Patent Grant
9442443
1. Field of the Invention
The present invention relates to a roller and a fixing apparatus including the roller.
2. Description of the Related Art
As a fixing apparatus that is included in an electro-photographic printer or copier, a film heating type fixing apparatus is known, which is constituted by a plate heater, a fixing film that moves with contacting the heater, and a pressure roller with which the heater forms a nip portion via the fixing film.
In the film heating type fixing apparatus, if small-sized recording materials are continuously printed, a temperature rise in a non-paper pressing region, that is, an excessive rise of temperature in a region where film or recording material of the pressure roller does not pass (non-paper passing region), is easily generated. If the state of the excessive temperature rise in the non-paper passing region continues, the pressure roller or the like tends to be damaged.
Therefore, in Japanese Patent Application Laid-open No. 2009-31772, a pressure roller, having an elastic layer constituted by two elastic layers whose thermal conductivity values are concentrically different around the core of the roller, is disclosed as a means of decreasing the above-mentioned temperature rise in the non-paper passing region. In this pressure roller, the thermal conductivity of the pressure roller in the longitudinal direction is increased by dispersing thermo-conductive filler, which is oriented in the longitudinal direction, in the surface side elastic layer, whereby the temperature unevenness of the pressure roller in the longitudinal direction is decreased. Furthermore, the thermal conductivity of the lower side elastic layer is set to be lower than the thermal conductivity of the surface side elastic layer, whereby the outflow of heat to the core is controlled.
However, in some types of pressure rollers having two elastic layers like this, a tapered portion is created at the edge of the elastic layers. If such a pressure roller is installed in the film heating type fixing apparatus and continuous printing is performed, it is observed that a portion of the surface of the fixing film, where an area around the tapered portion of the pressure roller contacts, is subject to abrasion more so than the surface where an untapered area contacts. The abrasion generated on the surface of the fixing film is hereafter called “surface layer abrasion”.
If an area where the hardness of the elastic layer is high is generated in an area near the tapered portion, created at the edge of the elastic layer of the pressure roller, the surface layer abrasion worsens, which is a problem.
An object of the present invention is to provide a roller used for a fixing apparatus, comprising: a core; a first elastic layer that is formed outside the core and includes a first tapered portion on an edge of the roller in an axis direction; and a second elastic layer that is formed outside the first elastic layer and includes a second tapered portion on the edge in the axis direction on the same side as the first elastic layer. The second elastic layer has a hardness that is higher than the hardness of the first elastic layer. A second start point, which is a start point of the second tapered portion, is set in a position closer to the center of the roller in the axis direction than a first start point which is a start point of the first tapered portion.
Another object of the present invention is to provide a roller used for a fixing apparatus, comprising: a core; and an elastic layer that is formed outside the core, the elastic layer including a first elastic layer and a second elastic layer formed outside the first elastic layer and having a hardness that is higher than the hardness of the first elastic layer. A tapered portion is formed on an edge of the elastic layer in an axis direction, and the tapered portion has a region where the ratio of the thickness of the second elastic layer to the thickness of the first elastic layer decreases gradually as a position approaches an edge of the roller in the axis direction on the side where the tapered portion is formed.
Another object of the present invention is to provide a roller used for a fixing apparatus, comprising: a core; a first elastic layer that is formed outside the core and includes a first tapered portion on an edge of the roller in an axis direction; and a second elastic layer that is formed outside the first elastic layer and includes a second tapered portion on the edge in the axis direction on the same side as the first elastic layer. The second elastic layer has a hardness that is higher than the hardness of the first elastic layer. A first start point, which is a start point of the first tapered portion, is set in a position closer to the center of the roller in the axis direction than a second start point, which is a start point of the second tapered portion.
Another object of the present invention is to provide a roller used for a fixing apparatus, comprising: a core; and an elastic layer that is formed outside the core, the elastic layer including a first elastic layer and a second elastic layer formed outside the first elastic layer and having a hardness that is higher than the hardness of the first elastic layer. A tapered portion is formed on an edge of the elastic layer in the axis direction. The tapered portion has a region where the ratio of the thickness of the second elastic layer to the thickness of the first elastic layer increases gradually as a position approaches the edge of the roller in the axis direction on the side where the tapered portion is formed.
Another object of the present invention is to provide a fixing apparatus that conveys and heats a recording material bearing a toner image at a nip portion, comprising: a heating rotating member; and a roller that contacts the heating rotating member and forms the nip portion. The roller includes a core, a first elastic layer that is formed outside the core, and a second elastic layer formed outside the first elastic layer and having a hardness that is higher than the hardness of the first elastic layer. A first tapered portion is formed on an edge of the first elastic layer in an axis direction of the roller, and a second tapered portion is formed on an edge of the second elastic layer in the axis direction. A second start point, which is a start point of the second tapered portion, is set in a position closer to the center of the roller in the axis than a first start point which is a start point of the first tapered portion.
Another object of the present invention is to provide a fixing apparatus that conveys and heats a recording material bearing a toner image at a nip portion, comprising: a heating rotating member; and a roller that contacts the heating rotating member and forms the nip portion. The roller includes a core, a first elastic layer that is formed outside the core, and a second elastic layer formed outside the first elastic layer and having a hardness that is higher than the hardness of the first elastic layer. A first tapered portion is formed on an edge of the first elastic layer in the axis direction of the roller, and a second tapered portion is formed on an edge of the second elastic layer in the axis direction. A first start point, which is a start point of the first tapered portion, is set in a position closer to the center of the roller than a second start point, which is a start point of the second tapered portion.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Hereinafter, embodiments of the present invention will be described in detail based on practical examples with reference to the drawings. Dimensions, materials, shapes, relative positions or the like of components described in the embodiments should be appropriately changed according to the configuration and various conditions of the apparatus to which the invention is applied. In other words, the scope of the present invention is not limited to the following embodiments.
An overview of the configuration of an electro-photographic type laser beam printer will be described with reference to
The image forming apparatus according to the present embodiment has an electro-photographic photoreceptor (hereafter called “photosensitive drum”) 1 as a rotating drum type image bearing member. The photosensitive drum 1 is constituted by a photosensitive material layer of OPC, amorphous Se, amorphous Si or the like formed on an outer peripheral surface of a cylinder (drum) type conductive substrate made of aluminum, nickel or the like.
The photosensitive drum 1 is drum driven in the arrow R1 direction (clockwise) in
The latent image formed on the surface of the photosensitive drum 1 is developed by the toner T supplied by a developing device 4 (developing unit). The developed latent image is visualized and a toner image (developer image) is formed on the surface of the photosensitive drum 1. For the developing method, a jumping developing method, a two-component developing method, a FEED developing method or the like is used, and the developing method is often used with a combination of image exposure and reversal development.
On the other hand, recording materials P, which are loaded and stored in a feeding cassette 9, are fed one at a time by the driving of a feeding roller 8 to a resist roller 11 by way of a sheet path, which includes a guide 10 and the resist roller 11. The resist roller 11 feeds recording materials P to a transfer nip portion between the surface of the photosensitive drum 1 and the outer peripheral surface (surface) of the transfer roller 5 at a predetermined control timing. Recording materials P are held and conveyed by the transfer nip portion T, and during this conveying process, the toner image on the surface of the photosensitive drum 1 is sequentially transferred onto the recording materials by the transfer bias applied to the transfer roller 5. As a result, each recording material P bears an unfixed toner image.
Each recording material P bearing the unfixed toner image is sequentially separated from the surface of the photosensitive drum 1, and is discharged from the transfer nip portion, and enters a nip portion N of the fixing apparatus 6 via a conveyance guide. The recording material P receives heat and pressure by the nip portion N of the fixing apparatus 6, whereby the toner image is heated and fixed to the surface of the recording material P. The recording material P that exited from the fixing apparatus 6 is discharged to a discharge tray 16 via a sheet path, which includes a conveyance roller 13, a guide 14 and a discharge roller 15.
The surface of the photosensitive drum 1, after the recording material P is separated, is cleaned by a cleaning apparatus 7 (cleaning unit) which removes adhering contaminants, such as untransferred toner, and is then repeatedly used for forming images. The image forming apparatus of the present embodiment is an A3 sized paper-supported printer, and the print speed thereof is 50 ppm (A4, landscape). The toner has styrene-acrylic resin as a base material, to which a charge control agent, a magnetic body, silica or the like, are internally or externally added as required, and has a glass transition point of 55to 65° C.
Next, details on the configuration of the fixing apparatus of the image forming apparatus according to the present embodiment will be described with reference to
The fixing apparatus 6 of the present embodiment is a film heating type fixing apparatus. As shown in
A film guide member (stay) 21 is a gutter-shaped member, which is formed in the longitudinal direction, and has a semicircular cross-sectional shape. The heater 22 is held in a groove, which is formed approximately at the center of the bottom face of the film guide member 21 along the longitudinal direction. The film 23 is an endless belt type (cylindrical) heat resistant film, which is flexible and loosely inserted into the film guide member 21. The driving force of a driving source M is transferred to the pressure roller 24 via such a power transfer mechanism as a gear (not illustrated), and the pressure roller 24 is rotary-driven in the arrow R3 direction (counterclockwise) at a predetermined peripheral velocity. The film 23 and the pressure roller 24 constitute a fixing nip portion N, which holds and conveys each recording material P, and fixes the unfixed toner on the recording material P.
The film guide member 21 is a molding made of heat resistant resin, such as PPS (polyphenylene sulfite) or liquid crystal polymer. The heater 22 is a heater made of low heat capacity ceramic. The heater 22 of the present embodiment includes a thin plate type heater substrate 22a, which is long sideways and made of alumina or the like, and a linear or narrow strip type electric heating element (resistance heating element) 22b,which is made of Ag/Pd or the like, formed in the longitudinal direction on the surface side (film sliding surface side) of the heater substrate 22a. The heater 22 also has a thin surface protective layer 22c, such as a glass layer, to cover and protect the electric heating element 22b. A thermometric element 25, such as a thermistor, is disposed on the rear surface side of the heater substrate 22a. This heater 22 is controlled so as to quickly heat up by the power supplied to the electric heating element 22b, then maintains a predetermined fixation temperature (target temperature) by a power control system (not illustrated) including the thermometric element 25.
To decrease the heat capacity and make startup quicker, the film 23 as the heating rotating member is a single layer film whose total film thickness is 100 μm or less, preferably 60 μm or less and 20 μm or more, or a composite layer film in which a releasing layer is coated on the surface of the base film. Examples of the materials used for the single layer film are: polytetrafluoroethylene (PTFE), tetrafluoroethylene-perfluoro alkyl vinyl ether (PFA) and PPS, which have, for example, good heat resistance, mold releasability, strength and durability. Examples of materials used for the base film are: polyimide, polyamide imide, polyether ether ketone (PEEK) and polyether sulfone (PES). Examples of materials used for the release layer are: PTFE, PFA and tetrafluoroethylene-perfluoro hexafluoropropylene (FEP).
The pressure roller 24 has a core 24d formed of iron, aluminum or the like, and a plurality of elastic layers formed of later mentioned materials using a later mentioned manufacturing method. The surface of the pressure roller 24 is pressed with a predetermined pressing force by a predetermined pressure mechanism (not illustrated) so as to press the surface protective layer 22c of the heater 22 via the film 23. According to this pressing force, the elastic layer 24b of the pressure roller 24 causes elastic deformation, and a nip portion N having a predetermined width is formed between the surface of the pressure roller 24 and the surface of the film 23.
The film 23 follows the rotation of the pressure roller 24 when the pressure roller 24 is rotary-driven in the arrow R2 direction (counterclockwise) in
In the state where the film 23 is rotated by the rotary driving of the pressure roller 24 and the heater 22 is started and controlled to the predetermined fixing temperature, a recording material P bearing a unfixed toner image t is introduced into the nip portion N. The recording material P is held between the surface of the film 23 and the surface of the pressure roller 24 in the nip portion N, and is conveyed in this state. In this conveying process, the heat of the heater 22 is applied to the toner image t via the film 23, and the nip pressure of the nip portion N is also applied to the toner image t. As a result, the toner image t is heated and fixed to the surface of the recording material P. The recording material P that exited from the nip portion N is separated from the surface of the film 23, and is then conveyed and discharged from the fixing apparatus 6.
A heater whose heat capacity is small and whose temperature rises quickly is used in the film heating type fixing apparatus 6 of the present embodiment, and hence the time for the heater 22 to reach a predetermined fixation temperature can be decreased dramatically. Therefore, the fixing apparatus 6 can easily rise to a high fixation temperature even when starting up from room temperature. This means that standby temperature control is unnecessary when printing is not performed and the fixing apparatus 6 is in standby status, and power can be conserved. With substantial tension not being generated in the rotating film 23 except in the nip portion N and the structure of the fixing apparatus 6 being simplified, only a flange member (not illustrated) is disposed to support the edge of the film 23 as a unit to prevent movement of the film from shifting to one side.
Details of a pressure roller of Practical Example 1 will be described with reference to
<Layer Configuration of Pressure Roller>
The pressure roller 24 of Practical Example 1 includes a core 24d, which is a cylindrical shaft, and an elastic layer 24a, which is a first elastic layer disposed on or outside the outer periphery of the core 24d. The pressure roller 24 also has an elastic layer 24b, which is a second elastic layer disposed on (outside) the outer periphery of the elastic layer 24a, and the elastic layer 24b has a higher thermal conductivity and higher hardness than that of the elastic layer 24a. The pressure roller 24 also has a release layer 24c on the outer periphery of the thermal conductive elastic layer 24b.
In Practical Example 1, the rubber hardness H1 of the rubber material used for the elastic layer 24a and the rubber hardness H2 of the rubber material used for the elastic layer 24b satisfy the relationship of H1<H2. In concrete terms, in Practical Example 1, the elastic layer 24a is a solid rubber layer made of silicon rubber with a 17° JISA hardness, and the elastic layer 24b is a rubber layer made of silicon rubber with a 60° JISA hardness, in which a thermo-conductive filler oriented in the longitudinal direction is dispersed. Generally, the rubber hardness tends to increase if the thermo-conductive filler is dispersed.
Here the thickness d of the entire elastic layer used for the pressure roller 24, which is a total of the thickness (width in the diameter direction) d1 of the elastic layer 24a and the thickness (width in the diameter direction) d2 of the elastic layer 24b, is preferably 2 to 10 mm. In the configuration of Practical Example 1, the thickness d1b of the elastic layer 24a in the center portion (portion excluding the tapered portion (diameter-reducing portion)) of the pressure roller 24 is 3 mm, the thickness d2b of the elastic layer 24b is 1 mm, and the thickness d of the entire elastic layer is 4 mm. The hardness of the pressure roller 24 having this configuration, measured by an Ascker-C hardness meter, was 56°.
<Layer Configuration of Edge of Pressure Roller>
In Practical Example 1, the diameters of both edges of the pressure roller 24 are smaller than the diameter of the center portion. In other words, as the cross-section in
It is assumed that the position of the end face S of the elastic layer in the rotation axis direction is 0, and the distances from the end face S to the taper start points A, a and b are assumed to be distances A, a and b respectively. In this case, the distances A, a and b have a relationship of a≦b=A. In Practical Example 1, in concrete terms, the distance A of the taper start point A and the distance b of the taper start point b are assumed to be 1.5 mm, and the distance a of the taper start point a is assumed to be 1.0 mm.
In Practical Example 1, it is assumed that the inclination when the outer diameter of the elastic layer 24a decreases as it approaches the end face S is approximately the same as the inclination when the outer diameter of the elastic layer 24b decreases as it approaches the end face S. The ratio of the thickness d1a of the elastic layer 24a and the thickness d2a of the elastic layer 24b at the taper start point a and the ratio of the thickness d1b of the elastic layer 24a and the thickness d2b of the elastic layer 24b at the taper start point b satisfy the following relationship: d2a/d1a≦d2b/d1b.
It is assumed that the thickness of the elastic layer 24a at an arbitrary position x, between the taper start point A to the taper start point a, is d1x, and the thickness of the elastic layer 24b at the position x is d2x. These thicknesses satisfy the relationship of d2a/d1a≦d2x/d1x≦d2b/d1b. In other words, the ratio of the thickness of the elastic layer 24b having a higher hardness decreases as a position moves from the taper start point A (taper start position b) to the taper start point a (edge side). Therefore, the hardness of the elastic layer as a whole in an area around the taper start point A decreases, and the elastic layer becomes softer.
<Effect of Practical Example 1>
An effect of using the configuration of Practical Example 1 will be described. As shown in
To satisfy this relationship, Practical Example 1 is configured such that the taper start point a of the elastic layer 24a having a low hardness is located closer to the edge in the rotation axis direction (axis direction) than the taper start point b of the elastic layer 24b having a higher hardness. In other words, the taper start point b is in a position closer to the center of the pressure roller 24 than the taper start point a. Therefore, the direction from the center to the edge of the pressure roller 24 is the same as the direction from the taper start point b to the taper start point a in the axis direction.
Hence, in the region between the taper start point b and the taper start point a in the axis direction, the outer diameter of the elastic layer 24b decreases as a position approaches the edge, but the outer diameter of the elastic layer 24a does not change. This means that the ratio of the thickness d2x/d1x decreases as a position approaches the edge from the taper start point A, as mentioned above. By using this configuration in Practical Example 1, the hardness of the elastic layer as a whole decreases in an area near the taper start point A.
In Practical Example 1, the taper start point a is a position in which the thickness of the elastic layer 24a starts to decrease, and is also a position in which the outer diameter of the elastic layer starts to decrease. The taper start point b is a position in which the thickness of the elastic layer 24b starts to decrease, and is also a position in which the outer diameter of the elastic layer 24b starts to decrease.
In this practical example, the elastic layer 24b is a rubber layer where thermo-conductive filler is dispersed, and the elastic layer 24a is a solid rubber layer, but the present invention is not limited to this. In other words, the effect of this example is demonstrated if the rubber hardness of the elastic layer 24b is higher than the hardness of the rubber of the elastic layer 24a. For example, the elastic layer 24b may be a solid rubber layer, and the elastic layer 24a may be a sponge rubber layer.
In this practical example, the fixing apparatus which includes the film as the heating rotating member is used, but the present invention is not limited to this configuration. For example, the fixing apparatus may include a heat roller as the heating rotating member.
Next, Practical Example 2 will be described with reference to
In Practical Example 2, when the distances from the end face S to the taper start point A of the pressure roller 24, the taper start point a of the elastic layer 24a, and the taper start point b of the elastic layer 24b are A, a and b, the relationship of A, a and b is A=b<a.
As shown in
To satisfy this relationship, Practical Example 2 is configured such that the tapered start point b of the elastic layer 24b having a lower hardness is located closer to the edge in the rotation axis direction than the taper start point a of the elastic layer 24a having a higher hardness.
In other words, in the axial direction of the pressure roller 24 the taper start point a is in a position closer to the center of the pressure roller 24 than the taper start point b. Therefore, the direction from the center to the edge of the pressure roller 24 is the same as the direction from the taper start point a to the taper start point b in the axis direction.
This means that the elastic layer 24a gradually becomes thinner as a position approaches the edge of the pressure roller 24 in the axis direction from the taper start point b, although the thickness of the elastic layer 24b is the same. As a result, the hardness of the elastic layer as a whole decreases as a position approaches the edge from the taper start point A.
Further, as shown in
By using this configuration in Practical Example 2, an abnormal increase of the hardness of the pressure roller near the tapered portion can be suppressed, just like Practical Example 1. As a result, the surface layer abrasion of the heating rotating member, such as the film and the heat roller, can be suppressed.
In Practical Example 2 as well, the effect of this example can be demonstrated if the rubber hardness of the elastic layer 24a is higher than the rubber hardness of the elastic layer 24b. Therefore, the elastic layer 24a may be a solid rubber layer, and the elastic layer 24b may be a sponge rubber layer.
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. 2014-214833, filed Oct. 21, 2014, which is hereby incorporated by reference herein in its entirety.
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