit 3. Conveyer rollers 49 are arranged at a suitable position in the third conveyance path 11 and the above discharge rollers 24 are arranged at the exit of the third conveyance path 11.
Next, first to third embodiments of the fixing unit 14 applied to the image forming apparatus 1 are successively described.
The fixing unit 14 includes the pressure roller 44, the fixing roller 45, the heat roller 46 and the heating belt 48 as described above. As described above, the pressure roller 44 is made of a metal, but the fixing roller 45 includes the elastic layer of silicon sponge on the outer layer. Thus, a flat nip NP is formed between the heating belt 48 and the fixing roller 45. It should be noted that a halogen heater 44a is disposed in the pressure roller 44. A base member of the heating belt 48 is made of a ferromagnetic material (e.g. Ni), a thin elastic layer (e.g. silicon rubber) is formed on the outer surface of the base member, and the mold releasing layer (e.g. PFA) is formed on the outer surface of the elastic layer. A core of the heat roller 46 is made of a magnetic metal (e.g. Fe) and a mold releasing layer (e.g. PFA) is formed on the outer surface of the core.
The fixing unit 14 conveys the sheet while holding it in the nip NP between the pressure roller 44 and the fixing roller 45 via the heating belt 48. In this conveyance process, the sheet receives heat from the pressure roller 44 and the heating belt 48, whereby the toner image transferred onto the sheet is fixed to the sheet.
The fixing unit 14 further includes an IH coil unit 50 (not shown in
As shown in
As shown in
The center core 58 is, for example, a ferrite core having a tubular or cylindrical shape. Substantially similar to the heat roller 46, the center core 58 has a length corresponding to the maximum paper width (width of maximum size sheet out of sheets conveyed by the fixing unit 14). Although not shown in
The center core 58 is arranged between a pair of the arch cores 54 and the heat roller 46 (heating belt 48), when seen in a direction in which a magnetic field is generated by the induction heating coil 52, in order to form magnetic paths together with the arch cores 54 and the side cores 56. More specifically, ends 54a (entrances or exits of the magnetic paths) of the arch cores 54 are distant from the heating belt 48, but the center core 58 is a member for forming intermediate magnetic paths between the ends 54a and the heating belt 48.
In the example of
The temperature control circuit 621 provided in the image forming apparatus 1 controls a power supply device 521 of alternating current power supplied to the induction heating coil 52 based on the temperature detected by the thermistor 62. The temperature control circuit 621 controls the alternating current power supplied from the power supply device 521 to the induction heating coil 52 such that a temperature T detected by the thermistor 62 is maintained at a target temperature Ta necessary to fix a toner image to a sheet. This control may be performed by on-off controlling the power supply device 521. Alternatively, a control to be executed may be such that the amount of alternating current power supplied to the induction heating coil 52 is increased and decreased by changing the voltage and/or frequency of the alternating current power generated by the power supply device 521.
One or more unillustrated thermostats (temperature responding elements) may be disposed inside the heat roller 46. The thermostats can be disposed at positions in the heat roller 46 where the amount of heat generation by induction heating is particularly large and operate in response to an excessive temperature increase of the heat roller 46 to stop the heating by the induction heating coil 52.
The center core 58 has an outer surface on which a shielding member 60 is mounted. The shielding member 60 may be employed in the number of two, each of which is mounted on one of the opposite ends of the center core 58. Each shielding member 60 is in the form of a thin plate and is curved to have an arcuate shape in conformity with the shape of the outer surface of the center core 58. The shielding members 60 may be, for example, embedded in the center core 58 as shown or may be attached to the outer surface of the center core 58. The shielding members 60 can be bonded, for example, using a silicon adhesive. In the fixing unit 14 of the first embodiment, the shielding members 60 constitute a magnetic shielding body together with the center core 58.
The material of the shielding members 60 is preferably nonmagnetic and good in electrical conductivity. For example, oxygen-free copper or the like is used. The shielding member 60 generates opposing magnetic field by the influence of induction current induced when a magnetic field perpendicular to a surface of the shielding member 60 penetrates the surface of the shielding member 60, and then cancel interlinkage flux (perpendicular penetrating magnetic field) to thereby shield the magnetic field. Further, by using a good electrically conductive material, the generation of Joule heat by the induction current is suppressed and the magnetic field can be efficiently shielded. In order to improve electrical conductivity, it is effective, for example, to select a material with as small a specific resistance as possible and to increase the thickness of the members. Specifically, it is preferable to select the thickness of the shielding members 60 in a range of 0.5 mm to 3 mm and the shielding members 60 having a thickness of 1 mm are, for example, used in this embodiment. In this way, the specific resistance of the shielding members 60 can be made sufficiently small and a magnetic shielding effect can be obtained sufficiently, while the shielding members 60 can be made lighter.
In the IH coil unit 50, magnetism adjusting members 90 are provided between the induction heating coil 52 and the heat roller 46 (the heating belt 48) and at the opposite sides of the center core 58. In
If a penetrating magnetic field (interlinkage flux) is generated in a direction (one direction) perpendicular to a frame surface or ring surface (imaginary plane) of the frame-shaped magnetism adjusting member 90, an induction current is accordingly generated in a circumferential direction of the magnetism adjusting member 90 as shown in
A case is assumed where penetrating magnetic fields are generated in both directions through the frame surface of the frame-shaped magnetism adjusting member 90 as shown in an upper part of
In view of the point that both an effect of shielding magnetism and an effect of not shielding magnetism can be obtained by states shown in
When the shielding members 60 are located at positions (shielding position) proximate to the outer surface of the heating belt 48 as shown in
As described above, the entire length of the center core 58 is substantially equal to or longer than a maximum sheet width W3 of sheets orthogonal to the sheet conveying direction. Two shielding members 60 are separated in the longitudinal direction of the center core 58 and are symmetrically shaped. Each shielding member 60 has, for example, a triangular shape in plan view or bottom view and a part thereof corresponding to the vertex of the triangular shape is located near the center of the center core 58. In other words, the lengths of the shielding members 60 in the circumferential direction of the center core 58 a shortest at the positions near the center of the center core 58 and the circumferential lengths of the shielding members 60 gradually increase from these positions toward the opposite ends of the center core 58.
Each of the shielding members 60 is provided in its most part outside the minimum paper width W1 orthogonal to the sheet conveying direction and only tiny part of the shielding member 60 is located within the range of the minimum paper width W1. Also, each of the shielding members 60 extends slightly beyond the maximum paper width W3 of sheets at the opposite ends of the center core 58. The minimum paper width W1 and the maximum paper width W3 are determined by sheets of the minimum size and the maximum size printable by the image forming apparatus 1. The size of sheet means a width orthogonal to the sheet conveying direction.
In this embodiment, a ratio of the length of each shielding member 60 to the outer circumferential length of the center core 58 in the rotating direction of the center core 58 differs in the longitudinal direction (lengthwise direction) of the center core 58. Here, if the ratio of the length (Lc) of each shielding member 60 to the outer circumferential length (L) of the center core 58 is a covering ratio (=Lc/L), the covering ratio is smaller at the inner side of the center core 58 and increases toward the outer sides (opposite ends) in the longitudinal direction. Specifically, the covering ratio is minimized in the vicinity of the minimum passage area (range of the minimum paper width W1) while being, conversely, maximized at the opposite ends of a maximum passage area, i.e. the center core 58 (range beyond the maximum paper width W3). The passage area means an area where a sheet comes into contact with the heating belt 48 when the sheet passes the heating belt 48 while being held between the pressure roller 44 and the fixing roller 45. In this passage area, a first area where the sheet does not come into contact with the heating belt 48 and a second area where the sheet comes into contact with the heating belt 48 are set according to the paper widths W1 to W3 of sheets. For example, when a sheet of the minimum paper width W1 is conveyed, a central part of the heating belt 48 is set as the second area and parts of the heating belt 48 near the opposite ends are set as the first area when viewed in the longitudinal direction of the heat roller 46. Further, when a sheet of the maximum paper width W3 is conveyed, a substantially entire part of the heating belt 48 is set as the second area when viewed in the longitudinal direction of the heat roller 46. In this case, no first area is set.
The respective sheet sizes can be dealt with by switching the positions of the shielding members 60 to partially suppress magnetic fluxes to be generated. At this time, excessive temperature increases can be prevented at the opposite ends of the heat roller 46 and the heating belt 48 by making an angle of rotation (rotational displacement amount) of the center core 58 differ according to the sheet size such that the larger the sheet size, the smaller the magnetic shielding amount and, conversely, the smaller the sheet size, the larger the magnetic shielding amount. Although only counterclockwise rotations are shown by arrows in
In the example shown in
Next, a mechanism for rotating the center core 58 about its longitudinal axis, i.e. a mechanism for displacing the shielding members 60 between the shielding position and the retracted position is described with reference to
As shown in
The drive shaft 70 is connected with one end of the center core 58, and supports the center core 58 without penetrating inside the center core 58. The angle of rotation of the center core 58 is controlled, for example, by the number of drive pulses applied to the stepping motor 66, and a control circuit (not shown) for this purpose is attached to the rotating mechanism 64. The control circuit may include, for example, a control IC, input/output drivers, a semiconductor memory and the like. A detection signal from the photointerrupter 74 is inputted to the control IC via the input driver and the control IC detects the present angle of rotation (position) of the center core 58 in accordance with this detection signal. On the other hand, information on the present sheet size is notified to the control IC from an unillustrated image forming controller. In response to this information, the control IC reads information on an angle of rotation suitable for the sheet size from the semiconductor memory (ROM) and outputs drive pulses necessary to reach this target angle of rotation in a specified cycle. The drive pulses are applied to the stepping motor 66 via the output driver and the stepping motor 66 accordingly operates.
At this time, at the inner sides of the magnetic paths passing the heating belt 48 and the heat roller 46 via the side cores 56, the arch cores 54 and the center core 58, magnetic fluxes leaking, for example, from the arch cores 54 pass the insides of the frame parts of the magnetism adjusting members 90, pass the heating belt 48 and the heat roller 46 and are converged to the arch cores 54 after passing the insides of the frame parts of the magnetism adjusting members 90 again. Such leaking magnetic fluxes do not pass the center core 58 and the side cores 56, but contribute to induction heating the heating belt 48 and the heat roller 46 at the inner sides of the magnetic paths.
For such leaking magnetic fluxes, the magnetism adjusting members 90 are in the state shown in the lower part of
At this time, the magnetic paths passing the heating belt 48 and the heat roller 46 via the side cores 56, the arch cores 54 and the center core 58 are shielded but, at the inner sides thereof, magnetic fluxes leaking, for example, from the arch cores 54 try to pass the heating belt 48 and the heat roller 46 after passing the insides of the frame parts of the magnetism adjusting members 90. If the heating belt 48 and the heat roller 46 are induction heated by such leaking magnetic fluxes, the shielding effect by the shielding members 60 is reduced.
In this embodiment, in the shielding state, the magnetism adjusting members 90 are in the state shown in
The magnetic shielding body constituted by the shielding members 60 and the center core 58 acts as a switcher for switching the magnetism adjusting members 90 to the first state in which the magnetism adjusting members 90 fulfill the magnetic shielding effect when the shielding members 60 are at the shielding position and to the second state in which the magnetism adjusting members 90 do not fulfill the magnetic shielding effect when the shielding members 60 are at the retracted position.
Next, condition setting found out by the inventors of the present invention is described by way of examples. The magnetism adjusting members 90 are preferably made of a material which is nonmagnetic and good in electrical conductivity in order to suppress the generation of Joule heat by the induction current and to efficiently shield magnetism in the case of compensating for the magnetic shielding effect by the shielding members 60 as described above. In this embodiment, oxygen-free copper or the like material is used as described above. In order to improve electrical conductivity, it is necessary to select a material with as small a specific resistance as possible and to increase the thickness (t in
Accordingly, if it is assumed that the shielding members 60 are displaced to the retracted position and the magnetic field canceling effect is not exhibited (thick-line distribution in
In such a magnetic field distribution, a point P where the radial magnetic field becomes 0 on the distribution curve is first taken and angles α1, α2 where integration values of the distribution curves in directions toward 0° and 90° from this point P are equal (areas S1, S2 in
Then, an angle (=(α1+α2)/2) as a midpoint of the angles α1, α2 on the horizontal axis is calculated and set as an angle of the frame center L at the retracted position. If a distance from the center of the heat roller 46 to the magnetism adjusting member 90 is a radius r, the length of a virtual arc having this radius r and located in the angle range of α1 to α2 is an optimal frame width of the magnetism adjusting member 90. In this example, the frame width WR can be calculated by the following equation. It should be noted that the radius r is larger than the radius (D/2 in
WR=rx{(α−α1)/180}×π
By setting the frame width of the magnetism adjusting members 90 to WR (above equation) and setting the arrangement angle of the frame centers to (α2−α1)/2 as described above, optimal conditions can be set. Particularly, since the magnetic field is balanced out (areas S1=S2) insides the frame parts with the shielding members 60 switched to the retracted position, there is no likelihood of hindering the generation of the magnetic field by the induction heating coil 52. In the first embodiment, the frame width WR is preferably selected from a range of 1 mm to 5 mm. The selection of the frame width WR in such a range contributes to making the specific resistance of the magnetism adjusting member 90 sufficiently small. The frame width WR means a distance between a pair of straight portions 90a, 90a of the magnetism adjusting member 90.
Hereinafter, first to fourth modifications of the fixing unit 14 of the first embodiment are described. In any of these modifications, constructions common to the first embodiment are identified and shown by common reference numerals and not repeatedly described. Even with common reference numerals given, description is added particularly in the case of using different materials and the like.
If the heat roller 46 is made of the nonmagnetic metal, the magnetic field generated by the induction heating coil 52 passes the side cores 56, the arch cores 54 and the intermediate core 55 and passes through the heat roller 46 to reach the center core 58 inside. The heating belt 48 is induction heated by the penetrating magnetic field.
In the case of the second modification, the shielding members 60 are distanced from the intermediate core 55 at the retracted position as shown in
Since it is not necessary to provide the shielding members in the case of the third modification, the center core, on which the shielding members are arranged, and the rotating mechanism therefor are not necessary, either. Therefore, the structure can be simplified.
The first embodiment and the first to fourth modifications described above can be embodied while being variously modified. For example, the shape of the center core 58 is not limited to the tubular or cylindrical one and may be a polygonal shape. The shape of the shielding members 60 in plan view is not limited to the triangular shape, but may be a trapezoidal shape.
The shapes, sizes and number of the frame parts of the magnetism adjusting members 90 are merely examples and are particularly not limited.
Besides, the specific shapes of the respective parts including the arch cores 54 and the side cores 56 are not limited to the shown ones and can be appropriately changed.
Next, a fixing unit 14 according to a second embodiment is described in detail.
The fixing unit 14 includes a pressure roller 44, a fixing roller 45 and a heating belt 148 wound around the fixing roller 45. The pressure roller 44 is a metallic roller, whereas the fixing roller 45 has an elastic layer of silicon sponge on its outer surface (at an inner side of the heating belt 148). Thus, a flat nip NP is formed between the heating belt 148 and the fixing roller 45. A halogen heater 44a is disposed inside the pressure roller 44. The base material of the heating belt 148 is a ferromagnetic material (e.g. Ni), a thin elastic layer (e.g. silicon rubber) is formed on the outer surface of the base material, and a mold releasing layer (e.g. PFA) is formed on the outer surface of the elastic layer.
The fixing unit 14 further includes an IH coil unit 50 arranged at an outer side of the fixing roller 45 (heating belt 148). The IH coil unit 50 includes an induction heating coil 52, arch cores 54 and a pair of side cores 56. These arch cores 54 and side cores 56 are magnetic bodies formed, for examples, by sintering ferrite powders. Although the arch cores 54 are three divided pieces here, they may be integrally formed.
As shown in
Although not shown here, the induction heating coil 52 is elliptically wound in plan view (state viewed from above in
In this second embodiment, a thermistor 62 (may be a thermostat) is disposed to face the outer side of the fixing roller 45. The thermistor 62 can be arranged, for example, at a position where the intensity of the magnetic field generated by the induction heating coil 52 is high and the thermistor 62 does not interfere with the induction heating coil 52.
The IH coil unit 50 includes magnetism adjusting members 160 located between the induction heating coil 52 and the arch cores 54. Each of the magnetism adjusting members 160 is made of a nonmagnetic metal (e.g. oxygen-free copper) and has a closed frame in rectangular shape in plan view. Because of its closed frame shape, the inner side of the magnetism adjusting member 160 is hollow and only an end thereof is shown in
A magnetism adjusting mechanism includes a supporting member 164 supporting the magnetism adjusting member 160, a drive shaft 164 mounted on the supporting member 164 and an unillustrated driving mechanism (stepping motor and speed reducing mechanism) connected to the drive shaft 166. The magnetism adjusting member 160 is supported at its longitudinal end by the supporting member 164. The supporting member 164 includes a side plate 164a having, for example, a fan shape and an arcuate top plate 164b, and the top plate 164b is mounted to the lower surface of one arcuate portion 160b of the magnetism adjusting member 160. The side plate 164a extends downward from the top plate 164b in
Since the principle of the magnetic shielding effect by the magnetism adjusting member 160 is similar to that of the magnetic shielding effect by the magnetism adjusting member 90 described with reference to
As shown in
Further, as shown in
In this way, the magnetism adjusting mechanism functions as a switcher for switching the magnetism adjusting member 160 to the shielding position, i.e. the first state where the magnetism adjusting member 160 exhibits the magnetic shielding effect and to the retracted position, i.e. the second state where the magnetism adjusting member 160 does not exhibit the magnetic shielding effect.
Next, condition setting for the fixing unit 14 of the second embodiment is described. The magnetism adjusting members 160 are preferably made of a material which is nonmagnetic and good in electrical conductivity in order to suppress the generation of Joule heat by an induction current and to efficiently shield magnetism, and oxygen-free copper or the like material is used as described above. In order to improve electrical conductivity, it is necessary to select a material with as small a specific resistance as possible and to increase the thickness of the material. According to conditions found out by the inventors of the present invention, the thickness of the magnetism adjusting member 160 is preferably selected from a range of 0.5 mm to 3 mm. In this example, the one having a thickness of 1 mm is used.
The following conditions are presented by the inventors of the present invention for an angle by which the magnetism adjusting member 160 is displaced. For example, as shown in
In such a magnetic field distribution, a point P where the radial magnetic field becomes 0 on the distribution curve is first taken and angles α1, α2 where integration values of the distribution curve in directions toward 0° and 90° from this point P are equal (areas S1, S2 in
Then, an angle (=(α1+α2)/2) as a midpoint of the angles α1, α2 on the horizontal axis is calculated and set as an angle of the frame center L at the retracted position. If a distance from the center of the fixing roller 45 to the magnetism adjusting member 160 is a radius r, the length of an imaginary arc having this radius r and located in the angle range of α1 to α2 is an optimal frame width of the magnetism adjusting member 160. In this example, the frame width WR can be calculated by the following equation.
WR=rx{(α2−α1)/180}×π
By setting the frame width of the magnetism adjusting member 160 to WR (above equation), setting the angle of the frame center at the retracted position to (α2−α1)/2 and setting the angle of the frame center at the shielding position to 90°, optimal conditions can be set. Particularly, since the magnetic field is balanced out (areas S1=S2) inside the frame at the retracted position, there is no likelihood of hindering the generation of the magnetic field by the induction heating coil 52. In the second embodiment, the frame width WR is preferably selected from a range of 1 mm to 5 mm. The selection of the frame width WR in such a range contributes to making the specific resistance of the magnetism adjusting member 160 sufficiently small.
In the arrangement example shown in
In the arrangement example shown in
In the arrangement example shown in
Various sheet sizes can be dealt with by switching the positions of the magnetism adjusting members 160 to 180 to partially shield the magnetic field. At this time, excessive temperature increases can be prevented at the opposite ends of the heating belt 148 by making the positions of the magnetism adjusting members 160 to 180 differ little by little according to the sheet size such that the larger the sheet size, the smaller the magnetic shielding amount and, conversely, the smaller the sheet size, the larger the magnetic shielding amount. Although only the term “magnetism adjusting members 160” is written to prevent complication in the following description, this term also means the magnetism adjusting members 170, 172, 174 and 180 shown in
This modification differs from the second embodiment in that the magnetism adjusting member 160 is displaced between the induction heating coil 52 and the fixing roller 45 (heating belt 148). The other constructions are common to the second embodiment, and items common to the already described constructions are identified by the same reference numerals and not repeatedly described.
When power is applied to the induction heating coil 52, magnetic paths passing the side cores 56 and the arch cores 54 and vertically passing an air gap at the position of the coil center C to reach the heating belt 148 are formed around the induction heating coil 52. At this time, if the magnetism adjusting members 160 are placed at intermediate positions of the magnetic paths passing the coil center C between the induction heating coil 52 and the fixing roller 45 as shown in
On the other hand, as shown in
Those shown in the second embodiment can be applied for the other condition setting. In this modification, the distance (radius r) from the center of the fixing roller 45 to the magnetism adjusting members 160 is shorter than in the second embodiment and, hence, the frame width is smaller by that much.
In this modification, induction heating is performed by arcuate parts of the heating belt 48 and the heat roller 46. In other words, the magnetic field generated by the induction heating coil 52 passes the side cores 56, the arch cores 54 and an air gap at the position of the coil center and passes through the heating belt 48 and the heat roller 46 to induction heat these.
In this modification as well, magnetism can be shielded in the ranges of the magnetism adjusting members 160 by moving the magnetism adjusting members 160 to the shielding position similar to the second embodiment. In this way, excessive temperature increases at the opposite ends of the heating belt 48 and the heat roller 46 can be reliably prevented at the time of switching the size. In the case of a large-size sheet, the magnetic shielding effect can be canceled by moving the magnetism adjusting members 160 to the retracted position to quickly warm up the heating belt 48 and the heat roller 46.
Although
Specifically, the fixing unit 14 of the third embodiment includes a pressure roller 44 and a heat roller 46 and fixes a toner image while conveying a sheet through a nip between these rollers. Since the heat roller 46 is a metallic roller, this structure is suitably applicable for fixing a black-and-white image. By providing an elastic layer as an outer layer of the heat roller 46, a flat nip NP may be formed between the heat roller 46 and the pressure roller 44. In this case, the structure is suitably applicable for fixing a full color image similar to the first and second embodiments.
The internal IH coil unit 50 includes an induction heating coil 52 and a ferrite core 59 provided inside the heat roller 46. In other words, the induction heating coil 52 is arranged along the inner circumferential surface of the heat roller 46 and the coil center thereof, for example, extends in a horizontal direction from the axial center of the heat roller 46 in
The ferrite core 59 is formed by combining two pieces in such a manner as to have a T-shaped cross section. One piece extends along the coil center of the induction heating coil 52 and the other piece extends in radial directions at the opposite sides of the coil center.
In the internal IH coil unit 50 as well, when power is applied to the induction heating coil 52, magnetic paths passing from the ferrite core 59 to parts of the heat roller 46 and converged to the ferrite core 59 at the position of the center core are formed around the induction heating coil 52. In such an internal IH coil unit 50 as well, if the magnetism adjusting members 160 are placed at intermediate positions of the magnetic paths passing the coil center as shown in
On the other hand, as shown in
In the third embodiment as well, magnetism can be shielded in the ranges of the magnetism adjusting members 160 by moving the magnetism adjusting members 160 to the shielding position similar to the second embodiment. In this way, excessive temperature increases at the opposite ends of the heat roller 46 can be reliably prevented at the time of switching the size. In the case of a large-size sheet, the magnetic shielding effect can be canceled by moving the magnetism adjusting members 160 to the retracted position to quickly warm up the heat roller 46.
Although
The fixing units 14 of the second and third embodiments can be variously modified and embodied. The shape and arrangement of the magnetism adjusting members 160 are not limited to those shown in
In the fixing unit 14 of the third embodiment, the IH coil unit 50 may be arranged at a flat part of the heating belt 48 instead of being arranged at the arcuate part of the heating belt 48. In this case, the magnetism adjusting members 160 may have a flat shape as a whole and may be displaced by being slid in straight directions between the induction heating coil 52 and the arch cores 54 or between the induction heating coil 52 and the heating belt 48.
The image forming apparatus, particularly the fixing unit described above mainly embraces the following constructions.
An image forming apparatus according to the present invention includes an image forming unit for transferring a toner image to a sheet, and a fixing unit having a heating member and a pressing member and adapted to convey the sheet while holding the sheet between the heating member and the pressing member and to fix the toner image to the sheet by heat at least from the heating member in a conveying process. The heating member has a first area where a sheet does not come into contact with the heating member when the sheet being conveyed by the fixing unit passes the heating member, and a second area where the sheet comes into contact with the heating member when the sheet being conveyed by the fixing unit passes the heating member, the first area and the second area set according to the size of the sheet. The fixing unit further includes a coil for forming a magnetic field by generating magnetism for induction heating the heating member, a core made of a magnetic material to form a magnetic path near the coil, a magnetism adjusting member made of a nonmagnetic material, arranged on the magnetic path and having a closed frame, and a switcher capable of switching the magnetism adjusting member between a first state where the magnetism adjusting member generates an induction current resulting from the magnetic field to shield the magnetism in the first area, and a second state where the magnetism adjusting member generates no induction current and the magnetism is not shielded in the first area.
According to the image forming apparatus of the present invention, an excessive temperature increase in the first area can be suppressed since the magnetism adjusting member shields the magnetism in the first area upon the switch to the first state by the switcher. Further, since the magnetism adjusting member does not shield the magnetism in the first area upon the switch to the second state by the switcher, the induction heating of the first area can be promoted.
In the image forming apparatus of the above construction, the coil is arranged along an outer surface of the heating member, the core is arranged at a side of the coil opposite to the heating member, the magnetism adjusting member is arranged between the coil and the heating member, the switcher is a magnetic shielding body switchable between a shielding state for shielding the magnetism in the first area and a permitting state for permitting the passage of the magnetism, and the magnetism adjusting member is switched to the first state when the magnetic shielding body is switched to the shielding state while being switched to the second state when the magnetic shielding body is switched to the permitting state.
According to this construction, the switch of the sheet size can be dealt with by shielding the magnetism and permitting the passage of the magnetism in the first area of the heating member by means of the magnetic shielding body. However, if the area of the magnetic shielding body is increased only aiming at the magnetic shielding effect, the influence on the magnetic field conversely increases by hindering the passage of the magnetism in the case of permitting the passage of the magnetism. Therefore, it is difficult to obtain a good magnetic shielding effect only by the magnetic shielding body.
However, in the above construction, an excessive temperature increase suppressing effect is improved without increasing the area of the magnetic shielding body and it is made more unlikely to influence the magnetic field at the time of permitting the passage of the magnetism by arranging the frame-shaped magnetism adjusting member between the coil and the heating member. In other words, the magnetism adjusting member compensates for the magnetic shielding by the magnetic shielding body and prevents magnetic fluxes leaking from the shielding by the magnetic shielding body in the first area from acting on the heating member.
The magnetism adjusting member employing the above construction has the following merits. Specifically, since the magnetism adjusting member is a closed frame, if a magnetic field (interlinkage flux) perpendicular to the plane of the inside of the frame penetrates, an induction current is generated in a circumferential direction of the frame to generate an opposite magnetic field acting in a direction opposite to the penetrating magnetic field. This opposite magnetic field cancels the magnetic field (interlinkage flux) penetrating the inside of the frame in the perpendicular direction, whereby the magnetism adjusting member can compensate for the magnetic shielding. On the other hand, if a magnetic field passes in opposite directions or in a U-turn direction inside the frame, no induction current is generated and no magnetic shielding effect is exhibited.
Focusing on the properties of the magnetism adjusting member as described above, the inventors of the present invention found out an optimal arrangement of the magnetism adjusting member between the coil and the heating member. If the magnetic shielding body is in the shielding state, the magnetism adjusting member in an optimal arrangement can cancel the magnetic field by the induction current generated in the frame since the magnetic field (magnetic flux) leaking from the magnetic shielding body tries to penetrate the inside of the frame. On the other hand, if the magnetic shielding body is in the permitting state, the magnetic field generated around the coil passes in both directions or in a U-turn direction inside the frame. Thus, almost no induction current is generated inside the frame this time and the passage of the magnetism can be permitted. Therefore, the excessive temperature increase suppressing effect can be exhibited more than at present without extremely increasing the area of a member for shielding.
In the above construction, the magnetic shielding body includes a shielding member made of a nonmagnetic metal and switches the shielding member between a shielding position where the shielding member is positioned in the magnetic path, passing the core and the heating member around the coil, to shield the magnetism, and a retracted position where the shielding member is positioned outside the magnetic path to permit the passage of the magnetism.
According to this construction, even without increasing the area of the shielding member very much, the magnetic shielding can be compensated by the magnetism adjusting member with the shielding member switched to the shielding position. On the other hand, with the shielding member switched to the retracted position, the magnetism adjusting member does not influence the magnetic field, wherefore the heating member can be sufficiently induction heated, contributing to the shortening of the warm-up time thereof.
In the above construction, the heating member is a ferromagnetic body and the magnetic shielding body includes, in addition to the shielding member, a movable core interposed between the core and the heating member with respect to a direction in which the magnetic field is generated by the coil and having an outer surface on which the shielding member is arranged.
In the above construction, the heating member is a nonmagnetic body, and the magnetic shielding body includes a movable core provided inside the heating member to form a magnetic path penetrating the heating member and having an outer surface on which the shielding member is arranged. Since the heating member causes the magnetic field to penetrate therethrough, it is sufficient to arrange the shielding member inside.
Further, in the above construction, the magnetic shielding body is formed by the heating member made of a magnetic shunt metal material and shields the magnetism in the magnetic field generated by the coil upon being heated to or above a Curie temperature while induction heating the heating member by permitting the passage of the magnetism in a state where the Curie temperature is not reached yet. In this way, even without particularly switching the shielding member to the shielding position and the retracted position, the heating member itself can shield the magnetism and permit the passage thereof according to temperature (Curie temperature). In this construction as well, by optimally arranging the magnetism adjusting member, it is possible to permit the passage of the magnetism without influencing the magnetic field during heating while assisting the magnetic shielding effect.
In the above construction, the magnetism adjusting member may be in the form of one rectangular frame having a common outer peripheral part and having the inside thereof divided into a plurality of sections in a direction orthogonal to the sheet conveying direction or may include a plurality of rectangular frame-shaped members arranged in a direction orthogonal to the sheet conveying direction.
As described above, since the magnetism adjusting member exhibits the magnetic shielding effect in the range of the inside of the frame, various sheet sizes can be dealt with by dividing the magnetism adjusting member into a plurality of frame parts or arranging a plurality of members.
In the image forming apparatus of the above construction, particularly in the fixing unit of another construction, it is preferable that the coil is arranged along the outer surface of the heating member and formed around a specified coil center to generate the magnetic field, the core is arranged at a side of the coil opposite to the heating member and forms the magnetic path passing the coil center around the coil, the magnetism adjusting member has a specified frame center, and the switcher switches the magnetism adjusting member between a first state where the frame center is substantially aligned with the coil center at an intermediate position of the magnetic path, passing the coil center and reaching the heating member, to shield the magnetism, and a second state where the magnetism adjusting member is displaced from the magnetic path with the frame center offset from the coil center to permit the passage of the magnetism.
In this construction as well, by the above properties of the magnetism adjusting member, a sufficient magnetic shielding effect can be obtained in the first area when the magnetism adjusting member is in the first state. Further, when the magnetism adjusting member is in the second state, the magnetic shielding effect in the first area can be suppressed. In this way, it is possible to obtain a sufficient temperature increase and to shorten the warm-up time without reducing heating efficiency during the induction heating of the heating member. Further, since the magnetism adjusting member may overlap with the winding area of the coil in the second state, it is not necessary to ensure a storage space up to the outside of the coil or core and, accordingly, space saving can be promoted. Since the magnetism adjusting member is frame shaped and hollow, the mass of the member can be suppressed even if a sufficiently wide range (frame width) is ensured. Thus, it is possible to reduce material cost and to suppress power (e.g. motor output) upon displacing the magnetism adjusting member to a minimum level.
The fixing unit of the above construction is structured such that the coil and the core are arranged outside the heating member (so-called external IH), it may be structured such that the coil and the core are arranged inside the heating member (so-called internal IH). In this case, in the fixing unit, it is preferable that the coil is arranged along a heating area on an inner surface of the heating member in a circumferential direction of the heating member and formed around a specified coil center to generate the magnetic field for induction heating the heating member in the heating area, the core is arranged inside the heating member together with the coil and forms the magnetic path passing the coil center of the coil, the magnetism adjusting member has a specified frame center, and the switcher switches the magnetism adjusting member between a first state where the frame center is substantially aligned with the coil center at an intermediate position of the magnetic path, passing the coil center and reaching the heating member, to shield the magnetism, and a second state where the magnetism adjusting member is displaced from the magnetic path with the frame center offset from the coil center to permit the passage of the magnetism.
Similarly in the above construction (internal IH), a sufficient magnetic shielding effect by the magnetism adjusting member can be obtained by displacing the magnetism adjusting member to the shielding position inside the heating member. In the second state, sufficient heating efficiency can be exhibited since the magnetism adjusting member satisfactorily permits the passage of the magnetism. In this case, sufficient space saving can be promoted since the coil and the core including the magnetism adjusting member can be arranged inside the heating member.
In the above construction of the external IH, it is preferable that the switcher is capable of displacing the magnetism adjusting member between the coil and the core. In the above construction of the internal IH, the switcher is capable of displacing the magnetism adjusting member between the heating member and the coil. In either construction, the magnetism adjusting member can shield the magnetism at the intermediate position of the magnetic path passing the coil center in the first state or can reliably permit the passage of the magnetism in the second state.
In the above external and internal IH constructions, the second state to which the switcher switches the state of the magnetism adjusting member is a state where a current flowing in a circumferential direction of the magnetism adjusting member is substantially zero upon the generation of the magnetic field by the coil. In other words, if the current flowing in the magnetism adjusting member (in the frame) is zero in the second state, a magnetic field opposite to the magnetic field generated by the coil is not generated therefrom, wherefore the magnetic induction of the heating member is not hindered.
In the above external and internal IH constructions, it is preferable that the switcher is capable of reciprocating the magnetism adjusting member between the first state and the second state to adjust a magnetic shielding amount according to a displacement amount of the magnetism adjusting member between these states. According to this construction, when the switcher displaces the magnetism adjusting member, the magnetism is hardly (not at all) shielded in the second state, but the magnetic shielding amount can be gradually increased as the state is switched from the second state to the first state. Therefore, as the temperature of the heating member increases, the magnetic shielding amount can be finely adjusted.
Further, in the above external and internal IH constructions, it is preferable that the magnetism adjusting member is divided, in a direction orthogonal to the sheet conveying direction, into a plurality of rectangular frame members and the frame members have different frame widths in the sheet conveying direction and the frame width is set to be minimum near a minimum sheet area where the sheet of minimum size out of the sheets conveyed by the fixing unit passes.
The frame-shaped magnetism adjusting members exhibit the magnetic shielding effect in the ranges of the insides of the frames. Thus, out of the plurality of magnetism adjusting members, the one having the largest frame width has a largest magnetic shielding amount and the one having the smaller frame width has a smaller magnetic shielding amount. Accordingly, if the frame width is minimized near the minimum paper area where an excessive temperature increase of the heating member is normally unlikely to become problematic and the frame width is increased in a sheet width direction (width direction of the heating member) away from the minimum paper area, the magnetism can be effectively shielded at the outer sides of the minimum paper area where an excessive temperature increase particularly becomes problematic. Therefore, the magnetic shielding can be reliably switched in accordance with the sheet size.
In the above construction, it is preferable that the magnetism adjusting member is made of a nonmagnetic metal conductor made of copper, and the width thereof is set to 1 mm to 5 mm and the thickness thereof is set to 0.5 mm to 3 mm. Since the magnetism adjusting member efficiently shields the magnetism by suppressing the generation of Joule heat of its own, it is necessary to maximally reduce the specific resistance (electrical resistance) of the member. If the material is selected and the dimension is set as above, the specific resistance of the magnetism adjusting member can be made sufficiently small. As a result, it is possible to ensure good electrical conductivity, to obtain a sufficient magnetic shielding effect and to make the magnetism adjusting member lighter.
In the present invention, it is preferable that the heating member is one of a metallic roller and a metallic belt wound around the metallic roller. In either case, it is suitable for an induction heating method by the coil.
This application is based on Japanese Patent Application Nos. 2008-000433 and 2008-000686 filed on Jan. 7, 2008 respectively, the contents of which are hereby incorporated by reference.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to embraced by the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008-000433 | Jan 2008 | JP | national |
| 2008-000686 | Jan 2008 | JP | national |
