Patent Application
20090230114
1. Field of the Invention
The present invention relates to an image heating apparatus which can be used as a heating and fixing apparatus (fixing device) that is mounted on an image forming apparatus such as an electrophotographic copying machine and an electrophotographic printer, and to a heater used for the image heating apparatus.
2. Description of the Related Art
Some heating and fixing apparatuses (fixing device) which are mounted on an electrophotographic printer or an electrophotographic copying machine have a heater having a heat generating resistor on a substrate made from ceramic, a flexible member (fixing film) which moves while contacting with the heater, and a pressure roller which forms a nipping portion with the heater through the flexible member. A recording medium which carries an unfixed toner image thereon is heated while being sandwiched in the nipping portion of the fixing device and transported therethrough, and thereby, an image on the recording medium is heated and fixed on the recording medium. This fixing device has such a merit of spending a short period of time for raising the temperature of the heater to a fixable temperature after having started the energization to the heater. Accordingly, a printer having this fixing device mounted thereon can shorten a period of time (FPOT: First Print Out Time) for outputting the first image after a print command has been input. This type of a fixing device has also a merit of consuming little electric power in a period of waiting for the print command.
By the way, it is known that when a recording medium with a small size is continuously printed at the same printing interval as that for a recording medium with a large size by using a printer that mounts a fixing device thereon which uses the flexible member, a region of the heater through which the recording medium does not pass (non-feeding region) excessively raises its temperature. When the non-feeding region of the heater excessively raises its temperature, the heat occasionally damages the holder which holds the heater and the pressure roller.
Therefore, when the printer that mounts the fixing device thereon which uses the flexible member continuously prints an image on a recording medium with a small size, the printer controls itself so as to extend a printing interval wider than in the case of continuously printing a recording medium with a large size, and inhibits the non-feeding region of the heater from excessively raising its temperature.
However, the control for extending the printing interval reduces the number of sheets to be output per unit time, and the number of sheets to be output per unit time is desired to be controlled so as to be equivalent to or slightly less than that in the case of printing the recording medium with the large size.
For this reason, it is considered to use a material having such negative resistance-temperature characteristics (NTC: Negative Temperature Coefficient) that the resistance value decreases as the temperature rises, for the heater used in the above described fixing device. This is a concept that when the heater has the negative resistance-temperature characteristics, the resistance value in the non-feeding region decreases even though the non-feeding region has excessively raised its temperature, and accordingly can inhibit the non-feeding region from excessively raising its temperature.
However, a heat generating resistor having the negative resistance-temperature characteristics generally has high volume resistance, and it is often difficult to obtain electric resistance in a range in which a commercial power source is usable, from a normal heat generating resistor pattern.
Japanese Patent Application Laid-Open No. 2007-proposes a heating member which is manufactured so as to obtain a resistance in a range in which a commercial power source is useful even when using the heat generating resistor having the negative resistance-temperature characteristics. This heating member has heat generating resistors having negative resistance-temperature characteristics such as graphite, for instance, divided in a longitudinal direction of a substrate; supplies an electric power to one area of the divided heat generating resistors in a transverse direction of the substrate (transport direction of recording medium); and makes the divided heat generating resistor areas connected to each other in series. By employing the heating member having a heat generating resistor pattern having such a configuration, the temperature rise in the non-sheet feeding portion could be lowered with a simple configuration.
The above described conventional heating member is desired to prevent the temperature in the non-sheet feeding portion from rising and simultaneously secure fixing properties in a gap between the divided heat generating resistors.
The present invention has been accomplished with respect to the above described problems, and provides an image heating apparatus which simultaneously prevents the temperature in a non-sheet feeding portion from rising and secures fixing properties in a gap between the divided heat generating resistors, and a heater used in this image heating apparatus.
Another object of the present invention is to provide an image heating apparatus comprising: an endless film; a heater which contacts with the inner face of said endless film and is arranged so that its longitudinal direction is parallel to a generatrix of said endless film; a back-up member for forming a nipping portion which sandwiches a recording medium together with said heater through said endless film, and transports the recording medium; wherein said heater has a first heat-generation segment provided in an upstream side, and a second heat-generation segment which is provided in a downstream side and is electrically connected to said first heat-generation segment in series, in a transport direction of the recording medium; wherein said first heat-generation segment and said second heat-generation segment have a plurality of heat generating parts in the longitudinal direction respectively, and the heat generating parts are electrically connected to each other in series; wherein each of the plurality of said heat generating parts has a first electro-conductive pattern which is provided along the longitudinal direction on a substrate, a second electro-conductive pattern which is provided along the longitudinal direction on said substrate and has a region that overlaps with said first electro-conductive pattern in the longitudinal direction, and a heat generating resistor which electrically connects the overlapping regions of said first electro-conductive pattern and said second electro-conductive pattern with each other and generates heat due to a supplied electric power; wherein the position of a gap between said adjacent heat generating parts in said first heat-generation segment is different from the position of a gap between said adjacent heat generating parts in said second heat-generation segment, in the longitudinal direction.
Further another object of the present invention is to provide an image heat apparatus comprising: a first heat-generation segment which is provided on one end side of said heater in a transverse direction; a second heat-generation segment which is provided on the other end side of said heater in the transverse direction and is electrically connected to said first heat-generation segment in series; wherein said first heat-generation segment and said second heat-generation segment have a plurality of heat generating parts in the longitudinal direction of said heater respectively, and the heat generating parts are electrically connected to each other in series; wherein each of the plurality of said heat generating parts has a first electro-conductive pattern which is provided along the longitudinal direction on a substrate, a second electro-conductive pattern which is provided along the longitudinal direction on said substrate and has a region that overlaps with said first electro-conductive pattern in the longitudinal direction, and a heat generating resistor which electrically connects the overlapping regions of said first electro-conductive pattern and said second electro-conductive pattern with each other and generates heat by a supplied electric power; wherein the position of a gap between said adjacent heat generating parts in said first heat-generation segment is different from the position of a gap between said adjacent heat generating parts in said second heat-generation segment, in the longitudinal direction.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
The present invention will now be described with reference to the drawings.
(1) Example of Image Forming Apparatus
An electrophotographic photosensitive drum 101 (hereinafter referred to as photosensitive drum) functions as an image carrier. The photosensitive drum 101 is rotated in a counterclockwise direction which is shown by the arrow, at a predetermined peripheral velocity (process speed).
A charging unit 102 is a contact charging roller or the like. This charging unit 102 uniformly electrostatically charges (primary charge) the peripheral surface (topside surface) of the photosensitive drum 101 into a predetermined polarity/potential.
A laser beam scanner 103 is an image exposure unit. The laser beam scanner 103 outputs a laser light which has been on/off modulated so as to correspond to electric digital pixel signals in time series of an objective image information that is input from an external equipment such as an unshown image scanner and computer, and scan-exposes (irradiates) the electrostatically charged surface of the photosensitive drum 101 to light. By thus being scan-exposed to light, an electric charge is removed in a portion exposed to light on the electrostatically charged surface of the photosensitive drum 101, and an electrostatic latent image corresponding to the objective image information is formed on the electrostatically charged surface.
A developing device 104 is shown. The developing device 104 supplies a toner (developer) to the electrostatically charged surface of the photosensitive drum 101 from a developer sleeve, and develops the electrostatic latent image (electrostatic image) on the electrostatically charged surface to form a toner image (developed image) thereon. The laser beam printer generally employs a reversal development system which develops an image by depositing a toner on the portion exposed to light of the electrostatic latent image.
A transfer roller 106 is a contact/rotation type of a transfer member. A transfer bias of opposite polarity to the toner is applied to the transfer roller 106, and thereby, the toner image of the photosensitive drum 101 is electrostatically transferred onto the surface of a recording medium P in a transfer portion which will be described later.
In the above, a structure of an image forming structural section of an image forming unit has been described.
A sheet-feeding cassette 109 is shown. The sheet-feeding cassette 109 loads and accommodates a recording medium P therein. A sheet-feeding roller 108 is driven according to a sheet-feeding start signal, and releases and feeds the recording medium P in the sheet-feeding cassette 109 one by one. The recording medium P is introduced to a transfer portion that is a nipping portion at which the photosensitive drum 101 abuts on the transfer roller 106, at a predetermined timing through a sheet path 112 which includes a transportation roller 110 and a resist roller 111. In other words, the resist roller 111 controls the transportation of the recording medium P so that the tip part of the recording medium P reaches the transfer portion just at the timing when the tip part of a toner image on the photosensitive drum 101 reaches the transfer portion.
The recording medium P which has been introduced to the transfer portion is pinched and carried through the transfer portion, and in the meantime, a transfer voltage (transfer bias) is applied to the transfer roller 106 from an unshown transfer bias application voltage. The transfer roller 106 and the transfer voltage control will be described later.
The recording medium P onto which the toner image has been transferred in the transfer portion is separated from the topside surface of the photosensitive drum 101, and is transported and introduced to the image fixing apparatus (fixing device) 107 of an image heating apparatus through a sheet path 113. Here, the toner image is heated, pressurized and fixed.
On the other hand, the topside surface of the photosensitive drum 101 after having released the recording medium (after having transferred toner image onto recording medium P) is cleaned by a cleaning device 105 which removes a toner remaining after the transfer operation and a paper powder from the topside surface, and is repeatedly used for an imaging operation.
The recording medium P which has been passed through the fixing apparatus 107 passes through a sheet path 114, and is ejected to a copy receiving tray 115 from a paper ejection port.
An elastic sponge roller to be used for the transfer roller 106 has generally an elastic layer of a semiconductive sponge having an electric resistance adjusted to approximately 1×106 to 1×1010Ω by carbon, an ion conductive filler or the like formed on a cored bar of SUS, Fe or the like. The ion conductive type of a transfer roller was used in the present exemplary embodiment 1, which had an elastic layer having electroconductivity formed into such a roller shape as to be concentrically integrated around the cored bar, by making an NBR rubber react with a surface active agent or the like. The used transfer roller had a resistance value in a range from 1×108 to 5×108Ω.
It is known that the electric resistance of the transfer roller 106 is easy to vary affected by the temperature and humidity of a surrounding environment. The variation of the electric resistance of this transfer roller 106 leads to the occurrence of a poor transfer and a paper mark. For this reason, in order to prevent the poor transfer and the paper mark from occurring due to the variation of the electric resistance of the transfer roller 106, “application transfer voltage control” is adopted which is a method of measuring the resistance value of the transfer roller 106, and correctly controlling a transfer voltage to be applied to the transfer roller 106 according to the measurement result of the electric resistance.
Examples of such an application transfer voltage control include an ATVC control (Active Transfer Voltage Control) disclosed in Japanese Patent Application Laid-Open No. H02-123385. The ATVC control is a unit for optimizing a transfer bias which is applied to the transfer roller when the image is transferred, and for preventing the occurrence of the poor transfer and the paper mark. As for the above described transfer bias, a desired constant current bias is applied to the photosensitive drum from the transfer roller during a forward rotation of the image forming apparatus, the resistance of the transfer roller is detected from the bias value applied at that time, and the transfer bias corresponding to the resistance value is applied to the transfer roller when a print stroke is transferred. In the present exemplary embodiment 1 as well, the above described ATVC control was employed.
(2) Fixing Apparatus 107
Next, a fixing apparatus 107 in the present exemplary embodiment 1 will now be described below.
In the following description, a longitudinal direction concerning a fixing apparatus and members which constitute the fixing apparatus means a direction orthogonal to a transportation direction of a recording medium, on the surface of the recording medium. A transverse direction means a direction parallel to the transportation direction of the recording medium, on the surface of the recording medium. A length means a dimension in a longitudinal direction. A width means a dimension in a transverse direction.
The tensionless type of a film heating type of a fixing apparatus uses a heat-resistant film (endless film) as a flexible member. The heat-resistant film to be employed is a film having an endless belt shape or a cylindrical shape. At least one part of a perimeter of the heat-resistant film used in the fixing apparatus is kept to be always in a tension-free state (state of no tension being applied), and the heat-resistant film is rotation-driven by a rotation driving force of the pressure roller of a pressure member (back-up member).
(2-1) Stay
A stay 1 functions as a supporting member for supporting a heating member (heater) 3. The stay 1 is a heat-resistant rigid member which functions as both a supporting member for the heating member and a film guide member. Both ends in a longitudinal direction of the stay 1 are held by a frame (unshown) of the apparatus. The heating member 3 is arranged on the lower face of the stay 1 along the longitudinal direction of the stay, and is held by the stay 1. The detail of the heating member 3 will be described later.
The stay 1 can be constituted by a high heat-resistant resin such as polyimide, polyamide-imide, PEEK, PPS and a liquid crystal polymer; a composite material of a resin thereof and a ceramic, a metal or glass; or the like. In the present exemplary embodiment 1, a liquid crystal polymer was employed.
(2-2) Heat-Resistant Film (Endless Film)
A heat-resistant film 2 (hereinafter referred to as film) is an endless (cylindrical) type of the film. The film 2 is fitted onto a stay 1 which holds a heating member 3. The inner peripheral length of the film 2 is set so as to be approximately 3 mm longer than the outer peripheral length of the stay 1 which supports the heating member 3. Accordingly, the film 2 is fitted onto the stay 1 while having a sufficient peripheral length. A transportation direction K of the recording medium is shown.
The film 2 can have a thickness of 100 μm or less and further 50 μm or less but 20 μm or more, so as to decrease its heat capacity and enhance the quick-starting property, and can employ a heat-resistant single-layer film or a composite-layer film of PTFE, PFA, FEP and the like. A usable composite-layer film includes a film of polyimide, polyamide-imide, PEEK, PES, PPS or the like, of which the outer peripheral topside surface is coated with PTFE, PFA, FEP or the like. The composite-layer film used in the present exemplary embodiment 1 was a polyimide film with a film thickness of 50 μm, of which the outer peripheral topside surface was coated with PTFE. The outside diameter of the film 2 was set at 24 mm.
(2-3) Pressure Roller (Back-Up Member)
A pressure roller 4 is shown. The pressure roller 4 is a roller member which sandwiches a film 2 in between the pressure roller 4 and a heating member 3 to form a nipping portion N (pressurization nipping portion and fixing nipping portion) with the heating member 3, and rotation-drives the film 2. The pressure roller 4 has a round-shaft-shaped cored bar 4a, an elastic layer 4b which is provided on the outer peripheral surface of the cored bar 4a so as to form a roller shape, and a releasing layer 4c of the outermost layer, which is provided on the outer peripheral surface of the elastic layer 4b. This pressure roller 4 is arranged in parallel to the film 2, and both ends in a longitudinal direction of the cored bar 4a are rotatably held by a frame of the apparatus through a bearing (unshown). The pressure roller 4 also urges the bearing with a predetermined pressing force by using an urge member (unshown) such as a pressing spring, pressurizes the outer peripheral surface (topside surface) of the pressure roller 4 toward the topside surface of the heating member 3 while making the film 2 sandwiched between the outer peripheral surface and the topside surface of the heating member 3, and thereby elastic-deforms the elastic layer 4b of the pressure roller 4 in a longitudinal direction. By the elastic deformation of the elastic layer 4b, the outer peripheral surface (topside surface) of the film 2 and the topside surface of the pressure roller 4 form such a nipping portion N in between themselves as to have a predetermined width necessary for heating and fixing an unfixed toner image T (see
A driving system M rotates and drives a driving gear G which is provided on one end in a longitudinal direction of the cored bar 4a, and the pressure roller 4 is thereby rotated with a predetermined peripheral velocity in a clockwise direction as shown by the arrow. By this rotation of the pressure roller 4, a rotation force is applied to the film 2 through a frictional force working between the topside surface of the pressure roller 4 and the topside surface of the film 2 in the nipping portion N. The film 2 is thereby driven and rotates around the outside of a stay 1 at the approximately same peripheral velocity as the peripheral velocity of the rotating pressure roller 4 in a counter clockwise direction shown by the arrow, while the inner peripheral surface (inner face) of the film 2 closely contacts with and slides along the topside surface of the heating member 3 in the nipping portion N.
(2-4) Heating Member (Heater)
Subsequently, a heating member 3 will now be described below.
The heating member 3 illustrated in the present exemplary embodiment 1 has a slim substrate 7 in a longitudinal direction. The heating member has also a heat generating resistor 6, power feeding electrodes 9 and 10 and an electro-conductive pattern 14 which function as electrodes for supplying an electric power to the heat generating resistor 6, and an overcoat layer 8 for protecting the heat generating resistor 6 and the electro-conductive pattern 14, provided on the topside surface (sliding surface of film) side of the substrate 7; and totally has a low heat capacity.
The substrate 7 has heat resistance, insulating properties and adequate thermal conductance. A material to be used for the substrate 7 includes, for instance, a material made from ceramics such as aluminium oxide and aluminum nitride. The substrate 7 used in the present exemplary embodiment 1 is a substrate which is made from aluminium oxide and has a width of 7 mm, a length of 270 mm and a thickness of 1 mm.
As for the heat generating resistor 6, two lines (plurality lines) of heat generating resistors 6 are provided on the surface of the substrate 7 along a longitudinal direction of the substrate 7 separately in terms of a transverse direction of the substrate 7. Specifically, the heat generating resistors 6 are provided in the inner side of an end of the substrate in an upstream side of the transportation direction of the recording medium, and in the inner side of an end of the substrate in a downstream side of the transportation direction of the recording medium, in a transverse direction of the substrate 7. Hereinafter, the heat generating resistor 6 which is provided in the inner side of the end of the substrate in the upstream side of the transportation direction of the recording medium is referred to as a heat generating resistor 6 in the upstream side. The heat generating resistor 6 which is provided in the inner side of the end of the substrate in the downstream side of the transportation direction of the recording medium is referred to as a heat generating resistor 6 in the downstream side. The heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side are each obtained by forming a film of a paste (hereinafter referred to as graphite paste) which has been prepared by mixing a powder of graphite and glass (inorganic binder) with an organic binder, on the substrate 7 with a screen printing technique. The shape and characteristics of the heat generating resistor 6 will be described later.
The heat generating resistor 6 in the upstream side and electro-conductive patterns 14-1 and 14-2 in both sides thereof are referred to as a first heat-generation segment, and the heat generating resistor 6 in the downstream side and electro-conductive patterns 14-3 and 14-4 in both sides thereof are referred to as a second heat-generation segment. The first heat-generation segment is electrically connected to the second heat-generation segment in series. As is illustrated in
The electro-conductive patterns 14-1 (first electro-conductive pattern) and 14-2 (second electro-conductive pattern) are provided on both sides in the transverse direction of the substrate 7 of the heat generating resistor 6 in the upstream side along the longitudinal direction of the substrate 7. The electro-conductive patterns 14-3 (first electro-conductive pattern) and 14-4 (second electro-conductive pattern) are provided on both sides in the transverse direction of the substrate 7 of the heat generating resistor 6 in the downstream side along the longitudinal direction of the substrate 7. The electro-conductive pattern 14-1 which is provided in the outside (upstream side) of the heat generating resistor 6 in the upstream side is connected to the electro-conductive pattern 14-3 which is provided in the inside (upstream side) of the heat generating resistor 6 in the downstream side. The power feeding electrode 9 is connected to the electro-conductive pattern 14-1, and the power feeding electrode 10 to the electro-conductive pattern 14-4 respectively.
As is illustrated in
The power feeding electrodes 9 and 10 and the electro-conductive patterns 14-1, 14-2, 14-3 and 14-4 are formed by screen-printing a paste containing silver as a material on the substrate 7. The power feeding electrodes 9 and 10 and the electro-conductive patterns 14-1, 14-2, 14-3 and 14-4 are provided for supplying an electric power to the heat generating resistor 6. Therefore, the electric resistances of the power feeding electrodes 9 and 10 and the electro-conductive patterns 14-1, 14-2, 14-3 and 14-4 are sufficiently lowered compared to that of the heat generating resistor 6.
The overcoat layer 8 is mainly directed at securing electrical insulation properties between the heat generating resistor 6 and the topside surface of the heating member 3, and securing sliding properties with respect to the inner face of the film 2. In the present exemplary embodiment 1, a high heat-resistant glass layer with a thickness of approximately 50 μm was used as the overcoat layer 8.
A thermometry element 5 for detecting the temperature of the heating member 3 is provided on the backside surface (non-sliding surface of film) of the substrate 7, as a temperature detecting unit. In the present exemplary embodiment 1, an external abutment type of a thermistor which is separated from the heating member 3 is employed as the thermometry element. The external abutment type of the thermistor 5 has such a structure as to have a heat insulation layer provided on a supporting member, have an element of a tip thermistor fixed thereon, direct the element toward the lower side (backside surface side of substrate 7) and make the element abut on the backside surface of the substrate 7 with a predetermined pressure force, for instance. The thermistor used in the present exemplary embodiment 1 had a high heat-resistant liquid crystal polymer for the supporting member, on which a ceramic paper was stacked as the heat insulation layer. The external abutment type of the thermistor 5 is provided in the smallest sheet-feeding region of the substrate 7, in other words, a region through which every recording medium having different sizes in a longitudinal direction of the substrate 7 pass. The thermistor 5 is connected to a CPU 11 which functions as a control unit.
This heating member 3 is fixed and provided in the lower surface side of a stay 1 so that its topside surface having the overcoat layer 8 formed thereon of the heating member 3 directs downward and is exposed to the film and is held by the stay 1. By adopting the above described structure, the whole heating member 3 can have a low heat capacity, and the image heating apparatus can quickly start its operation.
In the heating member 3, an electric power is supplied to power feeding electrodes 9 and 10 which are provided in the inner side of an end in a longitudinal direction of a substrate 7 from a power source 13 through a power feeding connector (unshown). Thereby, the electric power is supplied to heat generating resistors 6 in an upstream side and in a downstream side through electro-conductive patterns 14-1, 14-2, 14-3 and 14-4, while passing through an energization path shown by the arrows in
In a state in which the temperature of the heating member 3 has risen to a predetermined set temperature, and the peripheral velocity of the rotation of a film 2 caused by the rotation of a pressure roller 4 has been kept constant, a recording medium P which carries an unfixed toner image T thereon is introduced into a nipping portion N from a transfer portion. Subsequently, the recording medium P is pinched and carried in the nipping portion N together with the film 2, the heat of the heating member 3 is imparted onto the recording medium P through the film 2, and the toner image T on the recording medium P is heated and fixed on the surface of the recording medium P. The recording medium P which has passed through the nipping portion N is separated from the topside surface of the film 2 and transported.
A method of manufacturing a heating member 3 in the present exemplary embodiment 1 will now be described below.
Firstly, power feeding electrodes 9 and 10 and an electro-conductive pattern 14 are simultaneously screen-printed on a substrate 7 made from aluminum oxide. The power feeding electrodes 9 and 10 and the electro-conductive patterns 14-1, 14-2, 14-3 and 14-4 are dried, and then are baked at a temperature of approximately 800° C. Subsequently, the above described graphite paste is screen-printed, dried and baked to form a heat generating resistor 6. The surface of graphite begins to be oxidized at approximately 700° C., so that the baking temperature was set at approximately 600° C. Subsequently, an overcoat layer 8 is formed through a screen printing technique, and the overcoat layer 8 is dried and baked. In consideration of the heat resistance of the graphite, a glass which can be baked at 400 to 500° C. was selected as a material of the overcoat layer 8.
Next, the shape and characteristics of the heat generating resistor 6 in the present exemplary embodiment 1 will now be described in detail below.
In the present exemplary embodiment 1, the heat generating resistors 6 of the heating member 3 are divided into two lines of the heat generating resistor 6 in an upstream side and the heat generating resistor 6 in a downstream side, and the divided heat generating resistors 6 are connected in series by electro-conductive patterns 14-1, 14-2, 14-3 and 14-4. The heat generating resistor 6 in the upstream side is divided into four pieces in a longitudinal direction of a substrate 7, and the heat generating resistor 6 in the downstream side is divided into three pieces in the longitudinal direction of the substrate 7. In other words, the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side are divided into three or more portions.
The feature of the heating member 3 in the present exemplary embodiment 1 is that the divided number of the heat generating resistor 6 in the upstream side is different from that of the heat generating resistor 6 in the downstream side, and positions (divided position) of gaps formed in the longitudinal direction of the substrate 7 by the division are also different from each other (does not match) in the longitudinal direction of the substrate 7.
Electro-conductive patterns 14-1, 14-2, 14-3 and 14-4 are provided on sides of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side so as to supply an electric power to one each area of the divided heat generating resistors 6 in a transverse direction of the substrate 7. The divided areas are connected to each other in series in the longitudinal direction of the substrate 7 by the electro-conductive patterns 14-1, 14-2, 14-3 and 14-4. Therefore, when the electric power is supplied to power feeding electrodes 9 and 10, the electric current I passes through each of areas in a direction shown by the arrows in
The length (a) in one area of the heat generating resistor 6 in the upstream side is set at 55 mm. The length (b) in one area of the heat generating resistor 6 in the downstream side is set at 73.5 mm. The widths (d) of both the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side are set at 1.55 mm (which means that total width of heat generating resistor is set at 3.1 mm). The four areas of the heat generating resistor 6 in the upstream side and the three areas of the heat generating resistor 6 in the downstream side have the same shapes. The length (f) of a gap between the divided areas in any of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side was set at 0.5 mm. Therefore, the total length including the gaps of any of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side results in 221.5 mm. The thickness of any of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side was set at approximately 10 μm.
The width (c) of the electro-conductive patterns 14-1, 14-2, 14-3 and 14-4 was set at 0.5 mm. The width (gap) (g) between the electro-conductive pattern 14-2 and the electro-conductive pattern 14-3 was set at 0.5 mm. The width (e) between the edge in the upstream side of the substrate 7 and the electro-conductive pattern 14-1, and the width (e) between the edge in the downstream side of the substrate 7 and the electro-conductive pattern 14-4 were set at 0.7 mm respectively.
The above described length (f) and the widths (c), (e) and (g) are set at the minimum value which can be controlled when the heating member 3 is manufactured.
In the present exemplary embodiment 1, a graphite paste containing graphite glass as a main component is used as a material of a heat generating resistor 6. The sheet resistance of the graphite paste is approximately 100 Ω/sq (in thickness of 10 μm) at room temperature. In the present exemplary embodiment 1, the total resistance of heat generating resistors 6 in an upstream side (total resistance of four areas) is 11.5Ω at room temperature. The total resistance of heat generating resistors 6 in a downstream side (total resistance of three areas) is 6.5Ω at room temperature. The resistance in total of the resistance of the heat generating resistor 6 in the upstream side and the resistance of the heat generating resistors 6 in the downstream side (resistance between power feeding electrodes 9 and 10) is 18Ω at room temperature.
A conventional heat generating resistor is generally formed from a paste mainly containing a metal such as silver palladium (Ag/Pd), and shows the characteristics of Positive Temperature Coefficient (hereinafter, referred to as “PTC characteristic”). Here, the resistance-temperature characteristic is defined by the meaning of the resistance to the temperature. That is, the PTC characteristic implies positive resistance-temperature characteristics that electric resistance increases as temperature rises. On the other hand, the graphite which is used as a material of the heat generating resistor 6 in the present exemplary embodiment 1 has the property of showing the characteristics of negative Temperature Coefficient (hereinafter, referred to as “NTC characteristic”) at a certain temperature or lower, and showing the PTC characteristics at the certain temperature or higher. The temperature of the inflection point is approximately 700° C. The NTC characteristic implies negative resistance-temperature characteristics in which electric resistance decreases as temperature rises.
The highest reachable temperature of a heating member 3 is approximately 300° C., so that the heat generating resistor 6 in the present exemplary embodiment 1 shows the NTC characteristics when a fixing apparatus 107 is actually used. The change rate of the resistance of the heat generating resistor 6 in the present exemplary embodiment 1 was set at approximately −1,000 ppm/° C. (which is change rate of resistance in between 25° C. and 200° C., and hereinafter the same in values of change rate of resistance as well). Incidentally, the change rate of the resistance of the paste containing silver palladium, which is used in a conventional heating member, is 0 to approximately 1,000 ppm/° C. (of which the values vary depending on ratio of silver to palladium).
For the purpose of being compared to the present exemplary embodiment 1, a heating member 30 in a comparative example (which is referred to as Comparative example 1 hereinafter) will now be described below.
In
A heat generating resistor 17 is shown. The heat generating resistor 17 is obtained by preparing a paste by kneading a powder of silver palladium and glass (inorganic binder) together with an organic binder, and screen-printing the paste on a substrate 7 made from aluminum oxide to form a film of a strip shape having a width of 3.1 mm, a length of 220 mm and a thickness of approximately 10 μm. The heat generating resistor 17 has the same total width as the heat generating resistor 17 in the heating member 3 of the present exemplary embodiment 1. The substrate 7 made from aluminum oxide had the same shape as that of the substrate 7 in the present exemplary embodiment 1. The heat generating resistor 17 used in Conventional example 1 has a sheet resistance of approximately 0.25 Ω/sq (in thickness of 10 μm) at room temperature. The total resistance of the heat generating resistor 17 was set at 18Ω at room temperature, which is the same total resistance as that of the heat generating resistor 6 in the present exemplary embodiment 1. The change rate of the resistance of the heat generating resistor 17 was set at approximately 500 ppm/° C.
The heating member 30 in Comparative example 1 had the same structure as the heating member 3 in the present exemplary embodiment 1, except for the material/shape of the heat generating resistor 17 and the shape of the electro-conductive pattern 18. The heating member 30 in Comparative example 1 employs a heat-resistant glass layer which is compatible with a paste containing silver palladium as an overcoat layer and has a thickness of approximately 50 μm, but the overcoat layer is omitted for simplification in
In the heating member 30 of Comparative example 1, an electric power is supplied to the heat generating resistor 17 in a longitudinal direction of the substrate 7 from power feeding electrodes 9 and 10 and an electro-conductive pattern 18, and an electric current (i) passes through the heat generating resistor 17 in the longitudinal direction of the substrate 7. In the conventional heating member, an electric power is generally supplied in the longitudinal direction of the substrate 7, as in the heating member 30 of Comparative example 1.
When a small size sheet is fed (introduced) to a nipping portion of a fixing apparatus which is provided with a heating member 30 of Comparative example 1, the non-sheet feeding portion raises its temperature, which was described above. The temperature rise of the non-sheet feeding portion will now be described below with reference to a model diagram, while considering the case where the heating member 30 of Comparative example 1 is mounted on a fixing apparatus 107 described in the present exemplary embodiment 1.
When considering the case where a small size sheet having a width of 2 m (=110 mm) is fed for simplification, the area having the resistance of r1 in the central part shall be a sheet-feeding portion, and the area having the resistance of r2 in the end part shall be a non-sheet feeding portion. The temperature of the heating member 30 is controlled through a thermistor which is provided on the sheet-feeding portion, so that the temperature in the non-sheet feeding portion in which the heat is not absorbed by the small size sheet rises more highly than that in the sheet-feeding portion in which the heat is absorbed by the small size sheet. The heat generating resistor 17 shows the PTC characteristics, so that r1 becomes smaller than r2 when the small size sheet is fed. The electric current (i) of the same value passes in the sheet-feeding portion and the non-sheet feeding portion, so that q1 becomes smaller than q2, and the non-sheet feeding portion shows a larger heating value than that in the central part.
A heating member 3 according to the present exemplary embodiment 1 will be also considered with reference to a model diagram.
When considering the case where a small size sheet having a width of 2 m (=110 mm) is fed as in the case of a heating member 30 in Comparative example 1, the area having the resistance of R1 in the central part shall be a sheet-feeding portion, and the area having the resistance of R2 in the end part shall be a non-sheet feeding portion. In the heating member 3 of the present exemplary embodiment 1 as well as the case of the heating member 30 in Comparative example 1, the non-sheet feeding portion shows a higher temperature than the sheet-feeding portion when a small size sheet is fed. The heat generating resistor 6 of the heating member 3 in the present exemplary embodiment 1 shows NTC characteristics, so that R1 is larger than R2 when the small size sheet is fed. Because the electric current (I) of the same value passes through the sheet-feeding portion and the non-sheet feeding portion, Q1 becomes larger than Q2, which means that a heating value in the non-sheet feeding portion becomes smaller than that in the central part, in the case of the heating member 3 according to the present exemplary embodiment 1.
Fixing properties of the heating member 30 in Comparative example 1 are approximately equal to those of the heating member 3 in the present exemplary embodiment 1, because the heat generating resistors have the same total width of 3.1 mm. Accordingly, heating values (=fixing properties) in the sheet-feeding portion generated when the small size sheet is fed are approximately the same, in other words, q1 is equal to Q1. Therefore, q2 becomes larger than Q2, which are the heating values in the non-sheet feeding portion generated when the small size sheet is fed. It is understood from the result that the temperature rise in the non-sheet feeding portion of the heating member 3 in the present exemplary embodiment 1 is smaller than that of the heating member 30 in Comparative example 1.
The comparison test of the temperature rise in a non-sheet feeding portion between a heating member 3 of the present exemplary embodiment 1 and a heating member 30 of Comparative example 1 will now be described below. An image forming apparatus which was mounted with a fixing apparatus provided with the heating member 3 according to the present exemplary embodiment 1 and an image forming apparatus which was mounted with a fixing apparatus provided with the heating member 30 according to Comparative example 1 were prepared, and the fixing apparatuses were sufficiently acclimated to room temperature (25° C.). Then, 100 sheets of recording medium with a postcard size were continuously fed to respective nipping portions. The highest temperatures in the non-sheet feeding portions while the sheets were fed (which were obtained by measuring the temperatures on the backside surface of the heating bodies with a thermocouple) were compared. The fixing apparatuses mounted on the image forming apparatus have the same structure, except for heating bodies 3 and 30. The fixing temperature of the fixing apparatus was set at 230° C. The input voltages to the heating bodies 3 and 30 were set at 100 V, and the process speeds of the image forming apparatuses were set at 200 mm/sec.
The test result is shown in Table 1.
As is illustrated in Table 1, the heating member in the present exemplary embodiment could greatly lower the temperature (approximately by 50° C.) in the non-sheet feeding portion than that in Comparative example 1.
Next, a cardboard having a postcard size and a basis weight of 157 g/m2 was forcibly multi-fed to a nipping portion of a fixing apparatus as a recording medium, and the number of the multi-fed cardboards, which caused the deterioration/damage of the fixing apparatus, was examined. The fixing temperature/input voltage/process speed of the image forming apparatus were set at the same conditions as those set when the temperature rise in the non-sheet feeding portion was measured.
The test result is shown in Table 2.
As is shown in table 2, the heating member 30 in Comparative example 1 was damaged after 4-cardboards feeding or 3-cardboards feeding due to thermal stress generated in a substrate 7 by temperature rise in the non-sheet feeding portion, and the stay and the film of the fixing apparatus and the non-sheet feeding portion of the surface layer of the pressure roller showed recognizable deterioration.
On the other hand, a heating member 3 in the present exemplary embodiment 1 was not damaged in two times of multi-feeding in which the number of cardboards to be multi-fed was increased even to ten, and the stay and the film of a fixing apparatus 107 and the surface layer of the pressure roller showed no recognizable deterioration.
From this result as well, it is understood that the fixing apparatus can greatly decrease the temperature rise in the non-sheet feeding portion by employing the heating member 3 in the present exemplary embodiment 1 therein.
Next, so as to be compared with the present exemplary embodiment 1, a structure of a heating member proposed in Patent document 1 by the present inventors of the present patent application will now be described below. (Hereafter, heating member which has been proposed in Patent document 1 is referred to as Comparative example 2).
A heating member of Comparative example 2 had the same structure as that of a heating member 3 of the present exemplary embodiment 1, except for the material and shape of a heat generating resistor and the shape of an electro-conductive pattern. The same member/portion as that in the heating member 3 of the present exemplary embodiment 1 was designated by the same reference numerals.
A heating member 40 shown in Comparative example 2 employs a paste which contains the completely same graphite/glass as that of the heat generating resistor 6 in the present exemplary embodiment 1 as a main component, for the heat generating resistor 6. A substrate, an electro-conductive pattern, a power feeding electrode and an overcoat layer (which is omitted in
The heating member 40 according to Comparative example 2 has the heat generating resistor 6 divided into four parts. In other words, the heating member 40 in Comparative example 2 has such a shape as to have removed the heat generating resistor 6 in a downstream side from the structure of the heating member 3 in the present exemplary embodiment 1.
A length (a) in one divided area in the heat generating resistor 6 is set at 55 mm (same as that in one area of heat generating resistor 6 in an upstream side in present exemplary embodiment 1) and the width (d) is set at 2.6 mm. The four areas of the heat generating resistor 6 are set so as to have the same shape. The thickness of the heat generating resistor 6 was set at approximately 10 μm which was the same value as in the present exemplary embodiment 1. The length (f) of a gap between the divided areas was set at 0.5 mm. In a transverse direction of a substrate 7, electro-conductive patterns 19-1 and 19-2 are provided on both sides of the heat generating resistor 6 along the longitudinal direction of the substrate 7. Out of the electro-conductive patterns 19-1 and 19-2, the electro-conductive pattern 19-1 which is provided in the outside (upstream side) of the heat generating resistor 6 is connected to the electro-conductive pattern 19-3 which is provided in parallel to the electro-conductive pattern 19-2, in the inside of the edge in the downstream side of the substrate 7. The width (c) of each of the electro-conductive patterns 19-1, 19-2 and 19-3 was set at 0.5 mm. The width (gap) (g) between the electro-conductive pattern 19-2 and the electro-conductive pattern 19-3 was set at 0.5 mm. The width (e) from the edge in the upstream side of the substrate 7 to the electro-conductive pattern 19-1 was set at 0.7 mm. The width (e) from the edge in the upstream side of the substrate 7 to the electro-conductive pattern 19-1, and the width (e) from the edge in the downstream side of the substrate 7 to the electro-conductive pattern 19-3 were set at 0.7 mm respectively. In other words, the heating member 40 according to Comparative example 2 has the same lengths (a), (d), (f) and (g) as those of the heating member 3 according to the present exemplary embodiment 1, and has also the same widths (c) and (e) as those of the heating member 3. Incidentally, the heating member 40 according to Comparative example 2 has the total resistance of the heat generating resistor 6 of 18Ω at room temperature, similarly to the total resistance of the heat generating resistor 6 of the heating member 3 according to the present exemplary embodiment 1. In Comparative example 2, the width of the substrate 7 made from aluminum oxide is set at 6 mm.
A graphite paste has a lower sheet resistance among materials which show NTC characteristics, but has a larger sheet resistance than a paste containing a metal such as silver palladium. Therefore, when a pattern of the heat generating resistor which supplies an electric power in a longitudinal direction as in a heating member 30 according to Comparative example 1 is formed from the graphite paste, the total resistance becomes very large, and accordingly the heat generating resistor cannot be used in a heating member. For instance, when the pattern of the heat generating resistor according to Comparative example 1 in
The pattern in Comparative example 2 is devised so that the heat generating resistor prepared from the graphite paste having the large sheet resistance can provide the total resistance in a range to which a commercial power source can be applied. The heat generating resistor having this structure can effectively use the NTC characteristics of the graphite so as to lower the temperature rise in the non-sheet feeding portion, as was described on a model diagram. However, the heating member 40 according to Comparative example 2 has a problem of fixing properties in a gap between the heat generating resistors 6, which is formed by the essential division in this structure.
A heating member 40 according to Comparative example 2 does not have a heat generating resistor 6 in gaps at three portions in the heat generating resistor 6, and accordingly shows poorer fixing properties in the gaps than those in other portions. In order to compensate the poor fixing properties in the gap portions, a heating member in Patent document 1 compensates poor fixing properties by forming a heat generating resistor so that the shape of the gap can be diagonal. (Heating member having the gap formed into the diagonal shape is referred to as Conventional example 3. See
As was described above, when the process speed of an image forming apparatus is not so fast, it was possible to compensate the fixing properties in the gap portion of the heat generating resistor 6 up to an acceptable level for use, by employing the heating member 50 having a structure as illustrated in Comparative example 3.
However, the higher printing speed in the recent image forming apparatus makes it difficult to secure satisfactory fixing properties in the whole area in a longitudinal direction of a substrate, so that the structure as illustrated in the heating member 50 according to Comparative example 3 is imposing a limitation in securing the fixing properties in the gap of the heat generating resistor 6.
A heating member 3 according to the present exemplary embodiment 1 solves the problem of securing the fixing properties in the gap portion. As was described with reference to
Table 3 shows a result of having compared the heating member 3 according to the present exemplary embodiment 1 with the heating bodies 30, 40 and 50 according to Comparative examples 1 to 3, which were described above, from two viewpoints of a capability of preventing the temperature rise in the non-sheet feeding portion and a capability of reliably showing uniform and adequate fixing properties (securing fixing properties in gap portion) over the whole images.
As is illustrated in Table 3, it is understood that the heating member 3 according to the present exemplary embodiment 1 has a structure which can prevent the temperature rise in the non-sheet feeding portion and can uniformly and adequately secure the fixing properties over the whole image, at the same time.
In a heating member 3 of the present exemplary embodiment 1, a heat generating resistor 6 in an upstream side has the same width as a heat generating resistor 6 in a downstream side, and the division number of the heat generating resistor 6 in the upstream side is different from that of the heat generating resistor 6 in the downstream side, so that the resistance of the heat generating resistor 6 in the upstream side becomes larger than that of the heat generating resistor 6 in the downstream side. As long as the position of a gap of the heat generating resistor 6 in the upstream side does not match with that of the heat generating resistor 6 in the downstream side, the heat generating resistor 6 in the upstream side may have the same resistance of the heat generating resistor 6 in the downstream side, or may have a smaller resistance than the heat generating resistor 6 in the downstream side, by adjusting the width or the division number of the heat generating resistor 6.
The heating member 3 according to the present exemplary embodiment 1 employs two lines of heat generating resistors 6 which are the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side, but may have a structure in which three or more heat generating resistors are connected in series.
Furthermore, in the heating member 3 according to the present exemplary embodiment 1, each of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side is equally divided to have the same resistance in one area, but each of the heat generating resistors 6 is not necessarily equally divided. As long as the positions of the gaps between the respective heat generating resistors 6 do not match with each other, the heat generating resistor 6 may not be equally divided, but may give a difference of the resistance among areas of the respectively divided heat generating resistors 6 in a longitudinal direction of a substrate 7 (for instance, by shortening the area in the end part compared to that in the central part).
Thus, the heating member 3 according to the present exemplary embodiment 1 has an advantage as well of being capable of obtaining a desired total resistance suitable for various fixing apparatuses having different specifications by appropriately changing the number of the heat generating resistors, the width, the division number and a method of connecting the heat generating resistors to each other, even though employing a paste having the same sheet resistance.
Another example of a heating member will now be described below.
A heating member shown in the present exemplary embodiment 2 employs a substrate made from aluminum nitride, as a substrate. When aluminum oxide is used as a material of a substrate as in Exemplary embodiment 1, a generally employed structure has a heat generating resistor formed on a topside surface side of the substrate and a thermistor provided on a backside surface side of the substrate (topside surface heat-generation type). On the other hand, when aluminum nitride is used as the material of the substrate, aluminum nitride shows higher thermal conductivity than aluminum oxide. Therefore, a generally employed structure has the heat generating resistor formed in the backside surface side of the substrate and makes the thermistor abut the heat generating resistor from above through an insulating layer and control the temperature. The structure (backside-surface heat-generation type) shows higher fixing efficiency. Accordingly, the backside-surface heat-generation type was employed in the present exemplary embodiment 2 as well.
In the heating member according to the present exemplary embodiment 2, the same member/portion as in the heating member 3 according to Exemplary embodiment 1 is designated by the same reference numeral.
The heating member 3 according to the present exemplary embodiment 2 will now be described below.
The heating member 3 according to the present exemplary embodiment 2 employs a substrate made from aluminum nitride having a width of 7 mm, a length of 270 mm and a thickness of 0.6 mm as a substrate 15. The substrate 7 made from aluminum oxide in Exemplary embodiment 1 has the same width and length as the substrate 15 made from aluminum nitride in the present exemplary embodiment 2, but the thickness was 1 mm. It is due to the following reasons why both the substrate 7 and the substrate 15 have different thicknesses.
When the temperature of the heating member becomes high, a temperature difference in the substrate (temperature difference between a portion in which a heat generating resistor exists and a portion such as the end of the substrate, in which the heat generating resistor does not exist) generates a heat stress. If the heat stress exceeded the breaking strength of the substrate, the substrate is damaged. When the substrate is made to be thick, the strength of the substrate increases, but instead, a heat capacity increases, which is disadvantageous to quick start. In the case of the topside-surface heat-generation type, the high heat capacity causes a problem that the responsibility of the thermistor is aggravated. In the case of a backside-surface heat-generation type, the fixing efficiency is aggravated because the heat is hard to be conducted to a recording medium. Accordingly, the substrate can be as thin as possible in a capable range of sufficiently withstanding the heat stress which can be generated in the substrate. The substrate made from aluminum nitride has a higher thermal conductivity than the substrate made from aluminum oxide, so that a temperature difference generated in the substrate is small and the heat stress which is generated in the substrate is small. From the viewpoint that the substrate shall be as thin as possible in a range of making the heat stress generated in the substrate not to damage the substrate, the substrate made from aluminum oxide has selected a thickness of 1 mm, and the substrate made from aluminum nitride selects a thickness of 0.6 mm.
The heating member 3 according to the present exemplary embodiment 2 has a heat generating resistor 6 provided on the backside surface (non-sliding surface of film) of a substrate 15. Two heat generating resistors 6 are provided in parallel along a longitudinal direction of the substrate 15 in a transverse direction of the substrate 15, similarly to those in Exemplary embodiment 1. In the present exemplary embodiment 2 as well, a heat generating resistor 6 which is provided in the inside of an end of a substrate in an upstream side of a transportation direction of a recording medium is referred to as the heat generating resistor 6 in the upstream side. In addition, a heat generating resistor 6 which is provided in the inside of an end of a substrate in a downstream side of the transportation direction of the recording medium is referred to as the heat generating resistor 6 in the downstream side. The heat generating resistors 6 in the upstream side and the heat generating resistors 6 in the downstream side are overcoated with an insulating layer 20. The insulating layer 20 is a heat-resistant glass layer having a thickness of approximately 50 μm. This insulating layer 20 is provided in order to electrically insulate the heat generating resistors 6 in the upstream side and the heat generating resistors 6 in the downstream side from other members. On the other hand, a sliding layer 21 is provided on the topside surface (sliding surface of film) of the substrate 15. The sliding layer 21 is provided there in order to secure sliding properties between the heating member 3 and the inner face of a film 2. In the present exemplary embodiment 2, a heat-resistant glass layer having a thickness of approximately 10 μm was used as the sliding layer 21.
The heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side are obtained by forming a film of a paste which has been prepared by mixing a powder of graphite and glass (inorganic binder) with an organic binder, on the substrate 15 with a screen printing technique. The same material as the heat generating resistor 6 according to Exemplary embodiment 1 was used for the material of the heat generating resistor 6. The shape and characteristics of the heat generating resistor 6 will be described later.
In the transverse direction of the substrate 15, electro-conductive patterns 22-1 and 22-2 are provided on both sides of the heat generating resistor 6 in the upstream side along the longitudinal direction of the substrate 15. In the transverse direction of the substrate 15, electro-conductive patterns 22-3 and 22-4 are provided on both sides of the heat generating resistor 6 in the downstream side along the longitudinal direction of the substrate 15. The electro-conductive pattern 22-2 which is provided in the inside (downstream side) of the heat generating resistor 6 in the upstream side is connected to the electro-conductive pattern 22-4 which is provided in the outside (downstream side) of the heat generating resistor 6 in the downstream side. A power feeding electrode 9 is connected to the electro-conductive pattern 22-1, and a power feeding electrode 10 to the electro-conductive pattern 22-4 respectively.
In a heating member 3 in the present exemplary embodiment 2 as well, an electric power is supplied to power feeding electrodes 9 and 10 which are provided in the inner side of an end in a longitudinal direction of a substrate 7 from a power source 13 (
A manufacturing method of the heating member 3 in the present exemplary embodiment 2 is also similar to that of the heating member 3 in Exemplary embodiment 1. A sliding layer 16 is screen-printed on the topside surface of the substrate 15 made from aluminum nitride. The sliding layer 16 is dried, and then baked at a temperature of approximately 800° C. Subsequently, the power feeding electrodes 9 and 10 and the electro-conductive patterns 22-1, 22-2, 22-3 and 22-4 are simultaneously screen-printed on the backside surface of the substrate 15. The power feeding electrodes 9 and 10 and the electro-conductive patterns 22-1, 22-2, 22-3 and 22-4 are dried, and then are baked at a temperature of approximately 800° C. Subsequently, the above described graphite paste is screen-printed on the backside surface of the substrate 15, dried and baked to form the heat generating resistor 6. The surface of graphite begins to be oxidized at approximately 700° C., so that the baking temperature was set at approximately 600° C. An insulating layer 20 is screen-printed on the backside surface of the substrate 15, and the insulating layer 20 is dried and baked. In consideration of the heat resistance of the graphite, a glass which can be baked at 400 to 500° C. was selected as a material of the insulating layer 20 (which is the same material of overcoat layer 8 in Exemplary embodiment 1).
Next, the shape and characteristics of the heat generating resistor 6 in the present exemplary embodiment 2 will now be described in detail.
The pattern of a heat generating resistor in the present exemplary embodiment 2 is similar to that in Exemplary embodiment 1. Specifically, the heat generating resistor 6 is divided into two lines of the heat generating resistor 6 in an upstream side and the heat generating resistor 6 in a downstream side, and the divided heat generating resistors 6 are connected in series by electro-conductive patterns 22-1, 22-2, 22-3 and 22-4. The heat generating resistor 6 in the upstream side is divided into four pieces in a longitudinal direction of a substrate 15, and the heat generating resistor in the downstream side is divided into three pieces in the longitudinal direction of the substrate 15. In the heating member 3 of the present exemplary embodiment 2, the heat generating resistor 6 is provided on the backside surface of the substrate 15, so that the pattern of the heat generating resistor and the electro-conductive pattern are formed into a pattern in which the top and bottom of the heat generating resistor and the electro-conductive pattern in Exemplary embodiment 1 are reversed. The feature of the heating member 3 in the present exemplary embodiment 2 is also that the division number of the heat generating resistor 6 in the upstream side is different from that of the heat generating resistor 6 in the downstream side, and simultaneously positions of gaps formed by the division do not match with each other in the transverse direction of the substrate 15.
Similarly to Exemplary embodiment 1, electro-conductive patterns 22-1, 22-2, 22-3 and 22-4 are provided on sides of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side so as to supply an electric power to one each area of the divided heat generating resistors in the transverse direction of the substrate 15. The divided areas are connected to each other in series in the longitudinal direction of the substrate 15 by the electro-conductive patterns 22-1, 22-2, 22-3 and 22-4. Therefore, when the electric power is supplied to power feeding electrodes 9 and 10, the electric current I passes through each of areas in a direction shown by the arrows in
A length (a) of one area in the heat generating resistor 6 in the upstream side, a length (b) of one area in the heat generating resistor 6 in the downstream side and a length (f) of a gap between the divided areas were set at the same lengths (a), (b) and (f) respectively in Exemplary embodiment 1. The width of the heat generating resistor 6 was set at the same value as the width (d) in Exemplary embodiment 1. A width (gap) (g) between the electro-conductive pattern 22-2 in the inside of the heat generating resistor 6 in the upstream side and the electro-conductive pattern 22-3 in the inside of the heat generating resistor 6 in the downstream side was also set at the same value as in Exemplary embodiment 1. The width (e) from the edge in an upstream side of the substrate 15 to the electro-conductive pattern 22-1 in the outside of the of the heat generating resistor 6 in the upstream side, and the width (e) from the edge in a downstream side of the substrate 15 to the electro-conductive pattern 22-4 in the outside of the heat generating resistor 6 in the downstream side were also set at the same value as the width (e) in Exemplary embodiment 1. The thicknesses of both of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side were set at approximately 10 μm which was the same value as in Exemplary embodiment 1.
The sheet resistance of the graphite paste was set at approximately 100 Ω/sq (in thickness of 10 μm) at room temperature. The total resistance of the heat generating resistors 6 in the downstream side (total resistance of four areas) is 11.5Ω at room temperature. The total resistance of the heat generating resistors 6 in the upstream side (total resistance of three areas) is 6.5Ω at room temperature. The resistance in total of the resistance of the heat generating resistors 6 in the upstream side and the resistance of the heat generating resistors 6 in the downstream side (resistance between power feeding electrodes 9 and 10) is 18Ω at room temperature. The values of these resistances are set similarly to Exemplary embodiment 1. The change rate of the resistance of the heat generating resistor 6 was set at approximately −1,000 ppm/° C., similarly to in Exemplary embodiment 1.
A heating member 3 in the present exemplary embodiment 2 also shows an effect of lowering the temperature rise in a non-sheet feeding portion for a heating member 30 as in Comparative example 1, through the same mechanism as in the heating member 3 of Exemplary embodiment 1.
In addition, the heating member 3 in the present exemplary embodiment 2 has more excellent fixing properties in gap portions formed by the division of the heat generating resistor 6 in an upstream side and the heat generating resistor 6 in a downstream side than a heating member 3 in Exemplary embodiment 1, due to the following reason.
The heating member 3 of the present exemplary embodiment 2 is a backside-surface heat-generation type which uses aluminum nitride for the material of the substrate 15, and shows a higher fixing efficiency than a topside-surface heat-generation type which uses aluminum oxide for the material of the substrate 15 as in a heating member 3 of Exemplary embodiment 1. It is an easy method for determining the fixing efficiency, in other words, determining whether the heat which has been generated in the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side is efficiently conducted to a recording medium to compare a heat resistance toward a topside surface direction of the heating member with a heat resistance toward a backside surface direction of the heating member, which are directions viewed from the heat generating resistor 6. The heat resistance is a physical quantity for expressing the easiness of thermal conduction, and when a rectangular solid is considered to have a thickness (d) (m) and an area (A) (m2) of a face which is orthogonal to the thickness direction, a heat resistance (R) (K/W) in the thickness direction of the rectangular solid is defined by the following formula.
R=d/(λ·A)
Here, λ represents thermal conductivity (W/m·K) in the thickness direction of the rectangular solid.
The smaller the heat resistance is, the more easily heat is conducted, and the larger the heat resistance is, the more hardly heat is conducted. Accordingly, it can be said that when the heating member has a smaller heat resistance toward the direction of its topside surface and has a larger heat resistance toward the direction of its backside surface when viewed from the heat generating resistor 6, the heating member efficiently conducts the heat to a recording medium and shows adequate fixing efficiency.
As a result of having calculated heat resistances in the heating member 3 having a structure in Exemplary embodiment 1 and the heating member 3 having a structure in the present exemplary embodiment 2, values as shown in Table 4 are obtained. The thermal conductivities of materials employed in the heating member 3 of Exemplary embodiment 1 and in the heating member 3 of the present exemplary embodiment 2 are as follows. In the above calculation, (A) is presumed to be 1 m2 for simplification.
substrate of aluminum oxide: 20 W/m·K overcoat layer: 2 W/m·K
substrate of aluminum nitride: 170 W/m·K insulating layer/sliding layer: 2 W/m·K
A ratio of heat resistances in Table 4 is a value obtained by dividing the heat resistance in the topside surface side by the heat resistance in the backside surface side. As the value is smaller, the heat resistance in the topside surface side becomes smaller than that in the backside surface side, and accordingly the fixing efficiency is more excellent.
As is illustrated in Table 4, the heating member 3 in the present exemplary embodiment 2 has a smaller ratio of the heat resistances than that in the heating member 3 of Exemplary embodiment 1. It means, in other words, that the heating member 3 of the present exemplary embodiment 2 is easier to conduct heat to the topside surface of the heating member from the heat generating resistor 6. In the above described calculation, it is assumed that heat propagates toward a direction orthogonal to the topside surface of the heating member, but the heat naturally conducts toward a direction diagonal to the topside surface of the heating member, and the heating member 3 of the present exemplary embodiment 2 has more excellent heat conducting properties toward the diagonal direction as well than the heating member 3 of Exemplary embodiment 1.
It is considered that the heating member having more excellent heat conducting properties toward the direction diagonal to the topside surface of the heating member can compensate for the aggravation of fixing properties in a gap formed by the division of the heat generating resistor 6, with the heat conducted from the periphery of the gap. Therefore, the heating member 3 of the present exemplary embodiment 2 shows more excellent fixing properties in the gap than the heating member 3 of Exemplary embodiment 1. It means, in other words, that a difference of the temperature between a gap portion formed in the heat generating resistor 6 and other portions is more averaged and approaches to a more uniform value while the heat conducts to the topside surface of the heating member, in the heating member 3 of the present exemplary embodiment 2.
Therefore, the heating member 3 of the present exemplary embodiment 2 is more excellent than the heating member 3 of Exemplary embodiment 1, from the viewpoint of showing uniform and adequate fixing properties for the whole image. Accordingly, the heating member 3 of the present exemplary embodiment 2 has such a structure as to be easier to cope with a tendency of further increasing a speed of an image forming apparatus than the heating member 3 of Exemplary embodiment 1.
In a heating member 3 of the present exemplary embodiment 2, a heat generating resistor 6 in an upstream side has the same width as a heat generating resistor 6 in a downstream side, the division number of the heat generating resistor 6 in the upstream side is different from that of the heat generating resistor 6 in the downstream side, and the resistance of the heat generating resistor 6 in the upstream side is made to be larger than that of the heat generating resistor 6 in the downstream side. As long as the position of a gap of the heat generating resistor 6 in the upstream side does not match with that of the heat generating resistor 6 in the downstream side, the heat generating resistor 6 in the upstream side may have the same resistance of the heat generating resistor 6 in the downstream side, or may have a larger resistance than the heat generating resistor 6 in the downstream side, by adjusting the width or the division number of the heat generating resistor 6.
Furthermore, in the heating member 3 according to the present exemplary embodiment 2, each of the heat generating resistor 6 in the upstream side and the heat generating resistor 6 in the downstream side is equally divided to have the same resistance in one area, but each of the heat generating resistors 6 does not necessarily need to be equally divided. As long as the positions of the gaps between the respective heat generating resistors 6 do not match with each other, the heat generating resistor 6 may not be equally divided, but may give a difference of the resistance among areas of the respectively divided heat generating resistors 6 in a longitudinal direction of substrates 7 and 15 (for instance, by shortening the area in the end part compared to that in the central part).
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 Applications No. 2008-065155, filed Mar. 14, 2008, and No. 2009-053233, filed Mar. 6, 2009, which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008-065155(PAT.) | Mar 2008 | JP | national |
| 2009-053233(PAT.) | Mar 2009 | JP | national |
