Patent Grant
7873293
1. Field of the Invention
The present invention relates to an image heating apparatus suitable for use as an image heat fixing apparatus (fixer) mounted to an image forming apparatus such as an electrophotographic copying machine or an electrophotographic printer, and to a heater suitably used for the image heating apparatus.
2. Description of the Related Art
As an image heat fixing apparatus (fixer) to be mounted to an image forming apparatus such as an electrophotographic copying machine or a printer, there exists a film heating type apparatus. The film heating type fixing apparatus includes a heater having an electric heat generation member on a substrate made of a ceramic, a fixing film which moves while being in contact with the heater, and a pressure roller which forms a nip portion together with the heater through the fixing film. Japanese Patent Application Laid-Open Nos. S63-313182 and H04-044075 describe this type of fixing apparatus. A recording material bearing an unfixed toner image is heated while being pinched and conveyed at the nip portion of the fixing apparatus. As a result, the toner image formed on the recording material is fixed onto the recording material by heating. This fixer has an advantage in a short time required for raising temperature to a fixable temperature after starting energizing the heater. Therefore, a printer to which the fixer is mounted can reduce a “first printout time (FPOT)” corresponding to a time length required for outputting a first image after input of a print command. This type of fixer has another advantage in its low power consumption during a standby time for a print command.
Now, it is known that if a printer equipped with a fixer using a fixing film prints small size recording materials continuously at a print interval that is the same as that for large size recording materials, temperature of an area of a heater through which the recording materials do not pass (i.e., no sheet pass-through area) increases excessively. If temperature of the no sheet pass-through area of the heater increases excessively, a holder for holding the heater or a pressure roller may be damaged by heat. Therefore, the printer equipped with the fixer using the fixing film performs control to increase the print interval in the case of printing small size recording materials continuously compared with the case of printing large size recording materials continuously, so as to prevent temperature of the no sheet pass-through area of the heater from increasing excessively. However, the control of increasing the print interval reduces the number of sheets that can be output per unit time, and therefore it is desired to control the number of sheets that can be output per unit time to be almost the same or just a little smaller than that in the case of large size recording materials. Therefore, as the heater that is used for the above-mentioned fixer, two electrodes are provided to a heater substrate along the longitudinal direction of the heater substrate. Further, it is conceived to use the heater including a heat generation resistive member having a positive temperature coefficient (PTC) disposed between the two electrodes as described in Japanese Patent Application Laid-Open No. H05-019652, for example.
As to the above-mentioned heater, if small size recording materials are driven to pass through the area through which large size recording materials pass (large size pass-through area D) for use in the printer, the no sheet pass-through area F is generated outside the area through which small size recording materials pass (small size pass-through area E). Temperature in the small size pass-through area E hardly rises because heat of the area is removed by the recording material. Therefore, a resistance value of the heat generation resistive member 215 in the small size pass-through area E is hardly increased so that power supply to the heat generation resistive member 215 in the small size pass-through area E is maintained. On the contrary, the resistance value of the heat generation resistive member 215 increases because of the temperature rise in the no sheet pass-through area F. Therefore, the current becomes reluctant to flow so that excessive temperature rise in the no sheet pass-through area F can be suppressed.
However, when the above-mentioned heater was actually incorporated in the fixer and was investigated, it was found that unevenness of heat generation distribution occurred in the heat generation resistive member in the longitudinal direction of the heater substrate despite that no recording material was driven to pass through. The reason of that was revealed to be in the resistance of the electrode. The two electrodes disposed along the longitudinal direction of the heater substrate have high conductivity, but a resistance value thereof is not zero. Therefore, the electrode itself causes a voltage drop due to its own resistance. Therefore, in spite of the state in which no recording material is driven to pass through, heat generation amount on the side close to the area contacting with the feed power connector (left side of the heat generation member of
A purpose of the invention is to provide a structure of a heater in which the heater described in Japanese Patent Application Laid-Open No. 2005-234540 can be manufactured more simply so as to solve the technical problem.
Another purpose of the invention is to provide an image heating apparatus including a heater including a substrate, a heat generation resistive member formed on the substrate, and a first electrode and a second electrode for feeding power to the heat generation resistive member; a backup member for forming a nip portion together with the heater; a control unit for controlling power to be fed to the heat generation resistive member so that temperature of the heater maintains a set temperature during an image heating process, wherein the image heats apparatus heating an image on a recording material at the nip portion, wherein: each of the first electrode and the second electrode includes a first area contacting with a feed power connector and a second area on an electrically opposite side of the first area; the second area is disposed along a longitudinal direction of the substrate; the heat generation resistive member is disposed so as to electrically connect the second area of the first electrode with the second area of the second electrode; and the heat generation resistive member is formed by one of a sputtering method and a vapor deposition method.
A further purpose of the invention is to provide a heater to be used in an image heating apparatus, including a substrate; a heat generation resistive member formed on the substrate; and a first electrode and a second electrode for feeding power to the heat generation resistive member, wherein: each of the first electrode and the second electrode includes a first area contacting with a feed power connector and a second area on an electrically opposite side of the first area; the second area is disposed along a longitudinal direction of the substrate; the heat generation resistive member is disposed so as to electrically connect the second area of the first electrode with the second area of the second electrode; and the heat generation resistive member is formed by one of a sputtering method and a vapor deposition method.
A still further purpose of the invention is to provide a heater that can equalize the heat generation distribution of the heat generation resistive member so that a temperature difference between the pass-through area through which recording materials pass and the no sheet pass-through area through which no recording material passes can be reduced, and an image heating apparatus having this heater. The present invention is described with reference to the drawings.
Further features of the present invention become apparent from the following description of exemplary embodiments with reference to the attached drawings.
1) Stay
The stay 11 is made of heat resistant resin material formed to have a cross section of a gutter shape. A groove 11a having a recess shape is provided to the stay 11 along the longitudinal direction in the middle in the width direction of a lower surface thereof, whereby the heater 13 is held in the groove 11a. The film 12 is made of heat resistant film formed in an endless shape (like a cylinder). Further, the film 12 engages with an outer surface of the stay 11. There is a relationship between an inner circumference of the film 12 and an outer circumference of the stay 11 that the former length is longer than the latter length by approximately 3 mm, for example. Therefore, the film 12 engages with the stay 11 loosely so as to have a margin in the circumference length. Further, end portions of the stay 11 are held by a pair of plates (not shown) of the apparatus.
2) Fixing Film (Flexible Sleeve)
The film 12 has a total thickness of approximately 40 to 100 microns so as to have a small thermal capacity for improving quick start performance. As a material of the film 12, it is possible to use a single layered film such as PI, PTFE, PFA or FEP having heat resistant, releasing property, strength, durability and the like. In addition, as a material of the film 12, it is possible to use a composite layered film in which an outer surface of polyimide, polyamidimid, PEEK, PES, PPS or the like is coated with PTFE, PFA, FEP or the like. The film 12 of this embodiment is the one including a coat layer made of fluorine resin such as PTFE or PFA with conductive additives formed on the outer surface of a polyimide film. However, the film 12 is not limited to this structure, but a simple tube made of a metal or the like may be used.
3) Pressure Roller
The pressure roller 18 includes a core shaft 19 made of aluminum, iron, stainless steel or the like and a heat-resistant rubber elastic layer (hereinafter referred to as an elastic layer) 20 that is formed on an outer surface of the core shaft 19 and is made of silicone rubber or the like having good releasing property. The pressure roller 18 has an outer diameter of 20 mm, and the elastic layer 20 has a thickness of 3 mm. In addition, a coat layer (not shown) in which fluorine resin is dispersed is formed on an outer surface of the elastic layer 20, whereby conveying performance of the recording material P and the film 12 is improved and contamination thereof due to the toner can be prevented. The pressure roller 18 disposed below the film 12 in parallel to the film 12 are held by the pair of plates of the apparatus in a rotatable manner via bearings 25L and 25R at both ends of the core shaft 19. The film 12 is pressed to the pressure roller 18 by a pressing unit (not shown) such as a pressure spring via the stay 11, and the elastic layer 20 of the pressure roller 18 is deformed elastically by the pressure. Thus, the pressure roller 18 and the heater 13 form a nip portion (fixing nip portion) N having a predetermined width for sandwiching the film 12 therebetween.
4) Heater
The substrate 14 is a heater substrate made of glass or ceramic that is elongated in the longitudinal direction and has good characteristics of heat resistance and insulation. A synthetic quartz substrate having a low thermal coefficient of expansion is used as the substrate 14 in this embodiment. The substrate 14 has dimensions of a length of approximately 270 mm, a width of 10 mm and a thickness of approximately 0.7 mm.
The first electrode 21 is disposed along the longitudinal direction of the substrate 14 on one end side in the short side direction of the substrate 14. The second electrode 22 is disposed along the longitudinal direction of the substrate 14 on the other end side in the short side direction of the substrate 14. Each of the electrodes 21 and 22 is made by a screen printing method of paste (electric conductor) made of a conductive material such as Ag or Ag/Pt with glass powder on the substrate 14. Volume resistance values of the electrodes 21 and 22 can be adjusted by changing a composition of the electric conductive material and the glass powder.
The electrode 21 is formed on the one end side in the short side direction of the substrate 14 (on an upstream side in the recording material conveyance direction). The electrode 21 includes a first area 21a for feeding power and a second area 21b for supplying power to the heat generation resistive member 15 (black thick line portion of (c) of
The electrode 22 is formed on the other end side in the short side direction of the substrate 14 (on a downstream side in the recording material conveyance direction). The electrode 22 includes a first area 22a for feeding power, a second area 22b for supplying power to the heat generation resistive member 15 (black thick line portion of (c) of
All the first areas 21a and 22a and the second areas 21b and 22b of the electrodes 21 and 22 may be made of the same material. Otherwise, the first areas 21a and 22a may be made of a material different from that of the second areas 21b and 22b. In this embodiment, the first areas 21a and 22a and the second areas 21b and 22b are made of the same material. In addition, the second areas 21b and 22b have a length of approximately 220 mm, a width of approximately 1 mm and a thickness of approximately a few tens of microns.
The heat generation resistive member 15 is formed on the surface of the substrate 14 along the longitudinal direction of the substrate 14. The heat generation resistive member 15 is made by forming a film of electric resistance material such as ruthenium oxide having the PTC characteristic on the substrate 14 using a screen printing method. Further, the heat generation resistive member 15 is printed on the electrodes 21 and 22 so as to electrically connect the second area 21b of the electrode 21 with the second area 22b of the electrode 22. A length of the heat generation resistive member 15 is set to be the same as the lengths of the second areas 21b and 22b of the electrodes 21 and 22. A volume resistance value of the heat generation resistive member 15 can also be adjusted by changing a composition of the electric resistance material.
A heater 13 of this embodiment has a structure for connecting the second areas 21b and 22b of the electrodes 21 and 22 via the heat generation resistive member 15. Therefore, the heater 13 can be regarded to have a structure in which an infinite number of resistors are connected in parallel to the recording material conveyance direction between the second area 21b of the electrode 21 and the second area 22b of the electrode 22 (pass-through direction energizing type). Here, concerning the electrodes 21 and 22, the second areas 21b and 22b mean areas in which a voltage drop is generated so as to affect the heat generation distribution of the heat generation resistive member 15. In other words, the area connected to the heat generation resistive member 15 (black thick line portion of (c) of
In addition, the heater 13 of this embodiment is protected so that a part of the first areas 21a and 22a of the electrodes 21 and 22 as well as the heat generation resistive member 15 is covered with a protection layer 16 (
5) Variation of the Heater of this Embodiment
In addition, as to the heater 13 illustrated in
In addition, as to the heater 13 illustrated in (a), (b) and (c) of
A drive gear G (
The film 12 is wound around the stay 11 with the margin and is driven to rotate in this way, and hence a pulling moving force in the longitudinal direction of the heater 13 when the film 12 rotates can be reduced, whereby it is possible to eliminate a pulling moving control unit for the film 12. In addition, it is possible to reduce drive torque so that the structure of the apparatus can be simplified and downsized, and cost thereof can be reduced.
A CPU 101 (
Thus, the recording material P bearing the non-fixed toner image t is led into the nip portion N with the toner image bearing side being upward in the state where the pressure roller 18 and the film 12 are rotating and the heater 13 is supplied with electric power. The recording material P is held and conveyed by the nip portion N together with the film 12, and thermal energy of the heater 13 contacting with the inner surface of the film 12 at the nip portion N is given to the recording material P via the film 12 so that heat and press fixing of the toner image t is performed by the pressure at the nip portion N.
(a) and (b) of
The heater 113 illustrated in (a) of
On the contrary, in the heater 13 of the pass-through direction conductive pattern type like this embodiment, current flow is formed not only in the longitudinal direction but also in the pass-through direction with respect to the substrate 14 even if the heat generation resistive member 15 having the similar PTC characteristic is used. In other words, if the temperature rises in the no sheet pass-through area F (see
However, the heater 13 illustrated in
With the shape of the heater 13 of this embodiment, i.e., the structure in which the inlet of current is disposed at each end portion in the longitudinal direction of the substrate 14, the position that is farthest from the current inlet is the middle position of the heat generation resistive member 15 while the position that is closest thereto is each end of the heat generation resistive member 15. Therefore, the heat generation distribution becomes high at both ends in the longitudinal direction of the heat generation resistive member 15 while becomes low at the middle of the same.
If the heat generation amount is higher at both end portions in the longitudinal direction of the substrate 14 than that at the middle portion in this way, the nonuniform heat generation distribution may cause unevenness of fixing, a defect of fixing, a hot offset, and a breakage of the heater.
In order to avoid this problem, the heat generation resistive member 15 should have a resistance value that is sufficiently larger than a resistance value of the electrodes 21 and 22. As a method for realizing this, it is considered to decrease the resistance value of the electrodes 21 and 22, to increase the resistance value of the heat generation resistive member 15, or a combination method thereof. Of course, it is preferable that the temperature unevenness in the longitudinal direction of the substrate 14 should be as small as possible, but it is allowable that the temperature is substantially 10° C. or lower.
Here, major dimensions of the heater 13 in this embodiment are defined as illustrated in (a) and (b) of
As to the electrodes 21 and 22, a cross-section of one of the second areas 21b and 22b in the short side direction of the substrate 14 (cross-section of the second area cut along the short side direction of the substrate) is denoted by S1, and a length of one of the second areas 21b and 22b in the longitudinal direction of the substrate 14 is denoted by L1. Here, as to the electrodes 21 and 22, the cross-sections of the second areas 21b and 22b have the same value, and the lengths of the second areas 21b and 22b also have the same value. In addition, concerning the heat generation resistive member 15, a cross-section thereof in the longitudinal direction of the substrate 14 (cross-section of the heat generation resistive member cut along the longitudinal direction of the substrate) is denoted by S2, and a length thereof in the supply power direction (i.e., distance between the second areas 21b and 22b of the two electrodes, or a length of the part where the second areas 21b and 22b do not overlap) is denoted by L2. Further, a volume resistance value of one of the second areas 21b and 22b when the non-fixed toner image t on the recording material P is heated is denoted by A1, and a volume resistance value of the heat generation resistive member 15 when the non-fixed toner image t on the recording material P is heated is denoted by A2. In other words, each of the volume resistance values A1 and A2 is a value at 200° C. that is a temperature during the image heat-fixing process of the fixing apparatus 8. Hereinafter, unless otherwise noted, the volume resistance values A1 and A2 are values at 200° C. that is a temperature during the image heat-fixing process. In this case, the resistance value R1 of one of the electrodes 21 and 22, and the resistance value R2 of the heat generation resistive member 15 are expressed as follows, respectively.
R1=A1×L1/S1 (Relational expression 1)
R2=A2×L2/S2 (Relational expression 2)
If the volume resistance value A1 of the heat generation resistive member 15 is set to be higher than the volume resistance value A2 of the electrodes 21 and 22, the heat generation distribution must be uniform. If the ratio (R2/R1) in this case is denoted by Nx, and if the heat generation distribution is regarded to be uniform, Relational Expression 3 holds as below.
R1≦R2/N (here, N≧Nx) (Relational expression 3)
In addition, the above-mentioned Relational Expression 3 is rewritten by substituting Relational Expressions 1 and 2. Then, it is understood that the heater with suppressed heat generation unevenness should be constituted so as to satisfy Relational Expression 4 below.
A1≦A2×S1×L2/N×(S2×L1) (here, N≧Nx) (Relational expression 4)
Specifically, as to the heater 13 having the structure illustrated in (a), (b) and (c) of
As the electrode, a silver electrode having A1=2.10E−8 [Ω·m] ((2.1×10−8) [Ω·m]) was used. As for the heat generation resistive member, ruthenium tetroxide paste having A2=2.60E−2 [Ω·m] and the PTC characteristic of 7 ppm/° C. was used.
As the electrode, a silver electrode having A1=3.20E−8 [Ω·m] with silver purity lower than that of Heater example 1 was used. As for the heat generation resistive member, the same material as Heater example 1 was used but only the cross-section was reduced.
Totally the same materials as Heater example 1 were used as for the electrode and the heat generation resistive member. The cross-section of the electrode was set to be smaller than that of Heater example 1. The cross-section of the heat generation resistive member was also set to be smaller than that of Heater example 1.
Totally the same materials as Heater example 3 were used as for the electrode and the heat generation resistive member. Only the cross-section of the heat generation resistive member was set to be larger than that of Heater example 3.
Totally the same materials as Heater example 2 were used as for the electrode and the heat generation resistive member. Only the cross-section of the heat generation resistive member was set to be larger than that of Heater example 2.
The same materials as Heater example 2 and Heater example 5 were used as for the electrode and the heat generation resistive member. Only the cross-section of the heat generation resistive member was set to be larger than that of Heater example 5.
Totally the same materials as Heater example 1, Heater example 3 and Heater example 4 were used as for the electrode and the heat generation resistive member. The cross-section of the heat generation resistive member was set to be larger than that of Heater example 1.
Totally the same materials as Heater example 1, Heater example 3, Heater example 4 and Comparative example 2 were used as for the electrode and the heat generation resistive member. Only the cross-section of the electrode was set to be smaller than that of the Comparative example 2.
Totally the same materials as Heater example 2, Heater example 5 and the Comparative example 1 were used as for the electrode and the heat generation resistive member. The cross-section of the electrode was set to be smaller than that of the Comparative example 1, and the cross-section of the heat generation resistive member was also set to be smaller than that of the Comparative example 1. Table 1 indicates concrete dimensions and volume resistance values of the above-mentioned heaters.
In Table 1, the volume resistance values A1 and A2 have a unit of [Ω·m] and values at 200° C. that is an operating temperature of the heater. In addition, a unit of the cross-sections S1 and S2 is square meter [m2]. T1 denotes the film thickness of the electrodes 21 and 22. T2 denotes the film thickness of the heat generation resistive member 15. H1 denotes a width of the electrodes 21 and 22 (length in the short side direction of the substrate) ((b) of
Note that each of the volume resistance values A1 and A2 of the heat generation resistive member 15 at 200° C. was measured by the following method. The heat generation resistive member 15 was formed on the glass substrate in a shape having a surface area of 5 mm×12 mm and a thickness of 10 microns as a discrete heater, and it was placed on a heated hot plate together with the substrate so as to be heated up to a temperature of 200° C. After that, a resistance value of a 5 mm×10 mm area was measured by a resistance measuring instrument (Fluke 87V manufactured by Fluke Corporation) with a probe having a width of 5 mm. Then, the measured value was converted into the volume resistance value, which is described in Table 1.
Here, in order to determine a value of Nx, a ratio of heaters R2/R1=N (hereinafter referred to as an “N value”) was determined. Then, a relationship between the N value and the heat generation unevenness was investigated. Results thereof are indicated in Table 2 below.
In Table 2, Rac denotes a total resistance value, which is a resistance value measured between the point A of the electrode 21 and the point C of the electrode 22 illustrated in (a), (b) and (c) of
Therefore, according to the above-mentioned Relational Expression 4, the heat generation unevenness can be uniform if the following expression is satisfied.
A1≦A2×S1×L2/(29.4×S2×L1) (Relational Expression 4b)
The measurement of the heat generation unevenness was performed as follows. Temperature of the discrete heater was controlled at 200° C., while the heat generation distribution was measured with a thermography. As illustrated in
(a), (b) and (c) of
(a), (b) and (c) of
The heater 13 illustrated in (a), (b) and (c) of
The resistance value Rac is measured in the state where the heater 13 is heated at 200° C. in this embodiment, but there are multiple levels of the set temperatures in the heat-fixing process as described above. Therefore, it is preferable to satisfy Relational Expression 4b for all the set temperatures set in the fixing apparatus 8.
Next, the conventional heater 113 illustrated in (a) of
As the conditions, ten cards were fed continuously under the environment of room temperature of 23° C. and humidity of 50% for measuring the temperature difference. The temperature at the surface of the pressure roller was measured by a thermocouple disposed between the pressure roller and felt made of heat resistant fibers contacting with the pressure roller. Temperature of the heater was controlled by using a thermistor disposed at the heater back surface in the sheet pass-through portion (pass-through area). In addition, an input voltage is adjusted for each heater.
Table 3 indicates results thereof.
From a result of the above-mentioned Table 3, it is understood that the temperature difference between the no sheet pass-through portion and the sheet pass-through portion is significantly decreased in both Heater examples 1 and 2 of this embodiment so that the margin is increased compared with the conventional example.
As described above, it is understood that the heat generation distribution of the heat generation resistive member 15 can be uniform if the heater 13 is constituted so that Relational Expression 4b “A1≦A2×S1×L2/(29.4×S2×L1)” is satisfied. In addition, a temperature difference between the pass-through area through which the small size recording material P passes and the no sheet pass-through area through which the same does not pass can be decreased. Therefore, the fixing apparatus 8 equipped with the heater 13 can have an increased margin between the temperature for securing fixing performance of the non-fixed toner image t on the small size recording material P and the temperature at which the temperature rise in the no sheet pass-through area may cause a damage to a component of the fixing apparatus 8. Thus, comparing with the longitudinal dimension of the current fixing apparatus 8, a relatively small size recording material P can be printed at increased speed.
Another embodiment of the heater is described. In this embodiment, the same member or part as that of the heater 13 of the first embodiment is denoted by the same reference numeral so that overlapping description is omitted. The same is true for a third embodiment of the present invention.
It is understood that the heater of the pass-through direction conductive pattern type can have uniform heat generation distribution by constituting it so that the N value increases as described in the first embodiment.
The N value can be described as follows using Relational Expressions 1 and 2.
N=(A2/A1)×(L2/L1)×(S1/S2) (Relational Expression 4c)
The length L1 and the width H1 of the electrode, as well as the length L2 and the width H2 of the heat generation resistive member are substantially limited when the size of the fixing apparatus (heater) is determined. Therefore, it is understood that increase of the N value depends largely on volume resistance values of the material and thicknesses of the heat generation resistive member and the electrode.
The heater 13 of this embodiment is characterized in that the ratio of the cross-section S1 of the electrode to the cross-section S2 of the heat generation resistive member is set to be large, and hence the N value is set to be 29.4 or larger and that the volume resistance value A2 of the electrodes 21 and 22 can be small. Thus, uniform heat generation distribution is realized, and the effect of suppressing the temperature rise in the no sheet pass-through area can be increased.
First, for example, S1/S2 is estimated roughly in the case where both the heat generation resistive member 15 and the electrodes 21 and 22 are formed by the screen printing method as described in the first embodiment. In general, the minimum film thickness that can be formed by the screen printing method is the order of a several microns. Therefore, the film thickness T2 of the heat generation resistive member 15 is the same as the film thickness T1 of the electrodes 21 and 22. In addition, the width H2 of the heat generation resistive member 15 (length in the longitudinal direction of the substrate) has a value corresponding to the length of the substrate 14 (approximately 200 to 300 mm), while the width H1 of the electrodes 21 and 22 (length in the short side direction of the substrate) has only a value corresponding to the width of the nip portion N (approximately several millimeters). Therefore, S1/S2 can only have a value of one hundredth or less order.
Therefore, if the electrodes 21 and 22 are formed by the screen printing method, the volume resistance value of the heat generation resistive member 15 should be an order of approximately E−3 to E−2 [Ω·m] in order to satisfy Relational Expression 4b.
However, a substance having this order of volume resistance value bears characteristics of a semiconductor rather than characteristics of an electric conductor, electrically. Therefore, there are only a few cases where the resistance temperature characteristics indicate a conspicuous PTC characteristic, and many of them indicate a mild PTC characteristic or are close to zero. Searching under the condition that the material is substantially used for the screen printing method and the condition that the PTC characteristic is large, there are few materials that are suitable for the heater of the pass-through direction conductive pattern type.
As described above, it is preferable that the degree of the PTC characteristic should be large as a resistance of the heater of the pass-through direction conductive pattern type. For this reason, it is preferable that a substance having the order of the volume resistance value of 1.0E−5 [Ω·m] or lower should be used. In addition, it is necessary that the thickness of the heat generation resistive member is as thin as possible, and that the thickness of the electrode is as thick as possible.
As a method of forming a thin film, there is a sputtering method, for example. If the heat generation resistive member 15 is formed by means of the sputtering method or the like, it is possible to realize a wide range of the film thickness of approximately several tens angstroms to one micron. In addition, combining with the method of forming the electrodes 21 and 22 by the screen printing method, the value of S1/S2 can be a larger value. As a result, the N value in Relational Expression 4 can be large, and hence the heater having excellent heat generation distribution can be manufactured. In addition, a material of the electrodes 21 and 22 can be selected from a wider range of the volume resistance value. Thus, the heat generation resistive member material having a large PTC characteristic can be used, and hence the higher effect of suppressing the temperature rise at the no sheet pass-through portion can be obtained.
Hereinafter, examples are described, in which the heat generation resistive member 15 is formed actually by the sputtering method so that the heater having the same appearance as that of the first embodiment illustrated in
A silver electrode having A1=3.20E−8 [Ω·m] was used as the electrode. Nichrome alloy metal having A2=7.5E−5 [Ω·m] and the PTC characteristic of 250 ppm/° C. (nichrome alloy containing iron and manganese; hereinafter referred to as a nichrome alloy 1) was used for the heat generation resistive member.
A silver electrode having A1=2.10E−8 [Ω·m] with a higher purity than that of Heater example 6 was used as the electrode. Nichrome alloy metal having A2=1.50E−6 [Ω·m] that is the volume resistance value lower than that of the nichrome alloy 1 (nichrome alloy containing iron) and the PTC characteristic of 240 ppm/° C. (nichrome alloy containing iron; hereinafter referred to as a nichrome alloy 2) was used for the heat generation resistive member 15.
A silver electrode having A1=3.20E−8 [Ω·m] was used as the electrode. Nichrome alloy metal having the volume resistance value of A2=1.30E−5 [Ω·m] and the PTC characteristic of 240 ppm/° C. (nichrome alloy excluding iron and manganese; hereinafter referred to as a nichrome alloy 3) was used for the heat generation resistive member.
Materials of the electrode and the heat generation resistive member were entirely the same as those of Heater example 7, and only the cross-section of the electrode was set to be smaller.
Materials of the electrode and the heat generation resistive member were entirely the same as those of Heater example 9 and Heater example 7, and the cross-section of the electrode was set to be further smaller than that of Heater example 9.
Materials of the electrode and the heat generation resistive member were entirely the same as those of Heater example 8, and only the cross-section of the heat generation resistive member was set to be larger.
Materials of the electrode and the heat generation resistive member were entirely the same as those of Heater example 6 and Heater example 8, and only the cross-section of the heat generation resistive member was set to be further larger than that of Heater example 8.
Table 4 indicates concrete dimensions and volume resistance values of the individual heaters described above.
The volume resistance values A1 and A2 in Table 4 have a unit of [Ω·m] and values at 200° C. that is the operating temperature of the heater. In addition, the cross-sections S1 and S2 have a unit of square meter [m2]. T1 denotes the film thickness of the electrodes 21 and 22. T2 denotes the film thickness of the heat generation resistive member 15. H1 denotes the width of the electrodes 21 and 22 (length in the short side direction of the substrate). H2 denotes the width of the heat generation resistive member 15 (length in the longitudinal direction of the substrate). The unit of each dimension is meter [m].
Note that the volume resistance values A1 and A2 of the heat generation resistive member 15 at 200° C. were measured by the following method. The heat generation resistive member 15 was formed on the glass substrate in the shape having a surface area of 5 mm×12 mm and the same thickness as each heater under the same condition as the film formed as the heater, and was placed on a heated hot plate together with the substrate so as to be heated up to a temperature of 200° C. After that, a resistance value of a 5 mm×10 mm area was measured by the resistance measuring instrument (Fluke 87V manufactured by Fluke Corporation) with the probe having the width of 5 mm. Then, the measured value was converted into the volume resistance value, which is described in Table 4.
Table 5 indicates results of actually measuring the N value and temperature distribution using the heaters described above.
In Table 5, Rab denotes a total resistance value, which was measured between the point A of the electrode 21 and the point B of the electrode 22 as illustrated in (a), (b) and (c) of
From above description, it is understood that the N value should be 29.4 or larger in order that the unevenness of the heat generation distribution becomes 10° C. or lower also in the heater made by the sputtering method.
In addition, it is understood that the use of the sputtering method enables the volume resistance value A2 of the heat generation resistive member 15 to be the first half of E−6 like Heater example 7 or Heater example 9 without limiting to 1.0E−5.
With the structure as described above, a substantially uniform energized state can be obtained over the entire area of the heat generation resistive member 15. Thus, a temperature difference between the end portion and the middle portion in the longitudinal direction thereof can be reduced, whereby a uniform heat generation distribution can be obtained.
Next, it is described that Heater examples 6 to 9 of this embodiment have the higher effect of suppressing the temperature rise at the no sheet pass-through portion compared with the conventional heater 113 having the structure in which the heat generation member reciprocates as described in the first embodiment. In order to realize the same condition for the temperature rise at the no sheet pass-through portion, the individual heaters of the conventional heater 113 and Heater examples 6 to 9 were assembled to the fixing apparatus one by one, and the temperature rise at the no sheet pass-through portion was compared.
As the conditions, ten cards were passed continuously under the environment of room temperature of 23° C. and humidity of 50%. Then, the pressure roller temperatures at the sheet pass-through portion and the no sheet pass-through portion, and its temperature difference were compared. The temperature on the surface of the pressure roller was measured by a thermocouple disposed between the pressure roller and felt made of heat resistant fibers contacting with the pressure roller. Temperature of the heater was controlled by using a thermistor disposed on the heater back surface in the sheet pass-through portion (pass-through area). In addition, an input voltage is adjusted for each heater.
Table 6 shows results thereof.
From results of Table 6 above, it is understood that the temperature difference between the no sheet pass-through portion and the sheet pass-through portion is substantially decreased in any of Heater examples 6, Heater example 7, Heater example 8, and Heater example 9 of this example so that the margin is increased compared with the conventional example.
In addition, particularly, comparing with the Ruthenium oxide heater 13 of the above-mentioned the first embodiment, the heater 13 of the second embodiment can use a material having a larger resistance temperature characteristic by using a material having a small volume resistance value of the order of 1.0E−5 [Ω·m] or smaller. From this, it is understood that it is possible to obtain a larger effect than the first embodiment regarding the N value in suppressing a temperature difference between the pass-through area through which the small size recording material P passes and the no sheet pass-through area through which the small size recording material P does not pass, i.e., the temperature rise at the no sheet pass-through portion.
With the structure of the heater 13 of this embodiment, the heat generation distribution of the heat generation resistive member 15 can be made uniform. In addition, the temperature difference between the pass-through area through which the small size recording material P passes and the no sheet pass-through area through which the small size recording material P does not pass can be reduced. Therefore, the fixing apparatus 8 equipped with the heater 13 of this embodiment can also increase a margin between the temperature for securing fixing performance of the non-fixed toner image t on the small size recording material P and the temperature at which the temperature rise in the no sheet pass-through area may cause a damage to a component of the fixing apparatus 8. Thus, comparing with the longitudinal dimension of the current fixing apparatus 8, a relatively small size recording material P can be printed at increased speed.
In addition, the resistance value Rab was measured in the state where the heater 13 is heated at 200° C. in this embodiment, but there are multiple levels of the set temperatures in the heat-fixing treatment similarly to the first embodiment. Therefore, it is favorable to satisfy the above-mentioned Relational Expression 4b for all the set temperatures set in the fixing apparatus 8.
In addition, the sputtering method was used as the method of forming a thin film of the heat generation resistive member 15 in this embodiment, but it is also possible to use a vapor deposition method or the like. In general, however, the sputtering method is favorable because it can obtain higher kinetic energy of an atom (molecule) of a target material so that a stronger thin film can be formed. In addition, the screen printing method is used as the method of forming the electrode in the above-mentioned Heater examples, but it is possible to adopt other film forming method for the electrode other than the screen printing method as long as the method can form the electrode having a sufficiently larger thickness than that of the heat generation resistive member formed by the sputtering method or the vapor deposition method.
In addition, the nichrome alloy was used as the material of the heat generation resistive member 15 in this embodiment, but it is also possible to use other metal, alloy, metal oxide, or semiconductor. However, it goes without saying that the higher the PTC characteristic of the material is, the larger the effect of suppressing the temperature rise at the no sheet pass-through portion becomes.
Another example of the heater is described.
In the first and second embodiments, the heat generation resistive member 15 is disposed on the surface of the substrate 14 of the heater 13, and the electrode 22 is patterned as follows for simplifying electrode contacts with the heat generation resistive member 15. Through holes 14h1 and 14h2 are formed in the substrate 14 for disposing the first areas 21a and 22a inside one end portion of the substrate 14, and an extension area 22c of the electrode 22 is connected to the second area 22b at the inside of the other end portion of the substrate 14 by using the through holes 14h1 and 14h2. With this structure, the feed power directions from the electrodes 21 and 22 become symmetric with respect to the heat generation resistive member 15 in the longitudinal direction of the substrate 14. Therefore, the temperature difference can be suppressed between the electrode side and the non-electrode side in the heat generation resistive member 15.
The heater 13 described in this embodiment is a heater having no current flowing between opposite corners of the electrode 21 and the electrode 22 with respect to the heat generation resistive member 15 in the longitudinal direction of the substrate 14. In other words, as in the case of the heater 13 of the first embodiment, the through holes 14h1 and 14h2 are not formed in the substrate 14, and the width of the substrate 14 is not increased, whereby the heat generation distribution of the heat generation resistive member 15 is uniformed in the longitudinal direction. This structure can reduce cost because the through holes 14h1 and 14h2 are not provided. In addition, the electrode contacts are disposed at the inside of one end portion of the substrate 14, and thus it is not necessary to increase the width of the substrate 14, leading to merits such as cost reduction and space saving.
The heater 13 of this embodiment has the same structure as the heater 13 of the first embodiment except that the electrode 22 provided to the other end side in the short side direction of the substrate 14 has a form different from that of the electrode 22 of the heater 13 of the first embodiment.
The electrode 22 is formed in the same manner as the electrode 21. More specifically, the electrode 22 includes a first area 22a for feeding power and a second area 22b (gray thick line portion in (b) of
In this embodiment, the first areas 21a and 22a and the second areas 21b and 22b of the electrodes 21 and 22 are made of the same material. In addition, the second areas 21b and 22b have a length of approximately 220 mm, a width of approximately 1 mm, and a thickness of approximately a few tens of microns.
Major dimensions of the heater 13 of this embodiment are defined as illustrated in
The cross-section S1, the length L1 and the volume resistance value A1 in the second areas 21b and 22b of the electrodes 21 and 22 are basically defined in the same manner as the heater 13 of the first embodiment. The cross-section S2, the length L2 in the feed power direction, and the volume resistance value A2 of the heat generation resistive member 15 are also basically defined in the same manner as the heater 13 of the first embodiment.
In addition, the heater 13 of this embodiment also does not become a uniform energized state if the volume resistance value of the electrodes 21 and 22 is similar to that of the heat generation resistive member 15 in the state where the recording material P is not passed (led) in the nip portion N. In other words, as illustrated in
Therefore, Heater examples having different volume resistance values are described below, which were actually realized by changing thicknesses of the electrodes 21 and 22 and the heat generation resistive member 15, and the composition of the heat generation resistive member 15.
As the electrode, a silver electrode having A1=3.20E−8 [Ω·m] was used. As a material of the heat generation resistive member, a nichrome alloy 1 having A2=7.5E−5 [Ω·m] was used.
A silver electrode having A1=2.10E−8 [Ω·m] with higher purity than Heater example 6 was used for the electrode. As to the heat generation resistive member, a nichrome alloy 2 having A2=1.50E−6 [Ω·m] that has lower volume resistivity than the nichrome alloy 1 was used.
Also as to the above-mentioned Heater example 10 and Heater example 11, it is favorable to form the heat generation resistive member on the substrate by the sputtering method or the vapor deposition method similarly to the second embodiment. In addition, the film forming method of the electrode can be any method as long as it can form the electrode having a thickness sufficiently larger than the thickness of the heat generation resistive member formed by the sputtering method or the vapor deposition method. In particular, it is favorable to form the film of the electrode by the screen printing method.
The same electrode as that of Heater example 10 was used, and a nichrome alloy 4 having a volume resistance value of A2=1.50E−5 [Ω·m] was used for the heat generation resistive member.
The materials of the electrode and the heat generation resistive member were totally the same as those of Heater example 11, and only the cross-section of the electrode was reduced.
Table 7 shows specific dimensions and volume resistance values of the above-mentioned individual heaters.
In Table 7, the volume resistance values A1 and A2 have a unit of [Ω·m] and a value at 200° C. that is the operating temperature of the heater. In addition, the cross-sections S1 and S2 have a unit of square meter [m2]. T1 represents a film thickness of the electrodes 21 and 22. T2 represents a film thickness of the heat generation resistive member 15. H1 represents a width of the electrodes 21 and 22. H2 represents a width of the heat generation resistive member 15. The unit of each dimension is meter [m].
In Table 7, the volume resistance values A1 and A2 of the heat generation resistive member 15 at 200° C. were measured by the following method. The heat generation resistive member 15 was formed on the glass substrate in a shape having a surface area of 5 mm×12 mm and the same thickness as each heater under the same conditions of the above-mentioned film forming of a discrete heater, and placed on a heated hot plate together with the substrate so as to be heated up to 200° C. After that, a resistance value of a 5 mm×10 mm area was measured by a resistance measuring instrument (Fluke 87V manufactured by Fluke Corporation) with a probe having a width of 5 mm. Then, the measured value was converted into the volume resistance value, which is described in Table 7.
Here, in order to determine a value of Nx, a ratio of heaters R2/R1=N (hereinafter referred to as an “N value”) was determined. Then, a relationship between the N value and the heat generation unevenness was examined.
Table 8 shows a result.
In Table 8, Rab denotes a total resistance value, which is a resistance value measured between the point A of the electrode 21 and the point C of the electrode 22 illustrated in
As understood from the results of Heater example 10 and Heater example 11 above, the heat generation difference was 10° C. or smaller when the N value was 56.7 or larger at 200° C. that is the set temperature. In addition, it is understood that the temperature difference decreases as the N value increases. In addition, as understood from Comparative example 8 and Comparative example 9 on the contrary, the heat generation difference exceeds 10° C. if the N value is 56.7 or smaller at the set temperature 200° C. It is understood that the heat generation difference increases as the N value decreases. Therefore, if the following Relational Expression 4d is satisfied in Relational Expression 4 described in the first embodiment, the heat generation unevenness can be made uniform.
A1≦A2×S1×L2/(56.7×S2×L1) (Relational Expression 4d)
The heat generation unevenness was measured as follows. The temperature of the discrete heater was controlled to be 200° C., and the heat generation distribution was measured by the thermography. As illustrated in
Next, it is described that Heater example 10 and Heater example 11 actually have the effect of suppressing the temperature rise at the no sheet pass-through portion compared with the conventional heater 113 having the structure in which the heat generation member reciprocates as described in the first embodiment. In order to realize the same condition for the temperature rise at the no sheet pass-through portion, the individual heaters of the conventional heater 113 and Heater examples 10 and 11 were assembled to the fixing apparatus one by one, and the temperature rise at the no sheet pass-through portion was compared.
As the conditions for measuring the temperature difference, ten cards were fed continuously under the environment of room temperature of 23° C. and humidity of 50%. The temperature on the surface of the pressure roller was measured by a thermocouple disposed between the pressure roller and felt made of heat resistant fibers abutting on the pressure roller. Temperature of the heater was controlled by using a thermistor disposed at the heater back surface in the sheet pass-through portion (pass-through area). In addition, an input voltage is adjusted for each heater.
Table 9 shows a result thereof.
From results of Table 9, it is understood that the temperature difference between the no sheet pass-through portion and the sheet pass-through portion is decreased to a large degree in both Heater example 10 and Heater example 11 of this embodiment so that the margin is increased, compared with the conventional example.
As described above, the heat generation distribution of the heat generation resistive member 15 can be uniform if the heater 13 is constituted so that Relational Expression 4d “A1≦A2×S1×L2/(56.7×S2×L1” is satisfied. In addition, a temperature difference between the pass-through area through which the small size recording material P passes and the no sheet pass-through area through which the small size recording material P does not pass can be decreased. Therefore, the fixing apparatus 8 equipped with the heater 13 can increase a margin between the temperature for securing fixing performance of the non-fixed toner image t on the small size recording material P and the temperature at which the temperature rise in the no sheet pass-through area may cause a damage to a component of the fixing apparatus 8. Thus, comparing with the longitudinal dimension of the current fixing apparatus 8, a relatively small size recording material P can be printed at an increased speed.
[Others]
The heater 13 that is mounted on the fixing apparatus 8 of the tensionless type film heating method is described in the first to third embodiments, but the same action and effect can be obtained if the heater 13 is mounted on a fixing apparatus of a tension type film heating method.
In addition, the surface of the substrate 14 on the side of the heat generation resistive member 15 in the heater 13 contacts with the inner surface of the film 12 in the first to third embodiments, but the same action and effect can be obtained if the back surface on the opposite side of the heat generation resistive member 15 of the substrate 14 is made to contact with the inner surface of the film 12. In this case, the thermistor 19 is disposed on the surface on the side of the heat generation resistive member 15 of the substrate 14.
This application claims priority based on Japanese Patent Application No. 2007-322076 filed on Dec. 13, 2007, the entire contents of which are hereby incorporated by reference.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2007-322076 filed Dec. 13, 2007, which is hereby incorporated by reference herein its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-322076 | Dec 2007 | JP | national |
This application is a continuation of International Application No. PCT/JP2008/072901, filed Dec. 10, 2008, which claims the benefit of Japanese Patent Application No. 2007-322076, filed Dec. 13, 2007.
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| Number | Date | Country | |
|---|---|---|---|
| 20090220288 A1 | Sep 2009 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2008/072901 | Dec 2008 | US |
| Child | 12465066 | US |
