Patent Application
20220035296
The present invention relates to an image forming apparatus for forming an image on a sheet.
Hitherto, in order to create a confidential document that requires sealing, such as a salary payment statement, a pre-printed sheet is prepared in advance, and variable data is printed to each pre-printed sheet before the sheet is subjected to a sealing process performed as postprocessing. According to this method, the creation of pre-printed sheets requires much time because it requires application of adhesive, and it was inefficient to create small quantities of confidential documents.
Japanese Patent Application Laid-Open Publication No. 2006-171607 proposes an image forming apparatus configured to output a sealed document using normal paper by one apparatus through use of adhesive toner, i.e., powder adhesive, in addition to toner for forming images using an electrophotographic process. Adhesive toner is designed to melt at a temperature lower than toner for forming images, and adhesive toner is applied to a sheet serving as a recording medium by being transferred to the sheet via an electrophotographic process in a same manner as toner for forming image. Thereafter, the sheet is folded so that faces (i.e., bonding surfaces) on which adhesive toner is applied are opposed to each other, and finally, the sheet is bonded by being heated in a state where the bonding surfaces of the sheet are closely attached via adhesive toner. This method completes the printing process and the bonding process by one image forming apparatus, so that it can be efficiently applied to creating even small quantities of documents. Further, since the method for bonding sheets by heating and melting adhesive does not require application of strong pressure, it is advantageous from the viewpoint of downsizing and reducing noise of the apparatus.
However, in a case where the printing process and the bonding process are performed by one image forming apparatus as according to the technique disclosed in the above-mentioned publication, the following drawbacks may occur. In the bonding process, a surface on an outer side of the folded sheet comes into contact with a heating member such as a heating roller or a heating film and is heated thereby, and the heat is conducted through the sheet to heat the powder adhesive applied on an inner side of the folded sheet. Therefore, the temperature rise of powder adhesive is slow compared to a case where powder adhesive is in direct contact with the heating member. Meanwhile, the sheet is heated while being conveyed by a conveyance speed set in advance, so that the period of time during which the sheet is in contact with the heating member is limited. Therefore, it may be possible to set the heating temperature of the bonding process to a very high temperature to soften the powder adhesive, but there are cases where sufficient adhesive strength cannot be achieved according to this method.
The present invention provides an image forming apparatus capable of providing sufficient adhesive strength to an output product bonded using powder adhesive.
According to one aspect of the invention, an image forming apparatus includes an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet, a fixing portion configured to heat the toner image formed on the sheet by the image forming portion and fix the toner image to the sheet, a folding portion configured to fold the sheet having passed through the fixing portion such that a surface of the sheet to which the powder adhesive is applied is inside, and a bonding portion configured to heat the sheet folded by the folding portion and bond the sheet by the powder adhesive, wherein the fixing portion and the bonding portion are configured such that a relationship of Tmax1>Tmax2 is satisfied, where Tmax1 (° C.) is a highest temperature of the powder adhesive when being heated by the fixing portion and Tmax2 (° C.) is a highest temperature of the powder adhesive when being heated by the bonding portion.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Embodiments of the present disclosure will be described with reference to the drawings.
First, the entire configuration of the image forming apparatus will be described with reference to
At first, an internal configuration of the apparatus body 10 will be described. As illustrated in
The sheet cassette 8 is inserted in a drawable manner to the casing 19 at a lower part of the apparatus body 10, and stores multiple sheets P. The sheets P stored in the sheet cassette 8 are fed from the sheet cassette 8 by a feeding member such as a feed roller, and one of the sheets P is separated from other sheets by a separation roller pair and conveyed by a conveyance roller 8a. Further, it is also possible to feed sheets that are set on the tray 20 arranged in an opened state (
The image forming unit 1e is a tandem-type electrophotographic unit including four processing cartridges 7n, 7y, 7m and 7c, a scanner unit 2 and a transfer unit 3. A processing cartridge is a unit that includes a plurality of components carrying out an image forming process, which can be replaced integrally. A cartridge supporting portion 9 that can be supported in the casing 19 is provided on the apparatus body 10, and the respective processing cartridges 7n, 7y, 7m and 7c are detachably attached to attachment portions 9n, 9y, 9m and 9c provided on the cartridge supporting portion 9. The cartridge supporting portion 9 may also be a tray member that can be drawn out of the casing 19.
The processing cartridges 7n, 7y, 7m and 7c have approximately the same configuration, except for the different types of powder material stored in the four powder storage portions 104n, 104y, 104m and 104c. That is, each of the processing cartridges 7n, 7y, 7m and 7c include a photosensitive drum 101 serving as an image bearing member, a charge roller 102 serving as a charger, one of powder storage portions 104n, 104y, 104m and 104c storing powder material, and a developing roller 105 that develops image using the powder material.
Among the four powder storage portions, three powder storage portions 104y, 104m and 104c arranged on the right side in the drawing store printing toner Ty, Tm and Tc of yellow, magenta and cyan as toner, i.e., first powder material or powder developer, for forming a visible image on the sheet P. Meanwhile, the powder storage portion 104n on the leftmost side in the drawing stores the powder adhesive Tn which is powder material, i.e., second powder material for performing a bonding process after the printing process. The powder storage portions 104y, 104m and 104c are each an example of a first storage portion storing printing toner, and the powder storage portion 104n is an example of a second storage portion storing powder adhesive. Further, the processing cartridges 7y, 7m and 7c are each an example of a first processing unit for forming a toner image using printing toner, and a processing cartridge 7n is an example of a second processing unit for forming an image of powder adhesive according to a predetermined application pattern.
According to the present embodiment, in order to print a black image such as a text image, process black in which color toner of yellow (Ty), magenta (Tm) and cyan (Tc) are superposed to create black is used. However, it is possible to add a fifth processing cartridge containing black printing toner to the image forming unit 1e and enable a black image to be formed using black printing toner. The types and number of printing toner can be varied according to the purpose of use of the image forming apparatus 1.
The scanner unit 2 is arranged below the processing cartridges 7n, 7y, 7m and 7c and above the sheet cassette 8. The scanner unit 2 is an exposure unit or exposing portion of the present embodiment that emits laser light G to the photosensitive drum 101 of respective processing cartridges 7n, 7y, 7m and 7c to form an electrostatic latent image.
The transfer unit 3 is equipped with a transfer belt 3a that serves as an intermediate transfer body, i.e., secondary image bearing member. The transfer belt 3a is a belt member wound around a secondary transfer inner roller 3b and a tension roller 3c, and an outer peripheral surface of the transfer belt 3a opposes to the photosensitive drums 101 of the respective processing cartridges 7n, 7y, 7m and 7c. Primary transfer rollers 4 are arranged at positions corresponding to respective photosensitive drums 101 on the inner peripheral side of the transfer belt 3a. Further, a secondary transfer roller 5 serving as a transfer member is arranged at a position opposed to the secondary transfer inner roller 3b. A transfer nip 5n formed between the secondary transfer roller 5 and the transfer belt 3a is a transfer portion, i.e., secondary transfer portion, where toner image is transferred from the transfer belt 3a to the sheet P.
The first fixing unit 6 is arranged above the secondary transfer roller 5.
The pressure roller 6b includes a core metal 6b1 formed for example of iron or aluminum, an elastic layer 6b2 having a thickness of 2 to 4 mm formed for example of silicon rubber, and a release layer formed of fluororesin such as PFA or PTFE arranged on the outermost surface.
The heater 6a1 serving as a heating unit, i.e., first heating unit, includes a heating resistor 6a12 formed for example of Ag/Pd (silver-palladium alloy) that generates heat by passing electric current therethrough and an insulation protecting layer, which according to the present embodiment is a glass layer, 6a13, that are arranged on a thin plate-shaped substrate 6a11 mainly composed of ceramics such as alumina. A temperature detecting element 6a2 such as a thermistor is abutted against the substrate 6a11 and is connected to a CPU 6a3 serving as a control unit installed in the image forming apparatus 1. The heater 6a1 is heated by having power supplied to the heating resistor 6a12. The heating is detected by the temperature detecting element 6a2, and the CPU 6a3 controls the electric current supplied to the heating resistor 6a12 via a triac 6a4. For example, the heater 6a1 is maintained to a constant temperature by performing control to increase an electric energy supplied to the heating resistor 6a12 so that the temperature of the heater 6a1 rises if a detected temperature of the temperature detecting element 6a2 is lower than a predetermined set temperature and to decrease the electric energy if the detected temperature is higher than the preset temperature.
The heater 6a1 is held by a holding member 6a5 made of heat-resistant resin such as LCP (Liquid Crystal Polymer). The holding member 6a5 also has a guiding function to guide the rotation of the fixing film 6a. The holding member 6a5 receives force toward a direction approaching the pressure roller 6b from a spring not shown attached to a stay 6a6 made of metal. The pressure roller 6b is in pressure contact with the fixing film 6a toward the direction of the heater 6a1 with a total pressure of 10 to 30 kgf by a pressure unit such as a spring member not shown. Thereby, the fixing nip 6N having a width of 5 to 11 mm in the sheet conveyance direction is formed between the pressure roller 6b and a nip forming unit composed of the heater 6a1 and the holding member 6a5.
The pressure roller 6b receives power from a motor not shown and rotates in the direction of arrow r1 in
A sheet discharge port 12, i.e., first sheet discharge port, serving as an opening portion for discharging the sheet P from the apparatus body 10 is formed on the casing 19, and a sheet discharge unit 34 is arranged on the sheet discharge port 12. The sheet discharge unit 34 serving as a sheet discharge portion according to the present embodiment adopts a so-called triple roller composed of a first sheet discharge roller 34a, an intermediate roller 34b and a second sheet discharge roller 34c. Further, a switching guide 33 which is a flap-shaped guide that switches the conveyance route of the sheet P is provided between the first fixing unit 6 and the sheet discharge unit 34. The switching guide 33 is pivotable around a shaft portion 33a such that a tip 33b of the switching guide 33 moves back and forth in a direction of arrow c in the drawing.
The apparatus body 10 is equipped with a mechanism for performing duplex printing. A motor not shown is connected to the sheet discharge unit 34 for rotating the intermediate roller 34b in both a normal direction and a reverse direction. A duplex conveyance path 1r that serves as a conveyance path connected in a loop to a main conveyance path 1m is provided. The sheet P having an image formed on a first surface while passing through the main conveyance path 1m is nipped and conveyed by the first sheet discharge roller 34a and the intermediate roller 34b via the switching guide 33 pivoted in a clockwise direction, the position of which is shown by a dashed line. After a trailing edge of the sheet P in a feed direction passes through the switching guide 33, the switching guide 33 pivots in a counterclockwise direction, the position of which is shown by a solid line, and the rotation of the intermediate roller 34b is reversed, by which the sheet P is conveyed in a reverse manner to the duplex conveyance path 1r. While the sheet P having the front and back sides reversed passes through the main conveyance path 1m again, an image is formed on a second surface of the sheet P. The sheet P after being subjected to duplex printing is guided by the switching guide 33 pivoted in the counterclockwise direction, the position of which is shown by the solid line, and nipped and conveyed by the intermediate roller 34b and the second sheet discharge roller 34c to be discharged from the apparatus body 10.
The conveyance route that passes the conveyance roller 8a, a transfer nip 5N and a fixing nip 6N in the apparatus body 10 constitutes the main conveyance path 1m through which image is formed on the sheet P. The main conveyance path 1m extends from a position lower than to a position upper than the image forming unit 1e through one side in a horizontal direction when viewed in a main scanning direction for forming an image, that is, a width direction of the sheet perpendicular to a conveyance direction of the sheet conveyed in the main conveyance path 1m. In other words, the apparatus body 10 according to the present embodiment is a so-called vertical conveyance-type, also referred to as vertical path-type, printer in which the main conveyance path 1m extends in an approximately vertical direction. When viewed in the vertical direction, the first sheet discharge tray 13, an intermediate path 15 and the sheet cassette 8 are mutually overlapped. Therefore, the direction of movement of the sheet with respect to the horizontal direction when the sheet discharge unit 34 discharges the sheet P is opposite to the direction of movement of the sheet with respect to the horizontal direction when the sheet P is fed from the sheet cassette 8.
In the viewpoint of
As illustrated in
The configuration of the second fixing unit 32 according to the present embodiment is substantially the same as the first fixing unit 6, as illustrated in
Further, the postprocessing unit 30 includes the first sheet discharge tray 13 for rotatably supporting a tray switching guide 13a, the intermediate path 15 and the second sheet discharge tray 35. The first sheet discharge tray 13 is arranged on the upper surface of the postprocessing unit 30 and also arranged on the upper side of the whole body of the image forming apparatus 1 (
A positioning portion, such as a projected shape that fits to a recess portion on the casing 19, for positioning the casing 39 on the casing 19, i.e., first casing, of the apparatus body 10 is provided in the postprocessing unit 30. Further, a drive source and a control unit that differ from those of the apparatus body 10 are provided on the postprocessing unit 30, and by coupling a connector 36 of the postprocessing unit 30 to a connector 37 of the apparatus body 10, the postprocessing unit 30 is electrically connected to the apparatus body 10. Thereby, the postprocessing unit 30 will operate based on a command from a control unit provided in the apparatus body 10 using power supplied through the apparatus body 10.
The processing cartridges 7n, 7y, 7m and 7c have approximately common configurations except for the type of powder material stored in the four powder storage portions 104n, 104y, 104m and 104c, as mentioned earlier. The processing cartridge 7n will be described here as an example.
The photosensitive drum 101 serving as an electrophotographic photoreceptor, i.e., image bearing member, formed in a drum shape is attached rotatably via a bearing not shown to the photoreceptor unit CC. Further, the photosensitive drum 101 is driven to rotate in a clockwise direction (arrow w) in the drawing during image forming operation by receiving the driving force of motor serving as a driving unit, i.e., drive source, not shown. Further, the charge roller 102 for charging the photosensitive drum 101 and a cleaning member 103 are arranged on the circumference of the photosensitive drum 101 in the photoreceptor unit CC.
The developing roller 105 serving as a developer bearing member that contacts the photosensitive drum 101 and rotates in the counterclockwise direction (arrow d) is provided in the developing unit DT. The developing roller 105 and the photosensitive drum 101 are rotated so that their surfaces are moved in the same direction at the opposing portion, i.e., contact portion.
Further, a developer feed roller, hereinafter simply referred to as “feed roller 106”, that serves as a developer supply member that rotates in the clockwise direction (arrow e) in the drawing is provided in the developing unit DT. The feed roller 106 and the developing roller 105 are rotated so that their surfaces move in the same direction at the opposing portion, i.e., contact portion. The feed roller 106 feeds the powder adhesive, or the printing toner in the case of processing cartridges 7y, 7m and 7c, to the developing roller 105. At the same time, the feed roller 106 functions to scrape off the powder adhesive, or the printing toner in the case of the processing cartridges 7y, 7m and 7c, remaining on the developing roller 105 from the developing roller 105. Further, a developer blade 107 serving as a developer regulation member for regulating layer thickness of the powder adhesive, or the printing toner in the case of the processing cartridges 7y, 7m and 7c, supplied on the developing roller 105 by the feed roller 106 is provided in the developing unit DT.
The powder adhesive, or the printing toner in the case of the processing cartridges 7y, 7m and 7c, is stored as powder material in the powder storage portion 104n. Further, a conveying member 108 which is supported rotatably is provided in the powder storage portion 104n. The conveying member 108 rotates in the clockwise direction (arrow f) in the drawing to agitate the powder stored in the powder storage portion 104n and convey the powder to a developing chamber 109 including the developing roller 105 and the feed roller 106.
It is also possible to design the photoreceptor unit CC and the developing unit DT separately as a photoreceptor unit cartridge and a developing unit cartridge, that can be detachably attached to the image forming apparatus body. Further, it is also possible to provide the powder storage portion 104n and the conveying member 108 as a powder cartridge that can be detachably attached to the apparatus body separately from the processing cartridge including the photoreceptor and the developer bearing member.
Conventionally known printing toner can be used as printing toner Tm, Tc and Ty according to the present embodiment. Among such toner, a printing toner that uses thermoplastic resin as binder resin is preferable. The thermoplastic resin is not specifically limited to a certain type of resin, and any type of thermoplastic resin that have been used conventionally as printing toner, such as polyester resin, vinyl resin, acrylic resin and styrene-acrylic resin can be used. The toner can contain a plurality of such resins. Specifically, a printing toner using styrene-acrylic resin is preferable. The printing toner, i.e., printing developer, can contain a coloring agent, a magnetic body, a charge control agent, a wax and an external additive.
A powder adhesive containing thermoplastic resin as binding resin can be used as the powder adhesive Tn according to the present embodiment. The thermoplastic resin is not specifically limited, and known thermoplastic resin such as polyester resin, vinyl resin, acrylic resin, styrene-acrylic resin, polyethylene, polypropylene, polyolefin, ethylene-vinyl acetate copolymer resin and ethylene-acrylic acid copolymer resin can be used. The powder adhesive can also include a plurality of these resins.
The powder adhesive Tn should preferably further include wax. A known wax, such as ester wax which is an ester including alcohol and acid or a hydrocarbon wax such as paraffin wax, can be used.
The powder adhesive Tn can contain a coloring agent. Known coloring agents such as black coloring agent, yellow coloring agent, magenta coloring agent and cyan coloring agent can be used. The content of the coloring agent within the powder adhesive should preferably be 1.0 wt. % or less, and more preferably, 0.1 wt. % or less. The powder adhesive Tn can contain a magnetic body, a charge control agent, a wax or an external additive.
In order to configure a bonding portion using powder adhesive on the sheet P using the electrophotographic system, weight-average particle diameter of the powder adhesive Tn should preferably be 5.0 μm or more and 30 μm or less, and more preferably 6.0 μm or more and 20 μm or less. A printing toner can also be used as the powder adhesive Tn, as long as it satisfies the required adhesive property.
An example of a method for preparing the powder adhesive Tn will be described. At first, the following materials were prepared.
A mixture having mixed the above materials was maintained at a temperature of 60° C., agitated at 500 rpm using a T. K. Homogenizing Mixer (product of Tokushu Kika Kogyo Co., Ltd.) and uniformly dissolved to prepare a polymerizable monomer composition.
Meanwhile, 850.0 parts of 0.10 mol/L—Na3PO4 aqueous solution and 8.0 parts of 10% hydrochloric acid were added to a container equipped with a high speed agitation apparatus Clearmix (product of M Technique Co., Ltd.), which was heated to 70° C. with a rotation speed set to 15,000 rpm. Then, 127.5 parts of 1.0 mol/L—CaCl2 aqueous solution was added to prepare an aqueous medium containing a calcium phosphate compound.
After putting the above-described polymerizable monomer composition into the aqueous medium, 7.0 parts of t-butyl peroxypivalate, which is a polymerization initiator, was added, and granulation was performed for 10 minutes while maintaining a rotation speed of 15,000 rpm. Thereafter, the agitator was changed from the high speed agitator to a propeller-type agitator, and reaction was performed for five hours at 70° C. under reflux, before further reaction was performed for two hours with the solution temperature set to 85° C.
After completing polymerization reaction, the acquired slurry was cooled, and hydrochloric acid was added to the slurry to adjust the pH to 1.4, which was agitated for one hour to dissolve calcium phosphate salt. Thereafter, washing was performed using an amount of water three times the amount of slurry, then filtering and drying was performed, and finally, classification was performed to obtain powder adhesive particles.
Thereafter, 2.0 parts of silica particulates (number particle average diameter of primary particles: 10 nm, BET specific surface area: 170 m2/g) which had been subjected to hydrophobization treatment using dimethyl silicone oil (20 wt. %) was added as additive to 100.0 parts of powder adhesive particles. Then, powder adhesive particles having silica particulates added thereto were mixed for 15 minutes at 3,000 rpm using a Mitsui Henschel Mixer (product of Mitsui Miike Chemical Engineering Machinery Co., Ltd.) to obtain powder adhesive. The weight-average particle diameter of the powder adhesive being obtained was 6.8 μm.
Glass transition temperature (Tg) of the powder adhesive Tn can be measured using a differential scanning calorimetry analyzer “Q1000” (product of TA Instruments). Melting points of indium and zinc are used for temperature correction of temperature detecting portion, and fusion heat of indium is used to correct heat quantity.
Specifically, 1 mg of a sample is precisely weighed, which is put into an aluminum pan, and an empty aluminum pan is used as a reference. Measurement using a modulation measurement mode is performed for 60 seconds within the range of 0 to 100° C. with a temperature rising speed of 1° C./min and a temperature modulation condition of ±0.6° C./60 sec. Specific heat change is obtained in the temperature rising process, and an intersection point between a differential thermal curve and a line of an intermediate point between a base line before and after the appearance of specific heat change is set as the glass transition temperature (Tg). The obtained glass transition temperature (Tg) of the powder adhesive Tn was 52° C.
Next, an example of a method for preparing the printing toner Ty, Tm and Tc will be described. At first, the following materials were prepared.
The above materials were put into an attritor (product of Mitsui Miike Chemical Engineering Machinery Co., Ltd.), and zirconia particles having a diameter of 1.7 mm were used to perform dispersion for five hours by 220 rpm to obtain a pigment dispersion.
Further, the following materials were prepared.
The above materials were mixed and added to the pigment dispersion. The obtained mixture was maintained at a temperature of 60° C., agitated at 500 rpm using a T. K. Homogenizing Mixer (product of Tokushu Kika Kogyo Co., Ltd.), and uniformly dissolved to prepare a polymerizable monomer composition.
Meanwhile, 850.0 parts of 0.10 mol/L—Na3PO4 aqueous solution and 8.0 parts of 10% hydrochloric acid were added to a container equipped with a high speed agitation apparatus Clearmix (product of M Technique Co., Ltd.), which was heated to 70° C. with a rotation speed set to 15,000 rpm. Then, 127.5 parts of 1.0 mol/L—CaCl2 aqueous solution was added to the above to prepare an aqueous medium containing a calcium phosphate compound.
After putting the above-described polymerizable monomer composition into the aqueous medium, 7.0 parts of t-butyl peroxypivalate, which is a polymerization initiator, was added, and granulation was performed for 10 minutes while maintaining a rotation speed of 15,000 rpm. Thereafter, the agitator was changed from the high speed agitator to a propeller-type agitator, reaction was performed for five hours at 70° C. under reflux, and then further reaction was performed for two hours with a solution temperature set to 85° C.
After completing polymerization reaction, the acquired slurry was cooled, and hydrochloric acid was added to the slurry to adjust the pH to 1.4, which was agitated for one hour to dissolve calcium phosphate salt. Thereafter, washing was performed using an amount of water three times the amount of slurry, then filtering and drying was performed, and finally, classification was performed to obtain toner particles.
Thereafter, 2.0 parts of silica particulates (number particle average diameter of primary particles: 10 nm, BET specific surface area: 170 m2/g) having been subjected to hydrophobization treatment using dimethyl silicone oil (20 wt. %) was added as additive to 100.0 parts of toner particles. Then, toner particles having silica particulates added thereto were mixed for 15 minutes at 3,000 rpm using a Mitsui Henschel Mixer (product of Mitsui Miike Chemical Engineering Machinery Co., Ltd.) to obtain toner. The weight-average particle diameter of the obtained printing toner was 6.5 μm.
Weight-average particle diameter of the printing toner Ty, Tm and Tc and the powder adhesive Tn were obtained by the following method. A precise particle size distribution measurement device called “Coulter Counter Multisizer 3” (Registered Trademark, product of Beckman Coulter, Inc.) that adopts an aperture electrical resistance method using a 100-μm aperture tube was used as a measurement device. A specialized software attached to the device called “Beckman Coulter Multisizer 3 Version 3.51” (product of Beckman Coulter, Inc.) was used to set measurement conditions and analyze measurement data. Number of effective measurement channels for the measurement was set to 25,000 channels.
Electrolyte solution having analytical grade sodium chloride dissolved in ion exchanged water with a concentration set to 1 wt. %, such as “ISOTON II” (product of Beckman Coulter, Inc.) can be used as the electrolyte solution used for the measurement.
Prior to performing measurement and analysis, setting of the specialized software is performed as described below. On “change standard measurement method (SOM)” screen of the specialized software, a total number of counts of a control mode is set to 50,000 particles, and the number of times of measurement is set to once, and a value obtained by using “standard particles 10.0 μm” (product of Beckman Coulter, Inc.) is set as Kd value. By clicking on “Button for measuring threshold/noise level”, the threshold and the noise level are set automatically. Further, current is set to 1,600 μA, gain is set to 2, electrolyte is set to ISOTON II, and a check mark is entered in a box for “flush aperture tube after measurement”. On a “set conversion from pulse to particle diameter” screen of the specialized software, a bin interval is set to logarithmic particle diameter, particle diameter bin is set to 256 particle diameter bins, and particle diameter range is set from 2 μm to 60 μm.
An actual measurement method is as described below.
(1) 200 mL of electrolyte solution is poured into a 250-mL round-bottom beaker made of glass dedicated for use in Multi sizer 3, the beaker is set on a sample stand, and agitation of stirrer rod is performed in a counterclockwise direction at 24 rps. Then, using the “flushing of aperture tube” function of the specialized software, soiling and air bubbles in the aperture tubes are removed.
(2) 30 mL of electrolyte solution is poured into a 100-mL flat-bottom beaker made of glass. 0.3 mL of diluent obtained by diluting “Contaminon N” (Registered Trademark) (10 wt. % aqueous solution of neutral detergent of pH7 for washing precise measuring device composed of nonionic surfactant, anionic surfactant and organic builder, product of Wako Pure Chemical Industries, Ltd.) in ion exchanged water to three times by mass is added as dispersant.
(3) An ultrasonic dispersion device “Ultrasonic Dispersion System Tetora 150” (product of Nikkaki Bios Co., Ltd.) with an electrical output of 120 W is prepared, in which two oscillators with an oscillating frequency of 50 kHz are installed with a 180-phase difference. 3.3 L of ion exchanged water is poured into a tank of the ultrasonic dispersion device, and 2 mL of Contaminon N is added to the tank.
(4) The beaker mentioned in (2) is set to a beaker fixing hole of the ultrasonic dispersion device, and the ultrasonic dispersion device is activated. The height position of the beaker is set so that a resonant state of liquid level of the electrolyte solution within the beaker is maximized.
(5) Toner or powder adhesive is added and dispersed a little at a time to the electrolyte solution until a total amount of 10 mg is obtained while irradiating ultrasonic waves to the electrolyte solution in the beaker of (4). Then, ultrasonic wave dispersion processing is continued further for 60 seconds. During ultrasonic wave dispersion, the solution temperature in the tank is controlled to fall between 10° C. and 40° C.
(6) The electrolyte solution mentioned in (5) in which toner or powder adhesive is dispersed is dripped using a pipette to the round-bottom beaker mentioned in (1) placed on the sample stand, so that a measurement concentration of 5% is obtained. Then, measurement is performed until the number of measured particles reaches 50,000.
(7) Measurement data is analyzed using the specialized software attached to the device, and weight-average particle diameter is calculated.
Next, an image forming operation according to the image forming apparatus 1 of the present embodiment will be described with reference to
In a state where data of the image to be printed and a command to execute printing are entered to the image forming apparatus 1, a control unit of the image forming apparatus 1 starts a sequence of operations, i.e., image forming operation, in which the sheet P is conveyed and subjected to image formation, and if necessary, subjected to postprocessing by the postprocessing unit 30. In the image forming operation, at first as illustrated in
In parallel with the feeding of the sheet P, the processing cartridges 7n, 7y, 7m and 7c are driven sequentially, and the photosensitive drums 101 are driven to rotate in the clockwise direction (arrow w) in the drawing. In this state, a uniform charge is applied to the surface of each photosensitive drum 101 by the charge roller 102. Further, the scanner unit 2 irradiates laser light G modulated according to image data to the photosensitive drums 101 of respective processing cartridges 7n, 7y, 7m and 7c, by which electrostatic latent images are formed on the surface of the photosensitive drums 101. Next, the electrostatic latent images on the photosensitive drums 101 are developed as powder material images by powder material borne on the developing rollers 105 of the processing cartridges 7n, 7y, 7m and 7c.
The powder adhesive layer formed on the photosensitive drum 101 by developing the image using the powder adhesive Tn differs from the image formed of printing toner for recording an image such as a figure or a text to the sheet P, that is, normal toner image, since the former does not aim at transmitting visual information. However, the layer of powder adhesive Tn developed by an electrophotographic process of applying the powder adhesive Tn to the sheet P by a predetermined application pattern can also be considered as one type of “toner image”.
The transfer belt 3a rotates in a counterclockwise direction (arrow v) in the drawing. The toner images formed on the respective processing cartridges 7n, 7y, 7m and 7c are primarily transferred from the photosensitive drums 101 to the transfer belt 3a by electric field formed between the photosensitive drum 101 and the primary transfer roller 4.
As illustrated in
The toner image borne on the transfer belt 3a and having reached the transfer nip 5N is secondarily transferred to the sheet P conveyed through the main conveyance path 1m by the electric field formed between the secondary transfer roller 5 and the secondary transfer inner roller 3b. In that state, the order of the toner layers in the vertical direction is reversed. That is, from the lowermost layer, or layer in contact with the sheet P, printing toner of cyan (Tc), magenta (Tm) and yellow (Ty) are superposed to the sheet P having passed the transfer nip 5n, and the layer of powder adhesive Tn is formed on top. Thus, as illustrated in
Thereafter, the sheet P bearing the unfixed toner image is nipped and conveyed together with the fixing film 6a in the fixing nip 6N while having the image surface side of the sheet P being in close contact with the outer surface of the fixing film 6a at the fixing nip 6N. During the nipping and conveying process, the heat from the heater 6a1 is applied on the image surface of the sheet P via the fixing fil 6a, by which the printing toner Ty, Tm and Tc and the powder adhesive Tn are melted and fixed on the sheet P. The sheet P having passed the fixing nip 6N is self-stripped from the fixing film 6a (i.e., separated from the fixing film 6a because of the curvature of the film) while maintaining the fixed toner image, so that an image fixed to the sheet P is obtained.
Regardless of whether the printing is one-side printing or duplex printing, the sheet P discharged from the apparatus body 10 is nipped by the intermediate roller 34b and the second sheet discharge roller 34c, as illustrated in
The first route R1 illustrated in
The intermediate path 15 is provided between the first fixing unit 6 and the folding unit 31 in the second route R2. The intermediate path 15 is a sheet conveyance path that passes the upper surface portion, i.e., top panel portion, of the image forming apparatus 1, and extends approximately in parallel with the first sheet discharge tray 13 at the lower side of the first sheet discharge tray 13. The intermediate path 15 and the first sheet discharge tray 13 are inclined upward in the vertical direction toward the folding unit 31 with respect to the horizontal direction. Therefore, an inlet port of the folding unit 31, that is, the guide roller pair 312, is positioned upper in the vertical direction than an outlet port of the apparatus body 10, that is, the nip between the intermediate roller 34b and the second sheet discharge roller 34c.
The folding unit 31 includes four rollers, which are a first guide roller 31c, a second guide roller 31d, a first folding roller 31a and a second folding roller 31b, and a drawing portion 31e. The first guide roller 31c and the second guide roller 31d are a guide roller pair 312 that nips and conveys the sheet P received from a conveyance path arranged upstream of the folding unit 31, which is the intermediate path 15 according to the present embodiment. The first folding roller 31a and the second folding roller 31b constitute a folding roller pair 311 that folds the sheet P while conveying the sheet P.
A distance M (
A folding process performed by the folding unit 31 will be described with reference to
Along with the drawing of the sheet P by the guide roller pair 312, the leading edge q moves toward the depth of the drawing portion 31e while sliding against the wall 31g. Then, as illustrated in
As the sheet P is drawn further by the guide roller pair 312 from the state illustrated in
A depth N of the drawing portion 31e (
The folding unit 31 described above is an example of the folding portion, and other folding mechanisms can be adopted, such as a folding mechanism in which a folding line is formed by pressing a blade against the sheet P and pushing the sheet into the nip portion of a roller pair. Not only a two-fold folding process but also a Z-shaped fold or a three-fold folding process can be executed by the folding mechanism. Since the folding unit 31 according to the present embodiment is composed of rollers that are rotated and the drawing portion 31e that is fixed, the driving mechanism thereof can be simplified compared to the folding mechanism using a blade that moves in reciprocating motion. Further, the folding unit 31 according to the present embodiment only requires the drawing portion 31e having the depth N set to half the sheet length in addition to the four rollers, so that the postprocessing unit 30 can be downsized.
The sheet P that has been folded by folding unit 31 is conveyed to the second fixing unit 32, where the sheet P is subjected to a bonding treatment where the sheet receives heat and pressure while being nipped and conveyed by the bonding nip 32N. The sheet P is bonded in the state folded as illustrated in
The sheet P having been subjected to the bonding treatment by the second fixing unit 32 is discharged to a left side of the drawing through a sheet discharge port 32c, i.e., second sheet discharge port, provided on the casing 39 of the postprocessing unit 30, as illustrated in
The bonding area of the sheet P being folded can be changed according to the application pattern of the powder adhesive Tn on the sheet P.
As described, according to the image forming apparatus 1 of the present embodiment, a product that has been bonded by the bonding treatment can be made from a base sheet such as normal white paper that is not a preprinted sheet. The bonding area of the folded sheet P can be varied according to the application pattern of the powder adhesive Tn on the sheet P. For example, a semi-bonded product assuming use as an envelope for sealing a document or a salary payment statement that is intended to be peeled later can be created. Further, the image to be recorded using printing toner by the image forming apparatus 1 can include a format (unchanged portion) when using a preprinted sheet and a variable part such as personal information. Further, a preprinted sheet can be used as a recording medium and the image forming apparatus 1 according to the present embodiment can be used for the purpose of performing printing of the variable part and the bonding treatment.
Now, setting of conditions of a fixing process, i.e., first fixing process or first heating step, in which the sheet P is heated by the first fixing unit 6 and a bonding process, i.e., second fixing process or second heating step, in which the sheet P is heated by the second fixing unit 32 will be described.
In order to output the completely bonded product 54 such as the paper pouch illustrated in
At first, the difference in heating efficiency between the fixing process and the bonding process will be explained. In the fixing process, the powder adhesive Tn is heated highly efficiently since the fixing film 6a serving as the heating member is directly in contact with the layer of powder adhesive Tn on the sheet P and supplies heat thereto, as illustrated in
Therefore, if it is assumed that the powder adhesive Tn is to reach the exact same maximum temperature in both the fixing process and the bonding process, it is necessary to apply a greater heat quantity to the sheet P in the bonding process than the fixing process. In other words, it is considered necessary to set the controlled temperature of the heating film 32b to a high value so that a greater heat quantity is supplied to the sheet P in a short time.
Especially, in the case of an image forming apparatus having a high productivity, that is, a high sheet conveyance speed, the sheet P will pass through the bonding nip 32N in a short time. In order to have the powder adhesive Tn reach the exact same maximum temperature in such fixing process and bonding process, it is assumed that the heat supplied during the bonding process must be extremely greater, such as twice or more times greater, than the heat supplied during the fixing process. That is, it is assumed that the controlled temperature of the heating film 32b is set extremely high so that a large amount of heat is conducted to the sheet P in a short time.
However, if the controlled temperature of the heating film 32b is set high, hot offset may occur during the bonding process, as described later. In addition, high controlled temperature of the heating film 32b may lead to drawbacks such as increased power consumption and generation of heat of the image forming apparatus 1.
Therefore, the present embodiment proposes conditions of the fixing process and the bonding process for achieving a firm bond by the powder adhesive while suppressing the heat quantity supplied to the sheet during the bonding treatment as small as possible. In the following description, the heat quantity supplied per unit area of the sheet P during the fixing process is referred to as “supplied heat Q1 during fixing process” and the heat quantity supplied per unit area of the sheet P during the bonding process is referred to as “supplied heat Q2 during bonding process”. In other words, Q1 is a Joule heat supplied from the fixing film 6a per unit area of the sheet P from when the sheet P reaches the fixing nip 6N to when the sheet passes through the fixing nip 6N. Q2 is a Joule heat supplied from the heating film 32b per unit area of the sheet P, that is, unit area of an outer surface of the sheet in the folded state, from when the sheet P reaches the bonding nip 32N to when the sheet passes through the bonding nip 32N.
In the present embodiment, the heat supplied during the fixing process is set higher than a minimum value, and the heat supplied during the bonding process is suppressed as small as possible.
(a) As a specific condition, preferably, a ratio of the supplied heat Q2 during the bonding process to the supplied heat Q1 during the fixing process is between 1.0 and 2.2 (1.0≤Q2/Q1≤2.2).
(b) More preferably, the ratio of the supplied heat Q2 during the bonding process to the supplied heat Q1 during the fixing process is between 1.3 and 1.9 (1.3≤Q2/Q1≤1.9).
A highest temperature (Tmax1) of the powder adhesive Tn during the fixing process is set to a temperature range that exceeds a melting point of the powder adhesive Tn so that a melt viscosity approaches a fluid state. Meanwhile, a highest temperature (Tmax2) of the powder adhesive during the bonding process is set to a value close to a glass transition temperature Tg (softening point) that is lower than the melting point of the powder adhesive Tn. By adopting such heat distribution, a firm bond strength can be obtained even when the supplied heat during the bonding process is suppressed as small as possible, as described in detail later. The details of the calculation method will be described in detail below.
In the present embodiment, sheet conveyance speeds of the first fixing unit 6 and the second fixing unit 32 are set to a same value, and specifically, they are set to 210 mm/sec. An example of outputting a product formed by printing and bonding a sheet P folded in two using a sheet P formed of an A4-size (210 mm width×297 mm conveyance-direction length) paper will now be illustrated. In this case, the area of the sheet P is 62370 mm2 and the time required for the sheet P to pass through the fixing nip 6N of the first fixing unit 6 is approximately 1.41 sec. In the bonding process, the sheet P is folded in two and reduced to half the size (210 mm width×148.5 mm length), wherein the area is 31185 mm2 and the time required for the sheet P to pass through the bonding nip 32N of the second fixing unit 32 is approximately 0.71 sec (Table 1).
The temperature control conditions and electric power during the fixing process and the bonding process according to the above conditions will be illustrated in Table 2 below. Measurement of electric power was performed by connecting a wattmeter (Digital Power Meter WTn310, a product of Yokogawa Test & Measurement Corporation) in series with the heater 6a1 or the heater 32b1 of the first fixing unit 6 or the second fixing unit 32 and acquiring an average value of power consumption during passing of sheets. In the evaluation result of adhesive property, “Good” shows that when external force was applied in a direction to peel off the bonding surfaces of the product, the strength of the sheet P as paper reached its limit first and is torn before the bonding surfaces were peeled off from each other.
The highest temperatures Tmax1 and Tmax2 of the powder adhesive Tn were measured in the following manner. At first, a thermocouple having a small thermal capacity of a temperature detection portion (such as a K-type thermocouple wire having a diameter of 50 μm or smaller, a product of Anritsu Meter Co., Ltd.) was prepared. When measuring the highest temperature Tmax1 of the powder adhesive Tn in the fixing process, the thermocouple was adhered to the surface of the sheet P and the sheet P was passed through the fixing nip 6N for measurement. Further, when measuring the highest temperature Tmax2 of the powder adhesive Tn in the bonding process, the thermocouple was adhered to the sheet P after the fixing process and before being folded by the folding unit 31, and the thermocouple was sandwiched in the inner side of the folded sheet P passed through the bonding nip 32N for measurement. A potential difference signal output from the thermocouple was measured by a Memory HiCorder, a product of Hioki E.E. Corporation, and the highest temperatures among the time variation of temperature was specified and set as Tmax1 and Tmax2.
The controlled temperature during the fixing process, that is, target temperature of the heater 6a1, was 170° C., and power consumption during passing of sheet was 415 W on average. The time required for the sheet P to pass through the fixing nip 6N is approximately 1.41 sec, so that the applied heat quantity can be calculated by 415 (W)×1.41 (sec)=586.9 (J). Since the sheet area is 62370 mm2, the heat quantity applied per unit area (Q1) is 586.9/62370 (J/mm2), that is, approximately 0.009 (J/mm2). The highest temperature Tmax1 of the powder adhesive Tn according to these conditions was 120° C.
The controlled temperature during the bonding process, that is, target temperature of the heater 32b1, was 220° C., and power consumption during passing of the sheet was 617 W on average. The time required for the sheet P to pass through the bonding nip 32N is approximately 0.71 sec, so that the applied heat quantity can be calculated by 617 (W)×0.71 (sec)=436.3 (J). Since the sheet area is 31185 mm2, the heat quantity applied per unit area (Q2) is 436.3/31185 (J/mm2), that is, approximately 0.014 (J/mm2). The highest temperature Tmax2 of the powder adhesive Tn according to these conditions was 80° C.
The results are shown in Table 2. The relationship between the highest temperatures Tmax1 and Tmax2 of the powder adhesive Tn preferably satisfies Tmax1>Tmax2. Further, Tmax2 is preferably set to be higher than the glass transition temperature Tg, which according to the present embodiment is 52° C., due to reasons described later.
Now, the state of a bonding portion formed by the fixing process and the bonding process according to the present embodiment will be described. An ideal bond refers to a state where smooth surfaces are in close contact with each other and bonded members are sufficiently contiguous so that they are mutually within the influence range of intermolecular forces, according to which direct binding force in molecular levels is created. In this state, if the bonded members have similar bonding structures, a stronger binding force is obtained. Generally, it is known that an extremely high bond strength is achieved by polishing the surfaces of a solid body made of the same type of material such as metal and placing the surfaces in close contact with each other.
Incidentally, liquid glue is an example that enables to realize a practical adhesive strength for paper. As illustrated in
As described above, according to the present embodiment, bonding of the sheet P is performed using the powder adhesive Tn. By performing the processes described hereafter, an adhesive strength close to a firm bond realized by liquid glue GL is achieved.
At first, as illustrated in
After passing through the fixing nip 6N, an adhesive Tn1 is solidified in a state filling the unevenness on the surface, as illustrated in
If the heat quantity supplied to the powder adhesive Tn during the fixing process is not sufficient, the adhesive Tn1 will not sufficiently fill the unevenness of the paper, in other words, will not wet the paper sufficiently, and the surface of the adhesive Tn1 is not sufficiently smoothed. Meanwhile, if too much heat quantity is applied to the powder adhesive Tn during the fixing process, the viscosity of the melted powder adhesive Tn drops excessively and the adhesive penetrates to the inner side of the paper, such that the amount of adhesive retained on the surface of the paper is insufficient and the surface of the adhesive Tn1 is not smoothed.
As described, by supplying a somewhat higher electric power than the normal fixing process, the viscosity of the melted powder adhesive is lowered moderately and a smooth surface nature can be obtained.
As illustrated in
From this state, the sheet P is pressed and heated at the bonding nip 32N of the second fixing unit 32, and the temperature of the adhesive Tn2 is raised to 80° C., for example. The highest temperature Tmax2 during the bonding process is preferably 10 degrees or more higher than the glass transition temperature (Tg) of the powder adhesive Tn, and more preferably 20 degrees or more higher than Tg. However, the highest temperature Tmax2 during the bonding process is lower than the highest temperature Tmax1 during the fixing process.
The sheet is heated at the bonding nip 32N, and layers of softened adhesive Tn3 are in close contact with each other, as illustrated in
Table 3 shows a result of comparative experiment in which the supplied heat Q1 during the fixing process is varied, that is, the power supplied to the heater 6a1 of the first fixing unit 6 is varied, and the result having evaluated the adhesive property of the printed-and-bonded product obtained. As a method for evaluating the adhesive property, force was applied to the bonding surface of the paper pouch in a direction to peel off the bonded surfaces by hand. As a result, the surfaces not being bonded at all was evaluated as poor, the surfaces being bonded but was peeled off at the bonding surface was evaluated as fair, and paper torn without the bonding surfaces being peeled off was evaluated as good. Comparative examples 3 and 4 have achieved good results, but as for comparative examples 2 and 5, the bonding surfaces were peeled off before the paper gave way (fair). According to comparative examples 1 and 6, the papers were not bonded (poor).
A comparative example 1 where a ratio Q2/Q1 of supplied heat Q2 during the bonding process to supplied heat Q1 during the fixing process is lower than 1.0 will be explained. In this case, as illustrated in
Next, we will illustrate a comparative example 6 where the ratio Q2/Q1 of the supplied heat Q2 during the bonding process to the supplied heat Q1 during the fixing process is higher than 2.2. In this case, as illustrated in
As described, according to the present embodiment, the highest temperature Tmax2 of the powder adhesive Tn during the bonding process is set lower than the highest temperature Tmax1 of the powder adhesive Tn during the fixing process. Thereby, the state of the powder adhesive Tn is changed appropriately during the fixing process and the bonding process without setting the heating temperature during the bonding process excessively high, and the sheet P can be bonded firmly via the powder adhesive Tn.
According to the present embodiment, a method for reducing the occurrence of image defects related to the image formed using printing toner at the same time as enhancing the adhesive strength of the powder adhesive Tn will be described. Hereafter, it is assumed that elements denoted with the same reference numbers as the first embodiment have approximately the same configurations and effects as the first embodiment, so that only the parts that differ from the first embodiment will mainly be described.
As described above, the image forming apparatus 1 is capable of applying powder adhesive Tn according to a predetermined application pattern in parallel with the operation of recording an image on one or both sides of the sheet P using printing toner, so that a product having been subjected to folding and bonding treatments, i.e., printed-and-bonded product, can be output. Therefore, a product bonded by the bonding treatment and to which printed information is applied can be output using a base sheet such as normal white paper that is not a preprinted sheet.
In this state, according to conditions such as temperature and power applied during the bonding process, image defects 53d called hot offsets may occur, as illustrated in
As illustrated in
In the present embodiment, the sheet conveyance speed of the second fixing unit 32 is set to a low value, so as to enable the required heat quantity to be supplied to the powder adhesive Tn while the temperature of the heating film 32b being set to a low value. That is, if the sheet conveyance speed at the first fixing unit 6 is set to V1 and the sheet conveyance speed at the second fixing unit 32 is set to V2, a relationship of V1>V2 is satisfied.
Specifically, a sheet conveyance speed V1 of the first fixing unit 6 is 210 mm/sec, which is the same as the first embodiment, and a sheet conveyance speed V2 of the second fixing unit 32 is set to 104.5 mm/sec which is slower than 210 mm/sec. In this state, the temperature setting of the heater 32b1 is adjusted so that the heat quantity received by the sheet P during the bonding process is substantially the same as the first embodiment. Table 4 also shows a comparative example 1 where the sheet conveyance speed V2 of the second fixing unit 32 is set to 157.5 mm/sec and a comparative example 2 set to 70 mm/sec. A result of the adhesive property evaluated as “good” refers to a state where the bonding surface is not peeled off and the strength of the sheet P which is paper is exceeded first so that the paper is torn when external force is applied to the bonding surface of the product in the direction to peel off the bonding surface.
The evaluations of adhesive property of the second embodiment and comparative examples 1 and 2 in which the sheet conveyance speed V2 and the heater temperature are controlled as described above are all good. It is recognized that by performing appropriate control of the supplied heat quantity Q2 per unit area of the sheet P during the fixing process and the bonding process, the state of the powder adhesive Tn can be changed appropriately during the fixing process and the bonding process to realize a firm bond, as illustrated in the first embodiment.
Based on Table 4, it can be recognized that the temperature of the heater 32b1 and the heating film 32b tends to be lowered as the sheet conveyance speed V2 of the second fixing unit 32 becomes slower. This is because as the sheet conveyance speed V2 becomes slower, the time required for the sheet to pass through the bonding nip 32N becomes longer, so that the temperature of the heater 32b1 and the heating film 32b required to supply the same heat quantity Q2 (0.0140 J/mm2) to the sheet P becomes lower. In other words, since the sheet conveyance speed V2 during the bonding process is set slower than the sheet conveyance speed V1 during the fixing process, the heating temperature of the heater 32b1 and the heating film 32b can be suppressed to a low value while maintaining a good adhesive property. As a result, excessive melting of printing toner will not occur easily during the bonding process, and therefore, hot offsets will not occur easily.
As illustrated in Table 4, hot offsets do not occur easily according to the second embodiment and comparative examples 1 and 2 where the temperature of the heater 32b1 and the heating film 32b is set lower than the first embodiment. Especially according to the second embodiment and the comparative example 2, no hot offsets occurred. The conditions of the second embodiment are more advantageous than the conditions of the comparative example 2 since a higher productivity can be realized without causing hot offset.
The sheet conveyance speed during the fixing process and the bonding process can be selected arbitrary by determining the overall printing speed of the image forming apparatus or the method for folding the sheet P. For example, in a case where the sheet conveyance speed of the fixing process is 210 mm/sec and a printed-and-bonded product having folded the sheet P in two before performing the bonding process is to be output, the sheet conveyance speed during the bonding process can be reduced to half the speed, or 105 mm/sec, without deteriorating the overall productivity. In other words, it is preferable to set the sheet conveyance speeds V1 and V2 during the fixing and bonding processes to satisfy 0.5≤V2/V1≤0.75, for example.
As described, according to the present embodiment, the sheet conveyance speed of the bonding process is set relatively slower than the sheet conveyance speed of the fixing process to suppress the heating temperature during the bonding process to be as low as possible while ensuring a sufficient adhesive strength, to thereby reduce the possibility of occurrence of hot offsets.
In order to perform the fixing process and the bonding process by a single image forming apparatus as described in the first and second embodiments, a heating apparatus for fixing an image and a heating apparatus for bonding the sheet are used in combination. Known heating elements of the heating apparatus include a heating resistor, a halogen lamp and an induction heating mechanism, which are all elements requiring high power consumption within the image forming apparatus, so that there are demands to reduce power consumption. Further, if the temperature of the heating member such as a heating roller during the bonding process is too high, image defects called hot offsets may occur in which the printed image having been fixed is melted again and are adhered to the sheet.
Therefore, in the third embodiment, a configuration of an image forming apparatus is illustrated which is suitable for acquiring sufficient adhesive strength while reducing the heat quantity supplied to the sheet during the bonding process. Hereafter, it is assumed that elements denoted with the same reference numbers as the first embodiment have the same configurations and effects as the first embodiment, so that only the portions that differ from the first embodiment will mainly be described.
An opening portion 48 is provided in the postprocessing unit 30 according to the present embodiment, as illustrated in
It is known that moisture is evaporated from the sheet and vapor is generated around a normal fixing unit, so that a design that allows to discharge the air around the fixing unit is adopted to prevent dew condensation. However, according to the second fixing unit 32 of the present embodiment, moisture is released from the sheet after finishing the fixing process, so that normally, not much vapor will be generated after the bonding process, that is, second heating process, performed by the second fixing unit 32. Therefore, compared to the first fixing unit 6, the possibility of dew condensation at the second fixing unit 32 is low, and not much issue occurs by reducing the opening ratio of the top panel portion, or region 39a, of the cover member.
By lowering the opening ratio of the top panel portion of the cover member, the air warmed by the second fixing unit 32 can be accumulated in the postprocessing unit 30 and reused to heat the folding unit 31. As described later, the temperature of a roller member coming into contact with the sheet at the folding unit 31 being high is advantageous from the viewpoint of reducing energy consumption during the bonding process.
For printing toner Tm, Tc and Ty according to the present embodiment, similar toner as those described in the first embodiment can be used. Further, powder adhesive containing thermoplastic resin serving as binder resin can be used as the powder adhesive Tn according to the present embodiment. The powder adhesive Tn preferably further contains a crystalline material having compatibility with binder resin. A known crystalline resin such as crystalline polyester resin or crystalline vinyl resin or a known wax such as ester wax which is ester containing alcohol and acid or hydrocarbon wax such as paraffin wax can be used. The crystalline resin and wax can be used in combination. These crystalline materials function as plasticizer that provides plasticity to the powder adhesive Tn during heating. That is, the crystalline material that is dispersed in a crystalline state within the binder resin at normal temperature is melted instantaneously and dissolves with binder resin when the powder adhesive Tn is heated, so that it has an effect of facilitating deformation of the powder adhesive Tn.
An example of a method for preparing the powder adhesive Tn will be described. The powder adhesive Tn according to the present example contains ester wax and hydrocarbon wax as crystalline materials having compatibility with binder resin (styrene-butyl acrylate copolymer and polyester resin).
At first, the following materials were prepared.
Then, powder adhesive particles were prepared according to approximately the same procedure as the manufacturing example described in the first embodiment.
Next, an image forming operation performed by the image forming apparatus 1 according to the present embodiment will be described with reference to
When data of an image to be printed and a command to execute printing is entered to the image forming apparatus 1, the control unit of the image forming apparatus 1 starts a sequence of operations, i.e., image forming operation, in which the sheet P is conveyed and an image is formed thereon, and if necessary, the sheet is subjected to postprocessing by the postprocessing unit 30. In the image forming operation, at first, as illustrated in
The image forming apparatus 1 according to the present embodiment can form an image and/or applying powder adhesive to the sheets at a print speed of performing one-side printing to 40 sheets per minute while conveying the sheet at a speed, i.e., processing speed, of 210 mm/sec. When creating a paper pouch illustrated in
In parallel with the feeding of the sheet P, the processing cartridges 7n, 7y, 7m and 7c are sequentially driven, and the photosensitive drums 101 are driven to rotate at a surface speed of 210 mm/sec in the clockwise direction (arrow w) in the drawing. In this state, uniform charge is applied to the surface of each photosensitive drum 101 by the charge roller 102. Further, the scanner unit 2 emits laser light G being modulated based on image data to the photosensitive drums 101 of the respective processing cartridges 7n, 7y, 7m and 7c, and forms electrostatic latent images on the surface of the photosensitive drums 101. Specifically, the scanner unit 2 emits laser light G to the photosensitive drums 101 of the processing cartridges 7y, 7m and 7c to form electrostatic latent images at positions corresponding to the image 53c illustrated in
The transfer belt 3a rotates at a speed of 210 mm/sec to the counterclockwise direction (arrow v) in the drawing. The toner images formed by the respective processing cartridges 7y, 7m and 7c are primarily transferred from the photosensitive drums 101 to the transfer belt 3a by electric field formed between the photosensitive drums 101 and primary transfer rollers 4. Then, the toner image borne on the transfer belt 3a and having reached the transfer nip 5N is secondarily transferred to the sheet P conveyed along the main conveyance path 1m by electric filed formed between the secondary transfer roller 5 and the secondary transfer inner roller 3b.
Thereafter, the sheet P bearing an unfixed toner image is nipped and conveyed together with the fixing film 6a through the fixing nip 6N with the image surface side of the sheet P in close contact with an outer surface of the fixing film 6a at the fixing nip 6N. The speed of the first fixing unit 6 is controlled so that a surface speed of the pressure roller 6b is set to 210 mm/sec, and the sheet P is nipped and conveyed in synchronization with a transfer process. In the nipping and conveying process, the heat of the heater 6a1 is applied via the fixing film 6a to the image surface of the sheet P, by which the printing toner Ty, Tm and Tc and the powder adhesive Tn are melted and fixed on the sheet P. The sheet P having passed the fixing nip 6N is self-stripped from the fixing film 6a while maintaining the fixed toner image, and an image fixed to the sheet P is obtained.
The sheet P is nipped and conveyed by the switching guide 33 pivoted in the clockwise direction by the first sheet discharge roller 34a and the intermediate roller 34b. After the trailing edge of the sheet Pin the conveyance direction has passed through the switching guide 33, the switching guide 33 pivots in the counterclockwise direction and the intermediate roller 34b is reversed, so that the sheet P is conveyed in a reversed manner to the duplex conveyance path 1r. Then, in a state where the sheet P is passed through the main conveyance path 1m again with the front and back sides reversed, the powder adhesive Tn is applied to the second surface of the sheet P by an application pattern illustrated in
It is preferable to apply the powder adhesive Tn to the second side than the first side during the duplex printing operation. If the powder adhesive Tn is applied to the first side, the powder adhesive Tn will be heated during the fixing process performed to the first side before being in contact with the pressure roller 6b arranged on the opposite side of the fixing film 6a in the fixing process performed to the second side, and the temperature will be reduced. In contrast, the powder adhesive Tn applied to the second side receives heat from the fixing film 6a in the fixing process of the second side and can enter the folding process while the temperature is relatively high.
Regardless of whether the operation is one-side printing or duplex printing, the sheet P discharged from the apparatus body 10 is nipped by the intermediate roller 34b and the second sheet discharge roller 34c as illustrated in
The second guide roller 31d which is a rotary member in contact with the sheet comes into contact with the powder adhesive Tn on the sheet P, so that it is preferable to have the surface of the roller covered with a material having low thermal conductivity so as to take minimum heat away from the powder adhesive Tn and to have a moderate unevenness formed on the surface to reduce the contact area. An EPDM (Ethylene Propylene Diene Monomer) rubber layer is formed on the surface of the second guide roller 31d, and the surface roughness (ten-point average roughness Rzjis) is set to 10 μm or greater. The surface roughness of 10 μm or greater is preferable in order to obtain sufficient frictional force while minimizing contact with paper. The surface roughness (Rzjis) indicated here is a value measured using a surface roughness measuring instrument SE-3400 (product name) manufactured by Kosaka Laboratory Ltd. Ten-point average roughness Rzjis is an index of surface roughness provided in JIS B 0601:1994. The ten-point average roughness Rzjis refers to a sum of an average of heights of the five highest heights and an average of depths of the five deepest depths on a roughness curve of a reference length. The roughness curve is obtained by applying a high pass filter of a predetermined cutoff value to a profile curve by sampling a surface of a measurement target using a probe.
A thermal capacity of the second guide roller 31d is preferably set small so that the temperature rises speedily by a small heat quantity by adopting a hollow structure, that is, a structure in which a space is formed on the inner side in the radial direction of the outer circumference portion in contact with the sheet. In the present embodiment, a core metal of the second guide roller 31d is a pipe-like (i.e., tubular and cylindrical) hollow roller having a thickness of 1 mm.
The first guide roller 31c, the first folding roller 31a and the second folding roller 31b which are three rollers according to other examples of the rotary member in contact with the sheet adopt a similar configuration as the second guide roller 31d so as not to take away heat from the sheet.
A distance M (
The folding process performed by the folding unit 31 will be described with reference to
As the guide roller pair 312 draw in the sheet P, the leading edge q of the sheet P moves toward the depth of the drawing portion 31e while sliding against the wall 31g. Thereafter, the leading edge q is abutted against the end portion 31h of the drawing portion 31e as illustrated In
In a state where the sheet P is further drawn in by the guide roller pair 312 from the state of
In this example, a distance from a depth N (
When discharging the sheet P, immediately before the sheet P reaches the bonding nip 32N of the second fixing unit 32, the conveyance speed, i.e., surface speed, of the folding roller pair 311 is reduced to correspond to the conveyance speed of the second fixing unit 32. That is, the sheet conveyance speed of the folding unit 31 is reduced from the sheet conveyance speed V1 of the first fixing unit 6 to the sheet conveyance speed V2 of the second fixing unit 32 before the leading edge of the sheet P in the sheet conveyance direction reaches the second fixing unit 32. Specifically, the sheet conveyance speed V2 of the second fixing unit 32 is set to 105 mm/sec, so that the sheet conveyance speed of the folding roller pair 311 is reduced from 210 mm/sec to 105 mm/sec. The speed reduction timing is preferably as late as possible, so that the time difference (i.e., elapsed time) from the end of the fixing process to the start of the bonding process is made short. If the time difference is short, minimum heat stored in the sheet P is taken away and the bonding process is started while the temperature of the powder adhesive Tn is still high.
The sheet P folded by the folding unit 31 is conveyed to the second fixing unit 32, where the sheet P receives a bonding treatment in which the sheet P is nipped and conveyed by the bonding nip 32 N while being heated and pressed. The pressure roller 32a of the second fixing unit 32 is driven to rotate so that the surface speed is set to 105 mm/sec. The sheet P is subjected to bonding treatment, i.e., second heat fixing performed to the image surface to which powder adhesive is applied, while being nipped and conveyed by the bonding nip 32N, by which the sheet is bonded in a folded state as illustrated in
After receiving bonding treatment at the second fixing unit 32, as illustrated in FIG. 4, the sheet P is discharged to the left side in the drawing from the sheet discharge port 32c, i.e., second sheet discharge port, provided on the casing 39 of the postprocessing unit 30. Then, it is stored in the second sheet discharge tray 35 (refer to
Next, we will describe the issue that occurs when the fixing process, i.e., first fixing process or first heating process, and the bonding process, i.e., second fixing process or second heating process, are performed in one image forming apparatus 1. Image defects 53d that are also referred to as hot offsets as illustrated in
If the power supply during the bonding process is increased, the temperature of the heating film 32b is increased. However, if the temperature of the heating film 32b becomes excessively high, the image 53c of printing toner formed on the surface of the sheet P in direct contact with the heating film 32b is melted excessively into a fluid state. A part of the toner melted in a fluid state and having low viscosity may adhere to the heating film 32b as soiling from the surface of the sheet P. The adhered soiling may attach again to the sheet P when the heating film 32b rotates once and to be actualized as image defects 53d in
In order to prevent the occurrence of hot offsets while ensuring the adhesive strength of the product 54, it is desired to realize bonding via the powder adhesive Tn while preventing excessive rising of temperature of the heating film 32b. In other words, it is desired to suppress the heat supplied to the sheet P during the bonding process while mutually bonding the layers of powder adhesive Tn applied on the bonding surface of the sheet P.
Another reason for suppressing the heat supplied to the sheet P during the bonding process is to reduce power consumption. The first fixing unit 6 and the second fixing unit 32 are each a heat fixing-type heating apparatus, i.e., image heating apparatus, and they execute a process that consumes the most power among the electrophotographic processes. The image forming apparatus 1 according to the present embodiment includes two heating apparatuses for the fixing process and for the bonding process, so that it is desired to save as much power as possible. If power supply to the apparatus body 10 and the postprocessing unit 30 is realized through one plug, that is, a plug socket for a commercial power supply, there may be a limitation of suppressing the current flowing to the outlet to 15 A or smaller.
Temperature Change of Sheet Surface after Fixing Process
As can be recognized based on the graph, the temperature keeps on rising while the measurement area on the sheet surface, that is, the portion where the thermocouple is adhered on the surface opposing the fixing film 6a, is passed through the fixing nip 6N, and the temperature reaches a peak temperature of approximately 110° C. (point X). Temperature starts to drop immediately after the measurement area exits the fixing nip 6N, and as illustrated in
According to the image forming apparatus 1 of the present embodiment, the temperature at the timing of point Z, that is, the temperature at the timing when the bonding surfaces to which the powder adhesive Tn are applied start to abut against one another is important. Specifically, by setting the surface temperature of the surface to which the powder adhesive Tn is applied at this point of time to be higher than a crystallization temperature of compatible wax added to the powder adhesive Tn, which according to the present embodiment is 45° C., a sufficient adhesive strength can be achieved even if the temperature of the bonding process is set low. The reasons will be described below.
The graph of
The evaluation of adhesive property of products being output via the folding process and the bonding process was repeatedly performed while varying the temperature Z of powder adhesive at the folding start timing. As a result, if the sample was completely cooled to room temperature (20° C.) after the fixing process, sufficient adhesive property could not be obtained unless the heater temperature of the second fixing unit 32 was increased to 200° C. Further, if the time for cooling the sample after the fixing process was gradually reduced to increase temperature Z, the “heater temperature during bonding that is required to realize strong bonding” tended to be low.
In a case where the conveyance distance from the first fixing unit 6 to the folding unit 31 is set extremely short and the temperature Z of powder adhesive at the folding start timing is set to 75° C., the heater temperature during bonding that is required to realize strong bonding was 160° C. Then, by plotting the heater temperature during bonding that is required to realize strong bonding in a state where the temperature Z is between 75° C. and 20° C., it was recognized to be approximated by two straight lines K and L which are discontinuous in the vicinity of Z=45 (° C.).
If the plotted points do not have a discontinuous point and are varied continuously, the negative correlation between the heater temperature during bonding that is required to realize strong bonding and temperature Z of the powder adhesive at the folding start timing is considered to be explained by a simple magnitude correlation of heat accumulation quantity. That is, the lower the heat quantity accumulated in the sheet P at the point of time when the sheet P reaches the bonding nip 32N of the second fixing unit 32, the higher the temperature of the heater 32b1 of the second fixing unit 32 must be set to heat the powder adhesive Tn to a temperature suitable for bonding in the bonding process. However, since the above-mentioned discontinuity is observed in
Generally, if the toner used in the electrophotographic image forming apparatus contains a crystalline material having compatibility with binder resin, it is known that the hardness, or plasticity, of toner varies greatly depending on whether the crystalline material is melted and is mixed homogeneously with binder resin. Even according to the powder adhesive Tn of the present embodiment, the hardness, or plasticity, of the powder adhesive Tn varies greatly depending on whether the wax contained as crystalline material is melted. Depending on whether the wax melted by receiving the fixing process by the first fixing unit 6 has been crystallized prior to the folding process, the behavior of the powder adhesive Tn during the folding process and the bonding process is considered to be varied. In other words, it is considered that the crystallization temperature during dropping of temperature of the wax as the crystalline material contained in the powder adhesive Tn according to the present embodiment determines the boundary of the discontinuous points appearing in
The “crystallization temperature during dropping of temperature” of the crystalline material contained in the powder adhesive Tn can be calculated as a peak temperature (Qd1) of heat generation in the temperature dropping process based on the measurement results of heat flow as illustrated in
Hereafter, the behavior of the powder adhesive Tn in a print-and-bond operation will be described.
After the sheet P has passed through the first fixing unit 6, the adhesive Tn1 hardens in a state filling the unevenness of the sheet as illustrated in
At first, a case will be described where the adhesive Tn1 is cooled and plasticity is lost before the folding process is started will be described. In this case, since the adhesive Tn2 has a high hardness, the adhesive Tn2 on the bonding surfaces Ps1 and Ps2 will not easily deform even by receiving pressure from the folding roller pair 311, and a gap may remain between the surfaces of the adhesive Tn2 as illustrated in
In contrast, if the hardness of the adhesive Tn2 is low at a point of time when the folding process by the folding roller pair 311 is started, the adhesives Tn2 on the bonding surfaces Ps1 and Ps2 deform relatively easily by receiving pressure by the folding roller pair 311, and the surfaces of the adhesives Tn3 come in close contact with each other, as illustrated in
In the straight line K which is on the lower temperature side of the discontinuous point in
Meanwhile, in the straight line L which is on the higher temperature side of the discontinuous point in
As described above, by closely attaching the surfaces of the adhesives by folding the sheets before the wax serving as the crystalline material crystallizes, sufficient adhesive strength can be obtained while suppressing the heater temperature of the bonding process to a value as low as possible. By suppressing the heater temperature to a low value, the possibility of occurrence of hot offset of the image formed by printing toner can be reduced. Further, power consumption of the bonding process can be cut down.
In order to realize the above state, it is effective to shorten the elapsed time from the fixing process to the folding process. Thereby, it becomes possible to carry out the folding process while much of the heat accumulated in the sheet during the fixing process still remains. Further, it is effective to minimize the heat quantity that the parts coming in contact with the sheet between the fixing process and the folding process, especially the folding roller pair 311, takes away from the sheet. Specifically, the following configurations are combined according to the present embodiment.
(a) The heat quantity that the folding roller pair 311 takes away from the sheet is suppressed by reducing the contact area with the sheet by moderately increasing the surface roughness of the folding roller pair 311.
(b) The heat quantity that the folding roller pair 311 takes away from the sheet is suppressed by reducing the thermal capacity of the folding roller pair 311 by adopting a hollow structure.
(c) The heat quantity that the folding roller pair 311 takes away from the sheet is suppressed by accumulating warm air in the circumference of the folding roller pair 311 by setting the opening ratio of the top panel portion (region 39a of
(d) The sheet conveyance speed is maintained as much as possible after the sheet has passed through the first fixing unit 6 and immediately before the leading edge of the sheet reaches the bonding nip 32N of the second fixing unit 32, and the sheet conveyance speed is reduced immediately before the leading edge of the sheet reaches the bonding nip 32N. Thereby, the elapsed time from the fixing process to the folding process is shortened so that the heat accumulated in the sheet during the fixing process can be utilized.
In order to perform the folding process in a state where plasticity of the powder adhesive Tn is maintained, the above-mentioned configurations (a) to (d) can be used independently or in combination. That is, the level of cooling of the sheet suppressed in the section from the fixing process to the folding process can be considered according to the property, especially the crystallization temperature during dropping of temperature, of the crystalline material that provides plasticity to the powder adhesive, or the temperature setting of the first fixing unit 6.
The third embodiment illustrates a method for performing the folding process in a state where the plasticity of the powder adhesive is maintained, wherein the heat supplied to the sheet during the fixing process is kept as much as possible to maintain the melted state of the wax serving as the crystalline material. In the present embodiment, a method for preparing a crystalline material is considered so that the plasticity of the crystalline material can be maintained at a lower temperature. Hereafter, it is assumed that the elements denoted with the same reference numbers as the third embodiment have the same configurations and effects as the third embodiment, so that only the portions that differ from the third embodiment will be described.
An example of preparation of powder adhesive according to the present embodiment will be described. This powder adhesive is stored in the powder storage portion 104n of the image forming apparatus 1, similar to the powder adhesive Tn of the first embodiment, and applied to the sheet by the electrophotographic process when creating the printed-and-bonded product.
100.0 parts of ethyl acetate, 30.0 parts of crystalline polyester (condensate of 1,10-decanediol and sebacic acid, having a number average molecular weight (Mn) of 7200 and melting point of 72° C.), 0.3 parts of 0.1 mol/L sodium hydroxide, and 0.2 parts of anionic surfactant (Neogen RK, product of DKS Co., Ltd.) were loaded in a beaker having a stirring device, which was heated to 60.0° C. and continuously agitated until it was completely dissolved. Further, 90.0 parts of ion exchanged water were gradually added thereto, which was then subjected to phase-transfer emulsification and solvent removal to acquire a crystalline polyester dispersion (solid component concentration: 20 wt. %).
At first, the following materials were prepared.
The above-listed materials were put into a heat-dried two-mouth flask, nitrogen gas was introduced into the container, and the materials were agitated while maintaining an inert atmosphere and the temperature thereof was raised. After performing polycondensation reaction for approximately 13 hours at a temperature of 150 to 230° C., the pressure was gradually reduced at a temperature of 210 to 250° C. to acquire an amorphous polyester. The number average molecular weight (Mn) of the obtained amorphous polyester was 19,400, the weight-average molecular weight (Mw) was 85,000, and the glass transition temperature (Tg) was 58° C.
An amorphous resin particle dispersion was obtained in a similar manner as the example of preparation of the crystalline polyester dispersion, with the crystalline polyester changed to amorphous polyester.
The following materials were prepared.
The above-listed materials were mixed and heated to 95° C., and then dispersed using a homogenizer (ULTRA-TURRAX T50, product of IKA). Thereafter, the materials were subjected to dispersion processing using a Manton Gaulin high-pressure homogenizer (product of Gaulin), and a wax dispersion in which wax particles are dispersed (solid component concentration: 20 wt. %) was prepared.
The following materials were prepared.
The above-listed materials were loaded into a beaker, and after adjusting the total parts of water to 250 parts, the temperature thereof was controlled to 30.0° C. Thereafter, the materials were mixed by agitating for one minute at 5000 rpm using a homogenizer (ULTRA-TURRAX T50, product of IKA).
Further, 10.0 parts of 2.0 wt. % aqueous solution of aluminum chloride which is a polyvalent metal compound were gradually added as flocculant. The material dispersion was transferred to a polymerization tank having a stirring device and a thermometer and was heated to 50.0° C. using a mantle heater while agitating to promote growth of aggregated particles.
After elapse of 60 minutes, 200.0 parts of 5.0 wt. % aqueous solution of ethylenediaminetetraacetic acid (EDTA) was added to prepare an aggregated particle dispersion. Next, the aggregated particle dispersion was adjusted to pH 8.0 using a sodium hydroxide aqueous solution of 0.1 mol/L, and thereafter, the aggregated particle dispersion was heated to 80.0° C. and left standing for 180 minutes to coalesce aggregated particles.
After the elapse of 180 minutes, a powder adhesive particle dispersion in which powder adhesive particles are dispersed was obtained. After cooling the dispersion to 40° C. or lower at a temperature drop rate of 300° C./min, the powder adhesive particle dispersion was filtrated and then washed by ion exchanged water to extract powder adhesive particles. The obtained powder adhesive particles were dried for 24 hours in an oven set to 40° C. to obtain powder adhesive particles.
0.5 parts of sol-gel silica having a particle diameter of 100 nm and 0.8 parts of hydrophobic silica microparticles obtained by treating silica particles whose number average particle diameter of primary particles is 12 nm with silicone oil and whose BET specific surface area after the treatment was 120 m2/g were added to 100 parts of powder adhesive particles. Then, the materials were mixed using an FM mixer (product of Nippon Coke & Engineering Co., Ltd.) to obtain the powder adhesive. The glass transition temperature of the obtained powder adhesive was 49° C. and a weight-average particle diameter thereof was 5.8 μm.
In the powder adhesive obtained by the above method, the crystalline polyester acts as a plasticizer that give plasticity to the powder adhesive when heated. In other words, the crystalline polyester functions as the crystalline material according to the present embodiment. That is, when the powder adhesive which is an aggregate of crystalline polyester and amorphous resin is heated, the crystalline polyester is melted and becomes compatible with amorphous resin, allowing the powder adhesive to be deformed easily.
According to the powder adhesive of the present embodiment, even if the temperature of the adhesive is lowered to a temperature lower than the crystallization temperature (approximately 45° C.) of wax according to the first embodiment after the fixing process, crystallization of the crystalline polyester will not occur. In other words, if a graph of
Further according to the present embodiment, a sufficient adhesive strength can be achieved without suppressing the heat quantity supplied to the sheet during the bonding process without providing the configuration ((a) to (d) mentioned earlier) to retain the heat supplied to the sheet during the fixing process, so that design freedom is advantageously increased. However, it is also possible to additionally adopt the method of lowering the crystallization temperature during dropping of temperature of the crystalline material contained in the powder adhesive and the method of retaining the heat supplied to the sheet during the fixing process.
As described above, the pressure roller of the second fixing unit 32 for performing the bonding process includes an elastic layer formed of an elastomer such as silicone rubber. The pressure roller formed of such an elastomer may vary the conveyance speed of the sheet by thermal expansion of rubber. Therefore, the sheet conveyance speed at the nip portion formed by the pressure roller may be slower than the conveyance speed of the conveyance roller for conveying the folded sheet toward the nip portion. In that case, slackness or looseness of the sheet, which is called a waving hereinafter, may occur between the conveyance roller and the pressure roller, which may cause creasing of the sheet or misalignment of the folding position of the sheet.
Therefore, an embodiment suitable for suppressing the occurrence of waving of the sheet prior to bonding is illustrated as a fifth embodiment. It is assumed that the elements denoted with the same reference numbers as the first embodiment have the same configurations and effects as the first embodiment, so that only the parts that differ from the first embodiment will mainly be described.
The first folding roller 31a and the second folding roller 31b receive driving force transmitted from a motor serving as a drive source via a drive transmission portion (31a1, 31b1 and 31b2) such as a gear train, and rotate in the direction of the arrow in the drawing. Thereby, the sheet P is conveyed in the sheet conveyance direction shown by arrow H from a nip portion 31N of the first folding roller 31a and the second folding roller 31b toward the bonding nip 32N of the second fixing unit 32.
Thereby, as illustrated in
If the sheet conveyance speed of the second fixing unit 32 is designed to always be relatively faster than the sheet conveyance speed of the folding roller pair 311, even if the waving L1 is created temporarily, the waving L1 will be solved during conveyance of the sheet P without growth of the waving L1. In contrast, if the sheet conveyance speed of the second fixing unit 32 is designed to always be relatively slower than the sheet conveyance speed of the folding roller pair 311, the waving L1 is created during conveyance of the sheet P, and the waving L1 gradually grows, that is, the level of waviness is increased. When the waving L1 is created, a crease L2 may be created on the sheet P or a misalignment L3, that is, misalignment of positions of surfaces that oppose one another in the folded state, of the folding position of the sheet P may be caused.
Disadvantages of a case where the folding position of the sheet is misaligned will be described with reference to
One of the causes of the waving L1 being formed between the folding roller pair 311 and the second fixing unit 32 is the outer diameter of the pressure roller 32a which is a roller member according to the present embodiment being fluctuated by the change of temperature. Since the pressure roller 32a includes the elastic layer 32a2 (
Therefore, according to the present embodiment, the sheet conveyance speed of the second fixing unit 32 is set to 101 mm/sec at normal temperature (such as 20° C.) and the sheet conveyance speed of the folding roller pair 311 is set to 100 mm/sec. It is preferable for the sheet conveyance speed of the second fixing unit 32 to be set to a value greater by 0.1% or more and 10% or less than the sheet conveyance speed of the folding roller pair 311. In other words, if the sheet conveyance speed of the folding roller pair 311 is denoted as V1 and the sheet conveyance speed of the second fixing unit 32 is denoted as V2, it is preferable to satisfy 1.001≤V2/V1≤1.1. Thereby, a relationship is satisfied where the sheet conveyance speed of the second fixing unit 32 is faster than that of the folding roller pair 311 both immediately after turning on the power and during continuous use.
The sheet conveyance speed of the second fixing unit 32 refers to the peripheral speed of the pressure roller 32a and the heating film 32b serving as the rotary member pair that nips and conveys the sheets. Further, the sheet conveyance speed of the folding roller pair 311 refers to the peripheral speed of the first folding roller 31a and the second folding roller 31b in a state before the leading edge of the sheet P reaches the bonding nip 32N of the second fixing unit 32.
It is preferable to provide a one-way clutch 31b3 (i.e., free-wheel mechanism) between the second gear 31b1 that receives driving force from the drive source and the rotation shaft of the second folding roller 31b. The one-way clutch 31b3 allows the second folding roller 31b to rotate faster than the second gear 31b1 in the rotating direction r4 to convey the sheet P and regulates the second folding roller 31b from rotating slower than the second gear 31b1 in the rotating direction r4. In other words, the one-way clutch 31b3 is in a locked state when a torque in a direction opposite to the rotating direction r4 is loaded to the second gear 31b1 from the second folding roller 31b and is in a free state when a torque in the rotating direction r4 is loaded thereto.
Until the leading edge, that is, downstream end in the sheet conveyance direction shown by arrow H, of the sheet P reaches the bonding nip 32N, the sheet P is conveyed by the folding roller pair 311 by drive transmission via the one-way clutch 31b3 in the locked state. If the leading edge of the sheet P reaches the bonding nip 32N and abuts against both the folding roller pair 311 and the pressure roller 32a, the sheet P is started to be accelerated to the sheet conveyance speed of the second fixing unit 32. In this state, the one-way clutch 31b3 will be in a free state, and the folding roller pair 311 rotates freely following the movement of the sheet P drawn toward the bonding nip 32N. In order to ensure the conveyance force of the second fixing unit 32, a contact pressure and a nip width of the bonding nip 32N are preferably greater than the contact pressure and the nip width of the nip portion 31N of the folding roller pair 311. By providing the one-way clutch 31b3, the pulling of the sheet P caused by the speed difference of the second fixing unit 32 and the folding roller pair 311 can be prevented.
As described, according to the present embodiment, the sheet conveyance speed of the second fixing unit 32 is set faster than the sheet conveyance speed of the folding roller pair 311 that conveys the sheet P toward the bonding nip 32N of the second fixing unit 32. Thereby, the generation of a waving on the sheet P is suppressed prior to bonding between the folding roller pair 311 and the second fixing unit 32, and the possibility of generation of creases on the sheet or misalignment of the folding position caused by the waving can be reduced to acquire a printed-and-bonded product without creases and positional misalignments.
In the sixth embodiment, a configuration example adopting a detection unit for detecting waving of the sheet between the folding roller pair 311 and the second fixing unit 32 will be described. Hereafter, it is assumed that the elements denoted with the same reference numbers as the fifth embodiment have the same configuration and effect as the fifth embodiment, so that only the portions that differ from the fifth embodiment will be described.
As illustrated in
The control unit of the image forming apparatus controls the sheet conveyance speed of the second fixing unit 32 based on a detection signal from the distance sensor 40. For example, if the detection signal of the distance sensor 40 indicates that a waving has been formed on the sheet P, the control unit sends a control signal to the motor driving the pressure roller 32a to accelerate the rotational speed of the pressure roller 32a and dissolve the waving.
There are various detection systems of optical sensors capable of measuring distance to an object, such as a system using triangulation or a system using a time difference of the light emitted from the light emitting component being reflected on the object and reaching the photosensing portion, but the detection system is not limited as long as an appropriate accuracy is realized.
Further, a sensor combining a flag that swings by abutting against the sheet P and a photo-interrupter shaded by the flag can be used as the detection unit. In this case, if the magnitude of waving of the sheet P is smaller than a predetermined value, the flag is moved away from the detection position of the photo-interrupter so that the output is set to 0 (low). Further, if the magnitude of waving of the sheet P is greater than the predetermined value, the flag is moved to the detection position of the photo-interrupter so that the output of the waving sensor is set to 1 (high).
The present embodiment detects the waving of the sheet using the detection unit and performs feedback to control the sheet conveyance speed, so that the waviness of the sheet can be controlled with higher accuracy. The configuration of the present embodiment is advantageous, for example, in order to correspond to a long sheet in a large-size image forming apparatus.
The present embodiment does not necessarily require a configuration where the sheet conveyance speed of the second fixing unit 32 is always faster than the sheet conveyance speed of the folding roller pair 311 as according to the first embodiment. That is, the present embodiment can adopt a configuration where the sheet conveyance speed of the second fixing unit 32 is usually set equal to the sheet conveyance speed of the folding roller pair 311, and the second fixing unit 32 is accelerated only when the distance sensor 40 detects the waving of the sheet.
As described according to the first to sixth embodiments described earlier, in a state where the fixing process and the bonding process for creating the printed-and-bonded product is executed by a single image forming apparatus, the powder adhesive is applied to a surface to be an inner side of the folded sheet. Meanwhile, contents such as corporate logos and addresses are recorded on another surface to be an outer side of the folded sheet. Now, when heating the sheet via the heating member such as a roller or a film during the bonding process, hot offsets may be caused where toner of the image recorded on the outer side of the folded sheet is melted and transferred to the heating member and then re-attached to the sheet after the heating member rotates once. If the heating temperature during the bonding process is lowered to suppress the occurrence of hot offsets, the powder adhesive applied to the inner side of the folded sheet will not be sufficiently softened, and bonding of the sheet surfaces may become insufficient.
Therefore, an embodiment that is suitable for both suppressing hot offsets and realizing a preferable adhesive property will be described as a seventh embodiment. Hereafter, it is assumed that the elements denoted with the same reference numbers as the first embodiment have the same configuration and effect as the first embodiment, so that only the portions that differ from the first embodiment will be described.
The arrangement of rollers constituting the folding unit 31 of the image forming apparatus 1 according to the present embodiment differs from that of the first embodiment, as illustrated in
The folding process performed by the folding unit 31 will be described with reference to
Along with the drawing in of the sheet P by the guide roller pair 312, the leading edge q advances toward a depth of the drawing portion 31e while sliding against the wall 31g. Then the leading edge q abuts against the end portion 31h of the drawing portion 31e, as illustrated in
When the sheet P is further drawn in by the guide roller pair 312 from the state illustrated in
The sheet P folded by the folding unit 31 is conveyed to the second fixing unit 32, and receives bonding treatment in which the sheet P is heated and pressed while being nipped and conveyed by the bonding nip 32N. In this state, as described later, a portion of the sheet that was a leading portion when the sheet P being discharged from the first fixing unit 6 is exposed to the outer side of the folded sheet folded by the folding unit 31 and is in contact with the heating film 32b which constitutes the heat source of the second fixing unit 32 when passing through the bonding nip 32N. The sheet P is bonded in the folded state as illustrated in
The sheet P having received the bonding treatment by the second fixing unit 32 is discharged to a left side in the drawing from a sheet discharge port 32z, i.e., second sheet discharge port, provided on the casing 39 of the postprocessing unit 30, as illustrated in
According to the image forming apparatus of the present embodiment, in parallel with an operation for recording an image on one side or both sides of the sheet P using printing toner, the powder adhesive Tn is applied based on a predetermined pattern and a product to which the folding process and the bonding process are performed can be output. Therefore, a product that has been bonded by a bonding process from a base sheet such as a white paper that is not a preprinted sheet and to which printed information is added can be output.
When outputting such a product, one of the surfaces of the sheet P used as a base sheet will be on an outer side of the product, and the other surface will be on the inner side of the product. As illustrated in
In outputting such a product, depending on conditions such as temperature and power during the bonding process, i.e., second fixing process and second heating process, image defects called hot offsets may occur, as denoted by 53d in
As illustrated in
According to the present embodiment, in order to realize both suppression of hot offset and appropriate adhesive property, an arrangement is adopted where the leading-edge side of the sheet P being discharged from the first fixing unit 6 comes into contact with the fixing film 6a serving as a heat source member of the second fixing unit 32 after being folded by the folding unit 31. The description of “being discharged from the first fixing unit 6” refers to a state where the sheet is passed through the first fixing unit 6 to fix the toner image and then discharged after the toner image of printing toner has been transferred to the second surface of the sheet having the powder adhesive Tn already applied on the first surface thereof.
Specifically, an area from a leading edge of the sheet P when the sheet P is conveyed from the fixing nip 6N to the folding unit 31 (“q” of
As illustrated in
In the present embodiment, the sheet conveyance speed of the first fixing unit 6 and the second fixing unit 32 is set to the same speed, specifically, 210 mm/sec. In order to realize both suppression of hot offset and appropriate adhesive property at a high level, target temperature, i.e., controlled temperature of heater, of the heater 6a1 of the first fixing unit 6 is set to 170° C., and target temperature, i.e., controlled temperature of heater, of the heater 32b1 of the second fixing unit 32 is set to 220° C.
Next, the adhesive property and the occurrence of hot offsets were evaluated according to a comparative example 7 and the present embodiment. Comparative example 7 will be described with reference to
Highly white paper GF-0081 (grammage 81.4 g/m2) which is a product of Canon Inc. was used as the sheet P for evaluation. As a method for evaluating the adhesive strength, force was applied to the bonding surface of the paper pouch in a direction to peel off the bonded surfaces by hand to observe whether the bonding surfaces maintained their bonded state. The surfaces not being bonded at all was evaluated as poor, the surfaces being peeled off at the bonding surface was evaluated as fair, and paper torn without the bonding surfaces being peeled off was evaluated as good. As for the evaluation of hot offsets, the paper pouch on which no hot offset was observed was evaluated as good, the paper pouch having a slight hot offset was evaluated as fair, and the paper pouch with a hot offset that is considered as a deterioration of image quality was evaluated as poor.
As shown in Table 5, good results have been achieved for both adhesive property and hot offset according to the present embodiment. Meanwhile, according to the comparative example 7, it can be recognized that that there is no controlled temperature where the adhesive property and the hot offset both achieve satisfactory results in the same level as the present embodiment. The reason for this is considered as follows.
In a state where the sheet P in the folded state passes through the second fixing unit 32, a leading-edge side portion, i.e., first part P1, of the sheet P being discharged from the first fixing unit 6 normally has a lower temperature than the trailing-edge side portion, i.e., second part P2, of the sheet P being discharged from the first fixing unit 6. This is because the first part P1 is easily cooled by contact with the conveyance roller or the conveyance guide and by the temperature difference with the ambient temperature within the conveyance path after passing through the fixing nip 6N and before reaching the bonding nip 32N. For example, according to the present embodiment, the first part P1 is drawn into the drawing portion 31e of the folding unit 31 and comes into contact with peripheral walls of the drawing portion 31e where the heat is taken away, whereas the second part P2 does not pass through the drawing portion 31e. Further, if the first part P1 and the second part P2 come into contact with the same conveyance guide during conveyance of the sheet P, the heat of the first part P1 is easily taken away by the conveyance guide but temperature of the second part P2 is not easily reduced since it comes into contact with the conveyance guide being warmed by the heat from the first part P1. Further, since the elapsed time from passing through the fixing nip 6N to reaching the bonding nip 32N is longer for the first part P1 than the second part P2, radiation of heat tends to progress.
According to the configuration of the present embodiment, the first part P1 whose temperature when reaching the second fixing unit 32 is lower than the second part P2 comes into contact with the heating film 32b which is the heat source-side member of the second fixing unit 32. The heat of the heater 32b1 is conducted to the first part P1 of the sheet P via the heating film 32b, and further conducted to the powder adhesive Tn applied on the bonding surface on the inner side of the sheet P via the first part P1. While the powder adhesive Tn is raised to a temperature suitable for achieving a sufficient adhesive strength, the temperature of the image 53c formed of printing toner on the first part P1 is also increased. However, since the temperature prior to entering the bonding nip 32N is relatively low, the temperature of the powder adhesive Tn can be heated to a temperature suitable for bonding before the temperature of the image 53c rises excessively. As a result, the bonding surfaces of the sheet P can be bonded firmly by the powder adhesive Tn while suppressing the occurrence of hot offsets caused by the image 53c on the first part P1. As for the image 53c on the second part P2, there is little risk of hot offset since it is in contact with the pressure roller 32a which is a member arranged on the opposite side from the heat source.
Meanwhile, according to the configuration of the comparative example, the second part P2 whose temperature when reaching the second fixing unit 32 is higher than the first part P1 comes into contact with the heating film 32b which is the heat source-side member of the second fixing unit 32. In this case, the heat of the heater 32b1 is conducted to the second part P2 of the sheet P via the heating film 32b, and further conducted via the second part P2 to the powder adhesive Tn applied to the bonding surface on the inner side of the sheet P. In this state, if the controlled temperature of the second fixing unit is set high so that the powder adhesive Tn is raised to an appropriate temperature for achieving a sufficient adhesive strength, the temperature of the image 53c formed of printing toner on the second part P2 rises excessively and hot offsets tend to occur. If the controlled temperature of the second fixing unit is set low so as to suppress hot offsets, the temperature of the powder adhesive Tn will not rise sufficiently, and as a result, good adhesive property cannot be achieved. As described, it can be recognized that it is difficult to realize both suppression of hot offset and appropriate adhesive property at a high level. Similar results were observed in a case where the controlled temperature of the heater of the first fixing unit 6 is varied within the range of 160 to 180° C. to control the heat applied to the sheet P in the fixing process.
As described, according to the configuration of the present embodiment, both suppression of hot offsets and sufficient adhesive property can be realized easily.
An eighth embodiment has a configuration of a folding unit 38 and the second fixing unit 32 that differs from the seventh embodiment. Hereafter, the elements having the same configuration and effect as the seventh embodiment are denoted with the same reference numbers and detailed descriptions thereof are omitted.
The folding unit 38 includes four rollers, which are a first guide roller 38c, a second guide roller 38d, a first folding roller 38a and a second folding roller 38b, and the drawing portion 38e. The first guide roller 38c and the second guide roller 38d are a guide roller pair that nip and convey the sheet P received from a conveyance path, which according to the present embodiment is the intermediate path 15, upstream of the folding unit 38. The first folding roller 38a and the second folding roller 38b are a folding roller pair that send out the sheet P while folding the same.
The positional relationship of the folding unit 38 and the intermediate path 15e according to the present embodiment and the contents of the folding process executed by the folding unit 38 are approximately the same as the first embodiment. As a result, as illustrated in
The present configuration differs from the configuration of the seventh embodiment in that a heating film 32c′ having the heater 32c1 arranged in the inner side thereof is positioned under the conveyance path and the pressure roller 32d is positioned above the conveyance path. Therefore, as illustrated in
In order to realize both suppression of hot offsets and adhesive property at a high level, target temperature, i.e., controlled temperature of heater, of the heater 6a1 of the first fixing unit 6 is set to 170° C., and target temperature, i.e., controlled temperature of heater, of the heater 32c1 of the second fixing unit 32 is set to 220° C.
Next, the adhesive property and the occurrence of hot offsets were evaluated according to a comparative example 8 and the present embodiment. Comparative example 8 will be described with reference to
As shown in Table 6, good results have been achieved regarding adhesive property and hot offset according to the present embodiment. Meanwhile, according to the comparative example 8, it can be recognized that that there is no controlled temperature where the adhesive property and the hot offset both achieve satisfactory results in the same level as the eighth embodiment. The reason for this difference is considered to be because the first part P1 is easily cooled after passing the first fixing unit 6 and before reaching the second fixing unit 32 compared to the second part P2, similar to the seventh embodiment. That is, according to the present embodiment, the sheet P is heated from the side of the first part P1 having a low temperature when entering the bonding nip 32N, so that the powder adhesive Tn can be raised to a temperature suitable for bonding before the printing toner image of the first part P1 is melted excessively. Meanwhile, according to the comparative example 8, the sheet P is heated from the side of the second part P2 having a high temperature when entering the bonding nip 32N, so that hot offsets tend to occur if the controlled temperature of heater is increased, and sufficient adhesive property cannot be achieved if the controlled temperature of the heater is set low. Similar tendency was seen in a case where the heat applied to the sheet P was controlled in a fixing process where the controlled temperature of the heater of the first fixing unit 6 was varied within the range of 160 to 180° C.
As described above, according to the configuration of the present embodiment, suppression of hot offsets and sufficient adhesive property can both be realized easily.
Compared to the seventh embodiment, the present embodiment simply applies the powder adhesive Tn during forming of image on the second surface in duplex printing. Therefore, compared to the seventh embodiment, the folding process in the folding unit 38 and the bonding process in the second fixing unit 32 can be performed in a state where the temperature of the powder adhesive Tn remains relatively high. Therefore, the adhesive property according to the present embodiment is more advantageous compared to the seventh embodiment, and for example, a sufficient adhesive property can be achieved even if the controlled temperature of the heater of the second fixing unit 32 is set lower.
In the first to eighth embodiments, a film-type image heating apparatus having advantageous quick-start property is adopted as the first fixing unit 6 and the second fixing unit 32, but the configuration of the image heating apparatus is not limited thereto. For example, an image heating apparatus of a type where toner and powder adhesive on the sheet P is heated via a heating roller in pressure contact with pressure rollers 6b and/or 32a can be adopted as the first fixing unit 6 and/or the second fixing unit 32. The heating roller is, for example, a roller in which an elastic layer formed for example of silicone rubber and a release layer formed for example of fluororesin are formed on an outer circumference of a metal cylinder. A film-type nip forming unit is not limited to a system where the heater is directly in contact with the inner side of the film and can adopt a system where the heater comes into contact with the film via the sheet member having a thermal conductivity such as iron alloy or aluminum. Further, the heating unit is not limited to adopting heating resistors, and it can adopt halogen lamps or induction heating mechanisms.
(1) According to the present disclosure, the following apparatus is disclosed as illustrated in the third and fourth embodiments.
(1-1) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet by the image forming portion and fix the toner image to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion; and
a bonding portion configured to heat the sheet having been folded by the folding portion and bond the sheet by the powder adhesive,
wherein the folding portion includes a rotary member configured to contact the sheet and rotate, and
wherein a ten point average roughness Rzjis of a surface of the rotary member is 10 μm or greater.
(1-2) In the image forming apparatus according to (1-1), preferably, the rotary member adopts a hollow structure.
(1-3) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet by the image forming portion and fix the toner image to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion; and
a bonding portion configured to heat the sheet having been folded by the folding portion and bond the sheet by the powder adhesive,
wherein the folding portion includes a rotary member configured to contact the sheet and rotate, and
wherein the rotary member adopts a hollow structure.
(1-4) The image forming apparatus according to any one of (1-1) to (1-3), wherein preferably,
the rotary member is a roller member configured to nip the sheet, rotate, and convey the sheet while folding the sheet so that a surface on which the powder adhesive is applied is inside.
(1-5) The image forming apparatus according to any one of (1-1) to (1-4), wherein preferably,
the image forming apparatus further includes a cover portion that is arranged above the folding portion and the bonding portion, and that covers the folding portion and the bonding portion when viewed in a gravity direction,
wherein the cover portion includes an opening portion through which an outer space above the image forming apparatus and an inner space of the image forming apparatus are communicated, and
wherein a ratio of an opening area of the opening portion with respect to an area of the cover portion is 5% or smaller when viewed in the gravity direction.
(1-6) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet by the image forming portion and fix the toner image to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion;
a bonding portion configured to heat the sheet having been folded by the folding portion and bond the sheet by the powder adhesive; and
a cover portion that is arranged above the folding portion and the bonding portion, and that covers the folding portion and the bonding portion when viewed in a gravity direction,
wherein the cover portion includes an opening portion through which an outer space above the image forming apparatus and an inner space of the image forming apparatus are communicated, and
wherein a ratio of an opening area of the opening portion with respect to an area of the cover portion is 5% or smaller when viewed in the gravity direction.
(1-7) The image forming apparatus according to any one of (1-1) to (1-6), wherein preferably,
a sheet conveyance speed of the bonding portion is slower than a sheet conveyance speed of the fixing portion, and
after starting to convey the sheet toward the bonding portion at a sheet conveyance speed faster than the sheet conveyance speed of the bonding portion, the folding portion reduces the sheet conveyance speed to the sheet conveyance speed of the bonding portion before a leading edge of the sheet in the sheet conveyance direction reaches the bonding portion.
(1-8) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet by the image forming portion and fix the toner image to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion; and
a bonding portion configured to heat the sheet having been folded by the folding portion and bond the sheet by the powder adhesive,
wherein a sheet conveyance speed of the bonding portion is slower than a sheet conveyance speed of the fixing portion, and
after the folding portion starts to convey the sheet toward the bonding portion at a sheet conveyance speed faster than the sheet conveyance speed of the bonding portion, the folding portion reduces the sheet conveyance speed to the sheet conveyance speed of the bonding portion before a leading edge of the sheet in the sheet conveyance direction reaches the bonding portion.
(1-9) The image forming apparatus according to (1-7) or (1-8), wherein preferably,
the sheet conveyance speed of the fixing portion is V1, and the sheet conveyance speed of the bonding portion is V2,
the sheet is conveyed at a speed of V1 after passing the fixing portion and before the sheet conveyance speed of the folding portion is reduced, and
the folding portion reduces the sheet conveyance speed from V1 to V2 before the leading edge of the sheet in the sheet conveyance direction reaches the bonding portion.
(1-10) The image forming apparatus according to any one of (1-1) to (1-9), wherein preferably,
the powder adhesive contains a binder resin, and a crystalline material that is compatible with the binder resin and that melts when being heated by the fixing portion, and
the folding portion is configured to fold the sheet in a state where a surface temperature of the powder adhesive heated by the fixing portion after being applied to the sheet is higher than a crystallization temperature during dropping of temperature of the crystalline material.
(1-11) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet by the image forming portion and fix the toner image to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion; and
a bonding portion configured to heat the sheet having been folded by the folding portion and bond the sheet by the powder adhesive,
wherein the powder adhesive contains a binder resin, and a crystalline material that is compatible with the binder resin and that melts by being heated by the fixing portion, and
the folding portion is configured to fold the sheet in a state where a surface temperature of the powder adhesive heated by the fixing portion after being applied to the sheet is higher than a crystallization temperature during dropping of temperature of the crystalline material.
(1-12) The image forming apparatus according to (1-10) or (1-11), wherein preferably,
the crystalline material includes ester wax or hydrocarbon wax.
(1-13) The image forming apparatus according to any one of (1-10) to (1-12), wherein preferably,
the crystalline material includes a crystalline resin.
(2) According further to the present disclosure, the following apparatus is disclosed, as illustrated in the fifth and sixth embodiments.
(2-1) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet and the powder adhesive applied on the sheet by the image forming portion and fix the toner image and the powder adhesive to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion with a surface on which the powder adhesive is applied inside; and
a bonding portion including a roller member having an elastic layer formed of an elastomer and configured to bond the sheet by the powder adhesive by conveying the sheet by the roller member and heating the sheet having been folded by the folding portion,
wherein a sheet conveyance speed of the bonding portion is faster than a sheet conveyance speed of the folding portion conveying the sheet toward the bonding portion.
(2-2) The image forming apparatus according to (2-1), wherein preferably,
the folding portion includes a folding roller pair configured to fold the sheet while conveying the sheet toward the bonding portion, and a drive transmission portion configured to transmit a driving force from a drive source to the folding roller pair, and
the drive transmission portion includes a one-way clutch configured to allow the folding roller pair to be rotated by being pulled by the sheet in a state where the sheet is in contact with both the folding roller pair and the roller member.
(2-3) The image forming apparatus according to (2-1) or (2-2), wherein preferably,
a sheet conveyance speed by the bonding portion is greater by a ratio of 0.1% or more and 10% or less than the sheet conveyance speed of the folding portion conveying the sheet toward the bonding portion.
(2-4) The image forming apparatus according to any one of (2-1) to (2-3), wherein preferably,
the elastic layer is formed of silicone rubber.
(2-5) The image forming apparatus according to any one of (2-1) to (2-4), wherein preferably,
the bonding portion includes a tubular film that is in contact with the roller member at an outer surface, a heater arranged on an inner side of the film, and a nip forming unit that forms a nip portion by being in pressure contact with the roller member via the film, wherein the bonding portion is configured to heat the sheet by the heater while nipping and conveying the sheet between the roller member and film at the nip portion.
(2-6) The image forming apparatus according to any one of (2-1) to (2-5), wherein preferably,
the image forming apparatus further includes a detection unit configured to detect waving of the sheet between the folding portion and the bonding portion in the sheet conveyance direction, and
based on a detection signal of the detection unit, the sheet conveyance speed by the bonding portion is controlled so as to reduce the waving of the sheet between the folding portion and the bonding portion.
(2-7) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet and the powder adhesive applied on the sheet by the image forming portion and fix the toner image and the powder adhesive to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion with a surface on which the powder adhesive is applied inside;
a bonding portion including a roller member having an elastic layer formed of an elastomer and configured to bond the sheet by the powder adhesive by conveying the sheet by the roller member and heating the sheet having been folded by the folding portion; and
a detection unit configured to detect waving of the sheet between the folding portion and the bonding portion in the sheet conveyance direction,
wherein based on a detection signal from the detection unit, a sheet conveyance speed by the bonding portion is controlled so as to reduce the waving of the sheet between the folding portion and the bonding portion.
(3) According further to the present disclosure, the following apparatus is disclosed, as illustrated in the seventh and eighth embodiments.
(3-1) An image forming apparatus including:
an image forming portion configured to form a toner image on a sheet using printing toner and apply powder adhesive on the sheet;
a fixing portion configured to heat the toner image formed on the sheet and the powder adhesive applied on the sheet by the image forming portion and fix the toner image and the powder adhesive to the sheet;
a folding portion configured to fold the sheet having passed through the fixing portion with a surface on which the powder adhesive is applied inside; and
a bonding portion including a heating member configured to heat the sheet and a pressing member that abuts against the heating member, the bonding portion being configured to heat the sheet while nipping and conveying the sheet having been folded by the folding portion by a nip portion formed between the heating member and the pressing member so as to bond the sheet by the powder adhesive,
wherein the bonding portion is arranged such that a portion of the sheet that was a leading portion when the sheet was discharged from the fixing portion toward the folding portion comes into contact with the heating member at the nip portion of the bonding portion.
(3-2) The image forming apparatus according to (3-1), wherein preferably,
the image forming apparatus is configured such that, after forming the toner image using the printing toner to a first surface of the sheet by the image forming unit and fixing the toner image to the first surface by the fixing portion, the sheet is reversed, the powder adhesive is applied to a second surface opposite to the first surface of the sheet by the image forming unit and the powder adhesive is fixed to the second surface by the fixing portion, and thereafter, the sheet is folded with the second surface inside by the folding portion before being bonded by the bonding portion.
(3-3) The image forming apparatus according to (3-1) or (3-2), wherein preferably,
the folding portion is configured to fold the sheet being conveyed from the fixing portion to the folding portion in two such that the surface to which the powder adhesive is applied is inside, and
a portion of the sheet that was a trailing portion when the sheet was discharged from the fixing portion toward the folding portion comes in contact with the pressing member at the nip portion of the bonding portion.
(3-4) The image forming apparatus according to (3-3), wherein preferably,
the folding portion includes a folding roller pair configured to nip and convey the sheet, a drawing portion that extends upstream of the folding roller pair in a sheet conveyance direction of the folding roller pair, and a guide roller configured to send a leading edge of the sheet conveyed from the fixing portion to the drawing portion, wherein the folding roller pair is configured to nip and convey the sheet while folding the sheet with a part of the sheet being a leading end of the folded sheet, wherein the part of the sheet is a part where a warp of the sheet has been created in a state where a leading edge of the sheet abuts against an end portion of the drawing portion.
(3-5) The image forming apparatus according to (3-1) or (3-2), wherein preferably,
the folding portion is configured to fold the sheet a plurality of positions in the sheet conveyance direction, and
in a state where the sheet is folded at the plurality of positions, the portion of the sheet that was the leading portion when the sheet is discharged from the fixing portion toward the folding portion is on an outside of the folded sheet.
(3-6) The image forming apparatus according to any one of (3-1) to (3-5), wherein preferably,
the heating member includes a tubular film, and a heater arranged on an inner side of the film and configured to heat the sheet passing through the nip portion via the film, and
the pressing member is a roller configured to abut against the heater via the film.
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 Nos. 2020-129960, filed on Jul. 31, 2020, 2020-129961, filed on Jul. 31, 2020, 2020-129962, filed on Jul. 31, 2020, and 2020-156213, filed on Sep. 17, 2020, which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-129960 | Jul 2020 | JP | national |
| 2020-129961 | Jul 2020 | JP | national |
| 2020-129962 | Jul 2020 | JP | national |
| 2020-156213 | Sep 2020 | JP | national |
