# Patent

## Title
Sliding member for fixing device, fixing device, and image forming apparatus

## Abstract

A sliding member for a fixing device includes at least a fluororesin layer that has a sliding surface, the sliding surface including a first region that is dotted with a plurality of first recesses, and a second region that is dotted with a plurality of second recesses having a diameter larger than the first recesses.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2012-011289 filed Jan. 23, 2012.
BACKGROUND
(i) Technical Field
The present invention relates to a sliding member for a fixing device, a fixing device, and an image forming apparatus.
(ii) Related Art
Image forming apparatuses employing an electrophotographic system, such as copiers and printers, form an image by fixing an unfixed toner image formed on recording paper onto the recording paper by a fixing device.
As an example of this fixing device, a fixing device employing a so-called belt nip system exists. This fixing device is either configured to include a heat roller and a pressure belt placed in contact with the heat roller, or configured to include a heat belt and a pressure roller placed in contact with the heat belt.
In such a fixing device, the belt is pressed against the corresponding roller from its inner surface by a pressing member, and a sliding member is provided between the belt and the pressing member for the purpose of reducing sliding resistance caused by rotation of the belt.
SUMMARY
According to an aspect of the invention, there is provided a sliding member for a fixing device, including at least a fluororesin layer that has a sliding surface, the sliding surface including a first region that is dotted with a plurality of first recesses, and a second region that is dotted with a plurality of second recesses having a diameter larger than the first recesses.



BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiment of the present invention will be described in detail based on the following figures, wherein:
FIGS. 1A to 1C are schematic plan views each illustrating an example of how recesses are formed and placed in a sliding member for a fixing device according to the exemplary embodiment;
FIGS. 2A to 2C are schematic cross-sectional views each illustrating an example of the layer structure of the sliding member for a fixing device according to the exemplary embodiment;
FIG. 3 schematically illustrates the configuration of a fixing device according to a first exemplary embodiment;
FIG. 4 schematically illustrates the configuration of a fixing device according to a second exemplary embodiment; and
FIG. 5 schematically illustrates the configuration of an image forming apparatus according to the exemplary embodiment.



DETAILED DESCRIPTION
Hereinafter, a sliding member for a fixing device, a fixing device, and an image forming apparatus according to an exemplary embodiment are described in detail with reference to the attached figures.
Sliding Member for Fixing Device
FIGS. 1A to 1C are schematic plan views each illustrating an example of how recesses are formed and placed in a sliding member for a fixing device according to the exemplary embodiment. FIGS. 1A to 1C each illustrate a sliding surface in plan view. FIGS. 2A to 2C are each a schematic cross-sectional view of a region (1), illustrating an example of the layer structure of the sliding member for a fixing device according to the exemplary embodiment.
Hereinafter, the “sliding member for a fixing device” is sometimes simply referred to as “sliding member”.
While FIGS. 1A to 1C each illustrate a sliding member whose sliding direction is along the longer direction, the sliding member according to the exemplary embodiment is not limited to this. The sliding member may be a sliding member whose sliding direction is along the shorter direction (that is, a direction orthogonal to the sliding direction is the longer direction).
Recesses in the Sliding Surface of the Sliding Member
As illustrated in FIGS. 1A to 1C, in each of sliding members 101a to 101c according to the exemplary embodiment, a region (1) and a region (2) exist in a sliding surface 112A. The region (1) is dotted with first recesses 112B. The region (2) is dotted with second recesses 112C having a diameter larger than the first recesses 110B.
The first recesses 112B are used mostly for the purpose of retention/supply of oil that is present between the sliding member and a member to be slid. The second recesses 112C are mainly used to recover wear dust generated between the sliding member and the member to be slid, by exploiting their large diameter.
As mentioned above, the sliding member according to the exemplary embodiment includes recesses having the two functions mentioned above in its sliding surface. Therefore, the sliding member may keep friction coefficient from increasing due to the presence of wear dust generated between the sliding member and the member to be slid even after continued use.
This effect is considered to result from the following factors: (1) The retention/supply of oil that is present between the sliding member and the member to be slid keeps the friction coefficient substantially constant; and (2) The recovery of the wear dust generated between the sliding member and the member to be slid by the second recesses reduces clogging of the first recesses, with the result that the oil retention/supply function of the first recesses does not decrease. In particular, placing the region (2) in at least one of the front end portion and the rear end portion with respect to the sliding direction as in the case of the sliding members 101a to 101c allows the first recesses and the second recesses to exhibit their respective functions effectively, thus leading to the effect mentioned above.
Specific examples of the placement of the region (1) dotted with the first recesses and the region (2) dotted with the second recesses are described below.
In the case of the sliding member 101a illustrated in FIG. 1A, the region (2) is provided on the upstream side with respect to the sliding direction. In the case of the sliding member 101b illustrated in FIG. 1B, the region (2) is provided on the downstream side with respect to the sliding direction. The sliding members 101a and 101b are the same, except that their placement is reversed with respect to the sliding direction.
Further, in the case of the sliding member 101c illustrated in FIG. 1C, the region (2) is provided in both the upstream side and the downstream side with respect to the sliding direction.
The term “sliding direction” refers to the direction of sliding as applied to the member to be slid (a rotary body in a fixing device described later), and is the same direction as the rotational direction of the member to be slid.
As illustrated in FIG. 1A, in a case where the region (2) is placed on the upstream side with respect to the sliding direction, it follows that the region (1) is placed on the downstream side of the region (2). In this case, wear dust is recovered in the region (2) on the upstream side, making it less likely for the wear dust to reach the region (1) placed on the downstream side of the region (2). As a result, there is less possibility of the first recesses 112B being clogged by the wear dust, thereby preventing a decrease in the efficiency of oil retention/supply.
As illustrated in FIG. 1B, in a case where the region (2) is placed on the downstream side with respect to the sliding direction, it follows that the region (1) is placed on the upstream side of the region (2). In this case, wear dust generated in the region (1) placed on the upstream side is immediately recovered by the second recesses 112C. As a result, the efficiency of recovery of the wear dust by the second recesses 112C is high.
Further, as illustrated in FIG. 1C, in a case where the region (2) is placed on both the upstream side and the downstream side with respect to the sliding direction, it follows that the region (1) is placed in the intermediate portion between the upstream and downstream sides. In this case, the efficiency of retention/supply of oil by the first recesses 112B does not decrease, and also the efficiency of recovery of wear dust by the second recesses 112C is high, thus offering an additional effect of keeping friction coefficient from increasing even after more prolonged, continued use.
As illustrated in FIGS. 1A to 1C, the boundary line between the region (1) and the region (2) is defined as a line that passes through the midpoint of the distance between the first and second recesses located adjacent to each other at their closest positions, and extends orthogonally to the sliding direction.
The region (1) dotted with the first recesses 112B is a region dotted with the first recesses that are smaller in diameter than the second recesses. Hence, a large portion of the region (2) other than the recesses is a flat surface.
In the exemplary embodiment, as in the sliding member 101c, the region (1) dotted with the first recesses 112B may exist in the intermediate portion with respect to the sliding direction. This intermediate portion is the region that is subject to the greatest pressure between the sliding member and the member to be slid, and hence a large amount of wear. For this reason, by placing the region (1) with a large flat surface portion in the intermediate portion, durability of the sliding member can be maintained.
Layer Structure of the Sliding Member
Next, the layer structure of the sliding member according to the exemplary embodiment is described.
Sliding members 101d and 101e illustrated in FIGS. 2A and 2B each include a sheet-like substrate 110, and a fluororesin layer 112 provided on top of the substrate 110 (the adhesive layer for adhesion between the substrate 110 and the fluororesin layer 112 is not illustrated).
A sliding member 101f illustrated in FIG. 2C has the fluororesin layer 112 laminated on top of the sheet-like substrate 110 via a fluororesin fiber layer 114 (the adhesive layers for adhesion between the substrate 110 and the fluororesin fiber layer 114, and between the fluororesin fiber layer 114 and the fluororesin layer 112 are not illustrated).
As can be appreciated from its cross-section, in the sliding member 101d illustrated in FIG. 2A, the recesses 112B are defined by the fluororesin layer 112 alone.
In the sliding member 101e illustrated in FIG. 2B, the fluororesin layer 112 has through-holes that extend through the layer in the thickness direction, and the recesses 112B are defined by the through-holes and the surface of the substrate 110. Also, in the sliding member 101f illustrated in FIG. 2C, the recesses are defined by through-holes in the fluororesin layer 112, and the surface of the substrate 110 via the fluororesin fiber layer 114.
In the case of the sliding members 101e and 101f, the depth of the recesses can be increased by adjusting the thickness of the fluororesin layer 112, thereby making it possible to enhance oil retention performance. In particular, the presence of the fluororesin fiber layer 114 between the fluororesin layer 112 and the substrate 110 in the sliding member 101f allows the sliding member 101f to retain even more oil than the sliding member 101e. 
Since FIGS. 2A to 2C are schematic cross-sectional views of the region (1), only the first recesses 112B are described above. In this regard, the second recesses may be formed with the same depth as the first recesses 112B, or may be formed with a different depth.
In each of the sliding members 101d to 101f according to the exemplary embodiment, the fluororesin layer 112 is laminated on top of the substrate 110, and the fluororesin layer 112 that configures the sliding surface 112A is supported by the substrate 110.
This configuration reduces deformation of the fluororesin layer 112 due to the sliding movement between the sliding member and the member to be slid.
In a case where the recesses are defined by the fluororesin layer 112 alone as in the sliding member 101d, the substrate 110 is not necessarily required. As long as the fluororesin layer 112 has a sufficient thickness, the sliding member according to the exemplary embodiment may be a single-layer body configured by the fluororesin layer 112.
Specific Form of Recesses
The shape of the recesses formed in the sliding surface as viewed along a direction orthogonal to the sliding surface may be any shape such as a circle, an ellipse, a quadrangle (rectangle or another polygonal shape), or an irregular shape, as long as the first and second recesses are able to exert their respective functions. From the viewpoint of ease of machining, the shape of the recesses may be a circle as illustrated in FIGS. 1A to 1C.
Examples of the shape along the depth of the recesses as viewed in cross-section as in FIGS. 2A to 2C include a columnar, conical, taper, or inverted taper shape.
An example of the manner of arraying the recesses is to array the recesses at specific intervals in a grid form in one direction and in a direction crossing (i.e., orthogonal to) this direction, as viewed along a direction orthogonal to the sliding surface. The recesses may be arrayed in a staggered grid form as illustrated in FIGS. 1A to 1C. The term “staggered grid (form)” as used with regard to the exemplary embodiment refers to a grid array including multiple contiguous basic arrays. The basic arrays each include four grid points that define a square, a rectangle, or the like, and the central point in the array.
The manner of arraying the recesses is not limited to the grid form as mentioned above. The recesses may be arrayed in such a manner that a part of the grid array is missing, or may be arrayed in an irregular manner.
The manner of arraying as mentioned above is common to both the region (1) dotted with the first recesses and the region (2) dotted with the second recesses. In this regard, the recesses may be arrayed in such a way that when the sliding surface is viewed along the sliding direction with respect to the region (2), at least one second recess exists over the entire width of the region (2). In other words, when the sliding surface is viewed along the sliding direction, there may be no area within the region (2) where no second recess exists. Therefore, no matter in which area along the sliding direction wear dust is generated, it is possible to recover the wear dust. Such a configuration can eliminate imbalance in the recovery of wear dust within the sliding surface.
In some cases, the sliding member has an end portion that does not contact the member to be slid. In such cases, the second recesses may not be formed in the end portion that does not contact the member to be slid.
The manner of arraying the first recesses may satisfy the following conditions from the viewpoints of durability of the sliding surface and influence on the image.
In the region (1) dotted with the first recesses, the area occupied per one first recess in the first region (1) may be not less than 7×10−3 mm2 or approximately 7×10−3 mm2 and not more than 3.2 mm2 or approximately 3.2 mm2 (preferably not less than 0.03 mm2 and not more than 0.8 mm2).
Specifically, in a case where the shape of the first recesses in the sliding surface is a circle, the diameter of the circle may be not less than 100 μm and not more than 2 mm (preferably not less than 150 μm and not more than 1 mm).
Also, in the region (1), the period (array pitch) of the first recesses, that is, the center-to-center distance between adjacent first recesses may be not less than 0.2 mm or approximately 0.2 mm and not more than 2.0 mm or approximately 2.0 mm (preferably not less than 0.3 mm and not more than 1.5 mm).
In particular, from the viewpoint of reducing influence on the image while maintaining oil retention/supply performance, the area per one first recess may be within the above-mentioned range, and the period of the first recesses may be within the above-mentioned range.
Further, the ratio of the area occupied by all the first recesses to the total area of the region (1) may be not less than 10% and not more than 50% (preferably not less than 20% and not more than 45%).
In the area (2) dotted with the second recesses, the diameter of the second recesses may be not less than 300 μm or approximately 300 μm and not more than 1.5 mm or approximately 1.5 mm (preferably not less than 300 μm and not more than 1.0 mm).
In this regard, the “diameter of the second recesses” refers to the diameter of a circle if the shape of the second recesses as viewed along a direction orthogonal to the sliding surface is a circle, and refers to the maximum length in the direction orthogonal to the sliding surface if the second recesses have another shape (e.g., a triangle or an irregular shape).
Setting the diameter of the second recesses to be not less than 300 μm or approximately 300 μm makes the second recesses larger than the diameter of wear dust generally produced between the sliding member and the member to be slid, thereby improving the efficiency of the recovery of wear dust by the second recesses. Also, setting the diameter of the second recesses to be not more than 1.5 mm or approximately 1.5 mm may maintain durability of the sliding member.
Next, a member that configures the sliding member according to the exemplary embodiment is described in detail.
First, the fluororesin layer having the sliding surface which configures the sliding member is described.
The fluororesin layer may be any layer that contains fluororesin as its principal constituent. The fluororesin layer may contain an additive such as a filler as required.
Examples of the resin that configures the fluororesin layer include polytetrafluoroethylene, perfluoroalkoxy alkane, and ethylene-tetrafluoroethylene copolymer.
Among these, as the fluororesin layer 112, a layer containing cross-linked fluororesin as its principal constituent is preferred, in particular, a layer made of cross-linked polytetrafluoroethylene (hereinafter, referred to as “cross-linked PTFE”) is preferred.
The cross-linked PTFE that configures the fluororesin layer is, for example, cross-linked PTFE obtained by crosslinking un-crosslinked PTFE by radiating ionizing rays.
Specifically, the cross-linked PTFE is obtained by, for example, crosslinking un-crosslinked PTFE heated at a temperature higher than the crystalline melting point, by radiating ionizing rays (e.g., γ-rays, electron rays, X-rays, neutron rays, or high energy ions) with a radiation dose of not less than 1 KGy and not more than 10 MGy under the absence of oxygen.
The PTFE may contain a copolymerized component other than tetrafluoroethylene (such as perfluoro (alkylvinyl ether), hexafluoropropylene, (perfluoroalkyl)ethylene, or chlorotrifluoroethylene).
The filler and other additives are described.
The filler is added for the purposes of imparting electrical conductivity and improving durability and thermal conductivity.
The kind of the filler may be at least one kind selected from the group including metal oxide particles, silicate mineral, carbon black, and a nitrogen compound.
Among these, ketchen black, graphite, and acetylene black are preferred for imparting electrical conductivity, and graphite, copper, silver, aluminum nitride, boron nitride, aluminum, and the like are preferred for imparting thermal conductivity. One kind of filler material may be used alone, or two or more kinds of filler materials may be used in combination.
The average grain size of the filler may be not less than 0.01 μm and not more than 20 μm, for example.
In the case of using a filler, its content may be not less than 0.01 part by mass and not more than 30 parts by mass with respect to 100 parts by mass of the fluororesin component, for example.
The fluororesin layer may contain additives other than a filler as suited to the intended purpose.
The thickness of the fluororesin layer may be set in accordance with the rigidity of the layer, the kind or shape of the substrate placed adjacent to the layer, and the like. Normally, the thickness of the fluororesin layer is set within the range of 20 μm to 500 μm (preferably not less than 50 μm and not more than 400 μm).
In a case where the sliding member according to the exemplary embodiment is configured by a single-layer body of fluororesin layer, the thickness of the fluororesin layer may be set within a range not less than 200 μm and not more than 400 μm from the viewpoints of shape retention, durability, and the like.
Next, the sheet-like substrate is described.
The sheet-like substrate contains, for example, a resin material, and an additive such as a filler as required.
Examples of the resin material include polyimide resin, polyamide resin, polyamide-imide resin, polyether etherester resin, polyallylate resin, polyester resin, and polyester resin added with a reinforcing material. Among these, polyimide resin is preferred for its high heat resistance and mechanical strength.
The thickness of the sheet-like substrate is set within a range not less than 50 μm and not more than 150 μm (preferably not less than 60 μm and not more than 130 μm), for example.
Next, the fluororesin fiber layer is described.
The fluororesin fiber layer is a layer of fiber that is present between the substrate and the fluororesin layer having through-holes. Since the fluororesin fiber layer has the function of retaining oil within the layer, the oil that exists within each through-hole moves via the fluororesin fiber layer. As a result, the sliding member 101f exhibits superior oil retention performance, and also superior in-plane uniformity.
As the fluororesin fiber layer, for example, PTFE fiber or heat-resistant aramid fiber is used. Of these, the PTFE fiber is preferred for its high heat resistance and high adhesiveness with the fluororesin layer configured by crosslinked PTFE.
Specifically, as the PTFE fiber, Gore fiber cloth FS120-E (product name) (manufactured by W. L. Gore & Associates, Inc.; thickness 120 μm) is used.
Further, an adhesive layer is described.
An adhesive layer exists for adhesion between the substrate and the fluororesin layer, between the substrate and the fluororesin fiber layer, and further, between the fluororesin fiber layer and the fluororesin layer.
Such an adhesive layer may be formed using an existing adhesive such as heat-resistant silicone resin or epoxy-based resin, or may be forming using an adhesive sheet.
For example, in a case where through-holes are formed in the fluororesin layer, an adhesive sheet may be used for the adhesion between this fluororesin layer and the substrate in such a way that the through-holes are not filled in by the adhesive sheet. In this case, an adhesive sheet with holes having the same shape as the through-holes in the fluororesin layer may be used.
Also, as the adhesive layer used for the adhesion between the fluororesin fiber layer and the fluororesin layer in which through-holes are formed, an adhesive sheet with holes having the same shape as the through-holes in the fluororesin layer may be used so that the through-hole is not filled in by the adhesive sheet.
As the adhesive sheet mentioned above, a fluorine-based adhesive sheet is used, which undergoes thermal fusion when heated to temperatures higher than or equal to the melting point to thereby enable adhesion between the substrate and the fluororesin layer, between the substrate and the fluororesin fiber layer, and between the fluororesin fiber layer and the fluororesin layer. In particular, such a fluorine-based adhesive sheet may be used because of the absence of interaction with oil and its ability to reduce degradation due to oil.
Specifically, as the fluorine-based adhesive sheet, Silky Bond (product name) (manufactured by Junkosha Inc.) is used.
Also, the thickness of the adhesive sheet is set within a range not less than 10 μm and not more than 30 μm.
Manufacturing Method
A method of manufacturing each of the sliding members 101d to 101f according to the exemplary embodiment is described.
First, in the case of the sliding member 101d and the sliding member 101e, a sheet that serves as the substrate 110, and the fluororesin layer 112 are prepared. In the case of the sliding member 101f, in addition to these components, a sheet that serves as the fluororesin fiber layer 114 is prepared.
Next, recesses or through-holes are formed in the fluororesin layer 112.
Embossing can be used as a method of forming the recesses in the fluororesin layer.
The embossing used to form recesses at this time is a method of, for example, obtaining an intended shape by applying pressure after heating the fluororesin layer 112 to a temperature higher than or equal to the glass transition temperature of the fluororesin (e.g., crosslinked PTFE) that configures the fluororesin layer 112.
Specifically, this embossing forms recesses in the sliding surface 112A by pressing a die against the sliding surface 112A of the fluororesin layer 112. This die has cylindrical protrusions corresponding to the recesses to be formed, on the pressing surface to be pressed against the sliding surface 112A of the fluororesin layer 112.
In order to form the first and second recesses with different diameters as in the exemplary embodiment, multiple dies having protrusions corresponding to the respective diameters of the first and second recesses may be used.
While such a die is often fabricated by a numerically controlled (NC) machine tool or the like, in the case of forming recesses in the sliding surface 112A of the fluororesin layer 112, the die may be fabricated by etching of a metal. However, fabricating a die by etching introduces a taper in the depth direction and hence is sometimes difficult to control.
Examples of the method of fabricating a die with particularly good precision include use of Ni electrocasting or use of a combination of Ni electrocasting and photolithography (electroforming). Such fabrication methods are favorable in terms of cost and precision, and ease of replication.
Laser machining, machining using a drill, punching using a die, or the like is used to form through-holes in the fluororesin layer 112. Punching may be used when the hole diameter is relatively large (e.g., more than 0.3 mm), and laser may be used when the hole diameter is small (e.g., less than 0.5 mm).
At this time, a CO2 laser, a excimer layer, or the like is used for the laser machining.
In the case of manufacturing the sliding member 101f, through-holes are also formed in the fluorine-based adhesive sheet.
The formation of through-holes is performed in the same manner as the formation of through-holes in the fluororesin layer 112. The shape and position of the through-holes in the fluorine-based adhesive sheet are set so that the through-holes in the fluororesin layer 112 and the through-holes in the fluorine-based adhesive sheet communicate with each other when laminated together. The diameter of the through-holes formed in the fluorine-based adhesive sheet may be the same as that of the through-holes in the fluororesin layer 112, or may be slightly larger than that of the through-holes in the fluororesin layer 112 as long as there is no problem in terms of adhesion strength.
The fluorine-based adhesive sheet used in the manufacture of the sliding member 101e may or may not be provided with through-holes.
Subsequently, in the case of the sliding member 101d, 101e, the sheet serving as the substrate 110 and the fluororesin layer 112 having recesses or through-holes are bonded together by using a fluorine-based adhesive sheet.
This bonding is performed as follows. First, the fluorine-based adhesive sheet is sandwiched between the sheet serving as the substrate 110 and the fluororesin layer 112 having recesses or through-holes, in other words, a laminate including the sheet serving as the substrate 110 and the fluororesin layer 112 with recesses or through-holes is formed. Then, pressure is applied from above and below the laminate, further followed by heating.
In the case of the sliding member 101f, the sheet serving as the substrate 110 and the sheet serving as the fluororesin fiber layer 114 are bonded together by using a fluorine-based adhesive sheet (without through-holes), and the sheet serving as the fluororesin fiber layer 114 and the fluororesin layer 112 having recesses or through-holes are bonded together by using a fluorine-based adhesive sheet with through-holes.
This bonding is performed as follows. First, a laminate including the sheet serving as the substrate 110, the fluorine-based adhesive sheet without through-holes, the sheet serving as the fluororesin fiber layer 114, the fluorine-based adhesive sheet with through-holes, and the fluororesin layer 112 with recesses or through-holes is formed. Then, pressure is applied from above and below the laminate, further followed by heating.
The pressure applied to the laminate at the time of the bonding mentioned above may be set within a range not less than 1.0 MPa and not more than 2.0 MPa, and the heating temperature may be set within a range not less than 320 degrees and not more than 350 degrees.
Each of the sliding members 101d to 101f according to the exemplary embodiment is manufactured through the above-mentioned steps.
Each of the sliding members 101d to 101f according to the exemplary embodiment described above is a skeet-like member having at least the sheet-like substrate 110 and the fluororesin layer 112. The sliding member may be also configured as follows.
That is, the substrate may be configured by a pressing member (pressing pad) made of metal. A sliding pad having a fluororesin layer with recesses or through-holes corresponding to the first and second recesses placed on the surface of this substrate is also an example of the sliding member according to the exemplary embodiment. For example, as described in Proceedings of the 107th Imaging Conference JAPAN 2011, a peeling pad inside a fixing device installed in Color 1000/800 Press manufactured by Fuji Xerox Co., Ltd. exists as such a sliding pad.
Fixing Device
Hereinafter, a fixing device according to the exemplary embodiment is described.
The fixing device according to the exemplary embodiment can take various forms. Hereinafter, a fixing device including a heat roller having a heat source, and a pressure belt against which a pressing pad is pressed is described as a first exemplary embodiment, and a fixing device having a heat belt against which a heat source is pressed, and a pressure roller is described as a second exemplary embodiment.
The sliding member according to the exemplary embodiment described above is applied to a sheet-like sliding member in each of these fixing devices.
In this regard, the inner surface (inner periphery) of the heat belt or pressure belt may have a surface roughness Ra of not less than 0.1 μm or approximately 0.1 μm and not more than 2.0 μm or approximately 2.0 μm (preferably not less than 0.3 μm and not more than 1.5 μm), for example. The heat belt or pressure belt is an example of second rotary body in which the sliding member according to the exemplary embodiment is placed, and with which the sliding surface of the sliding member is brought into contact.
As a result, the sliding resistance between the heat belt or pressure belt as an example of second rotary body, and the sliding member decreases. In a case where a lubricant (oil) is provided between these members, in particular, retention of the lubricant (oil) between these members is facilitated, thereby improving the wear resistance of the sliding member.
The surface roughness Ra is measured by using a surface roughness tester Surfcom 1400A (manufactured by Tokyo Seimitsu Co., Ltd.) in compliance with JIS B0601-1994, under the conditions of an evaluation length Ln of 4 mm, a reference length L of 0.8 mm, and a cut-off value of 0.8 mm.
In the fixing device according to the exemplary embodiment, the sliding member according to the exemplary embodiment can be installed as in the examples of placement illustrated in FIGS. 1A to 1C.
The effects of specific placement of the region (1) dotted with the first recesses and region (2) dotted with the second recesses in the sliding member according to the exemplary embodiment are as described above in detail with reference to FIGS. 1A to 1C.
First exemplary embodiment of the fixing device
First, a fixing device 60 according to the first exemplary embodiment is described. FIG. 3 schematically illustrates the configuration of the fixing device 60 according to the first exemplary embodiment.
As illustrated in FIG. 3, the fixing device 60 according to the first exemplary embodiment includes, for example, a heat roller 61, a pressure belt 62, and a pressing pad 64. The heat roller 61 is an example of first rotary body that is rotationally driven. The pressure belt 62 is an example of second rotary body. The pressing pad 64 is an example of pressing member that presses the heat roller 61 via the pressure belt 62.
The pressing pad 64 may be configured in any way as long as the pressing pad 64 presses the pressure belt 62 and the heat roller 61 relative to each other. Accordingly, the pressure belt 62 may be pressed against the heat roller 61, or the heat roller 61 may be pressed against the heat roller 61.
The heat roller 61 is configured by, for example, a heat-resistant elastic body layer 612 and a release layer 613 that are laminated around a core made of metal (cylindrical cored bar) 611. A halogen lamp 66 as an example of heating section is arranged inside the heat roller 61. The heating section is not limited to a halogen lamp but another heat generating member may be used.
For example, a temperature-sensitive element 69 is placed in contact with the surface of the heat roller 61. Lighting of the halogen lamp 66 is controlled on the basis of the value of temperature measured by the temperature-sensitive element 69, thereby keeping the surface temperature of the heat roller 61 at a preset temperature (e.g., 150° C.)
The pressure belt 62 is, for example, rotatably supported by the pressing pad 64 and a belt travel guide 63 that are placed inside the pressure belt 62. In a nip region N (nip part), the pressure roller 62 is pressed against the heat roller 61 by the pressing pad 64.
For example, the pressing pad 64 is placed inside the pressure belt 62 so as to be pressed against the heat roller 61 via the pressure belt 62. The pressing pad 64 defines the nip region N together with the heat roller 61.
The pressing pad 64 has a front nip member 64a that is placed on the entrance side of the nip region N in order to secure a wide nip region N, and a peeling nip member 64b that is placed on the exit side of the nip region N in order to apply distortion to the heat roller 61.
In order to reduce the sliding resistance between the inner periphery of the pressure belt 62 and the pressing pad 64, for example, a sheet-like sliding member 68 is provided on the side of the front nip member 64a and the peeling nip member 64b that contacts the pressure belt 62. The pressing pad 64 and the sliding member 68 are held by a holding member 65 made of metal.
For example, the sliding member 68 is provided in such a way that its sliding surface contacts the inner surface of the pressure belt 62. The sliding member 68 is involved in retention/supply of oil that is present between the sliding member 68 and the pressure belt 62. As mentioned above, the sliding member according to the exemplary embodiment exhibits superior performance in terms of wear dust recovery and oil retention/supply. Since the sliding member may keep the coefficient of friction with the pressure belt 62 (the member to be slid) inside the fixing device from increasing even after continued use, the life of the fixing device may be extended.
The holding member 65 is attached with the belt travel guide 63, for example, thus allowing the pressure belt 62 to rotate.
For example, the heat roller 61 rotates in the direction of an arrow C by a drive motor (not illustrated). Following this rotation, the pressure belt 62 rotates in a direction opposite to the direction of rotation of the heat roller 61. In other words, for example, the heat roller 61 rotates in the clockwise direction in FIG. 3, whereas the pressure belt 62 rotates in the counter-clockwise direction.
A sheet of paper K (recording medium) with an unfixed toner image is guided by, for example, an entry guide 56, and transported to the nip region N. Then, as the paper K passes through the nip region N, the toner image on the paper K is fixed by the pressure and heat acting on the nip region N.
In the fixing device 60 according to the first exemplary embodiment, for example, a wide nip region N is secured owing to the front nip member 64a having a recessed shape that conforms to the outer periphery of the heat roller 61, as compared with a case where the front nip member 64a is not provided.
Also, in the fixing device 60 according to the first exemplary embodiment, for example, the peeling nip member 64b is placed in a projecting fashion with respect to the outer periphery of the heat roller 61, thereby increasing local distortion of the heat roller 61 in the exit region of the nip region N.
When the peeling nip member 64b is placed in this way, for example, as the paper K with a fixed image passes through the peeling nip region, the paper K passes through an area of increased local distortion, thus allowing the paper K to easily peel from the heat roller 61.
As an auxiliary peeling section, for example, a peeling member 70 is arranged on the downstream side of the nip region N of the heat roller 61. The peeling member 70 is held by a holding member 72 in such a way that a peeling claw 71 is located in close proximity to the heat roller 61 in a direction counter to the rotational direction of the heat roller 61.
Second Exemplary Embodiment of the Fixing Device
Next, a fixing device 80 according to the second exemplary embodiment is described. FIG. 4 schematically illustrates the configuration of the fixing device according to the second exemplary embodiment.
As illustrated in FIG. 4, the fixing device 80 according to the second exemplary embodiment includes a fixing belt module 86 and a pressure roller 88. The fixing belt module 86 includes a heat belt 84 as an example of second rotary body. The pressure roller 88 is an example of first rotary body placed so as to be pressed against the heat belt 84 (the fixing belt module 86). For example, a nip region N (nip part) where the heat belt 84 (the fixing belt module 86) and the pressure roller 88 contact each other is defined in the fixing device 80. In the nip region N, pressure and heat are applied to a sheet of paper K as an example of recording medium, thereby fixing a toner image to the paper K.
The fixing belt module 86 includes, for example, the heat belt 84 that is an endless belt, a heat pressing roller 89, and a support roller 90. The heat belt 84 is wound around the heat pressing roller 89 on the pressure roller 88 side. The heat pressing roller 89 is rotationally driven by the torque of a motor (not illustrated), and presses the heat belt 84 against the pressure roller 88 side from the inner surface of the heat belt 84. The support roller 90 supports the heat belt 84 from the inside at a position different from the heat pressing roller 89.
The fixing belt module 86 is provided with, for example, a support roller 92, an orientation-correcting roller 94, and a support roller 98. The support roller 92 is placed outside the heat belt 84 and defines the revolution path of the heat belt 84. The orientation-correcting roller 94 corrects the orientation of the portion of the heat belt 84 between the heat pressing roller 89 and the support roller 90. The support roller 98 applies tension to the heat roller 84 from its inner surface on the downstream side of the nip region N where the heat belt 84 (the fixing belt module 86) and the pressure roller 88 contact each other.
The fixing belt module 86 is provided in such a way that, for example, a sheet-like sliding member 82 lies between the heat belt 84 and the heat pressing roller 89.
The sliding member 82 is provided in such a way that, for example, its sliding surface contacts the inner surface of the heat belt 84. The sliding member 82 is involved in retention/supply of oil that is present between the sliding member 82 and the heat belt 84. As mentioned above, the sliding member according to the exemplary embodiment exhibits superior performance in terms of wear dust recovery and oil retention/supply. Since the sliding member may keep the coefficient of friction with the heat belt 84 (the member to be slid) inside the fixing device from increasing even after continued use, the life of the fixing device may be extended.
The sliding member 82 is provided with its ends being supported by a support member 96, for example.
The heat pressing roller 89 is a hard roller having a fluororesin coating as a protective layer for preventing metal wear of the surface of a cylindrical cored bar made of aluminum. The fluororesin coating has a basis weight of 200 μm and is formed on the surface of the cored bar.
Inside the heat pressing roller 89, for example, a halogen heater 89A is provided as an example of heat source.
The support roller 90 is a cylindrical roller made of aluminum. Inside the support roller 90, a halogen heater 90A is arranged as an example of heat source, thereby heating the heat belt 84 from the inner surface side.
At either end of the support roller 90, for example, a spring member (not illustrated) is arranged to press the heat roller 84 outwards.
The support roller 92 is, for example, a cylindrical roller made of aluminum. A release layer made of fluororesin with a thickness of 20 μm is formed on the surface of the support roller 92.
The release layer of the support roller 92 is provided for the purpose of, for example, preventing toner or paper dust from the outer periphery of the heat belt 84 from building up on the support roller 92.
Inside the support roller 92, for example, a halogen heater 92A is provided as an example of heat source, thereby heating the heat belt 84 from the outer periphery side.
That is, for example, the heat belt 84 is heated by the heat pressing roller 89, the support roller 90, and the support roller 92.
The orientation-correcting roller 94 is, for example, a cylindrical roller made of aluminum. An end position measuring mechanism (not illustrated) that measures the end position of the heat belt 84 is placed near the orientation-correcting roller 94.
For example, an axial displacement mechanism (not illustrated) is arranged in the orientation-correcting roller 94. The axial displacement mechanism displaces the abutment position along the axial direction of the heat belt 84 in accordance with the measurement results from the end position measuring mechanism, thereby controlling meandering of the heat belt 84.
The pressure roller 88 includes, for example, a cylindrical roller 88A made of aluminum as a substrate, and an elastic layer 88B and a release layer that are laminated in this order from the substrate side. The elastic layer 88B is made of silicon rubber. The release layer includes fluororesin with a film thickness of 100 μm. The pressure roller 88 is rotatably supported in place, and is pressed by an urging section such as a spring (not illustrated) against the area where the heat belt 84 is wound around the heat pressing roller 89. Therefore, as the heat belt 84 (the heat pressing roller 89) of the fixing belt module 86 rotates in the direction of an arrow E, the pressure roller 88 rotates in the direction of an arrow F following the heat belt 84 (the heat pressing roller 89).
Then, the paper K with an unfixed toner image is guided to the nip region N of the fixing device 80. The toner image is fixed to the paper K by the pressure and heat acting on the nip region N.
Image Forming Apparatus
Next, an image forming apparatus according to the exemplary embodiment is described.
FIG. 5 schematically illustrates the configuration of the image forming apparatus according to the exemplary embodiment.
The fixing device according to the exemplary embodiment mentioned above is applied to the image forming apparatus according to the exemplary embodiment.
As illustrated in FIG. 5, an image forming apparatus 100 according to the exemplary embodiment is an image forming apparatus employing an intermediate transfer system which is generally called a tandem type. The image forming apparatus 100 includes multiple image forming units 1Y, 1M, 1C, and 1K, a first transfer section 10, a second transfer section 20, and the fixing device 60. In the image forming units 1Y, 1M, 1C, and 1K, toner images of various color components are formed by electrophotography. The first transfer section 10 sequentially transfers the toner images of various color components formed by the image forming units 1Y, 1M, 1C, and 1K to an intermediate transfer belt 15 (first transfer). The second transfer section 20 transfers the superimposed toner images transferred onto the intermediate transfer belt 15, to a sheet of paper K that is a recording medium at once (second transfer). The fixing device 60 fixes each of the images obtained after second transfer onto the paper K. The image forming apparatus 100 also has a controller 40 that controls the operations of various devices (various sections).
The fixing device 60 corresponds to the fixing device 60 according to the first exemplary embodiment described above. The fixing device has the sliding member 68 according to the exemplary embodiment mentioned above. The image forming apparatus 100 may be also configured to include the fixing device 80 according to the second exemplary embodiment described above (the sliding member 82 according to the exemplary embodiment mentioned above).
The image forming units 1Y, 1M, 1C, and 1K of the image forming apparatus 100 each include a photoconductor 11. The photoconductor 11 is an example of image carrier that carries a toner image formed on its surface. The photoconductor 11 rotates in the direction of an arrow A.
A charging unit 12 and a laser exposure unit 13 (the exposure beam is denoted by a symbol Bm in FIG. 5) are provided around the photoconductor 11. The charging unit 12 is an example of charging section that charges the surface of the image carrier. The charging unit 12 electrically charges the photoconductor 11. The laser exposure unit 13 is an example of latent image forming section that forms a latent image on the surface of the image carrier that has been charged by the charging section. The laser exposure unit 13 writes an electrostatic latent image onto the photoconductor 11.
Also, a developing unit 14 and a first transfer roller 16 are provided around the photoconductor 11. The developing unit 14 is an example of developing section that develops a latent image formed on the surface of the image carrier by the latent image forming section, with a toner to form a toner image. The developing unit 14 stores toners of various color components, and renders an electrostatic latent image on the photoconductor 11 visible with the corresponding toner. The first transfer roller 16 transfers toner images of various color components formed on the photoconductor 11 to the intermediate transfer belt 15 in the first transfer section 10.
Further, a photoconductor cleaner 17 is provided around the photoconductor 11. The photoconductor cleaner 17 removes toner remaining on the photoconductor 11. Electrophotographic devices including the charging unit 12, the laser exposure unit 13, the developing unit 14, the first transfer roller 16, and the photoconductor cleaner 17 are sequentially arranged along the rotational direction of the photoconductor 11. The image forming units 1Y, 1M, 1C, and 1K corresponding to these components are placed substantially linearly from the upstream side of the intermediate transfer belt 15 in the order of yellow (Y), magenta (M), cyan (C), and black (K).
The intermediate transfer belt 15 is configured by a film-like pressure belt having resin such as polyimide or polyamide as a base layer and containing an appropriate amount of antistatic agent such as carbon black. The intermediate transfer belt 15 has a volume resistivity of not less than 106 Ωcm and not more than 1014 Ωcm, and a thickness of, for example, approximately 0.1 mm.
The intermediate transfer belt 15 is driven to circulate (rotate) at a predetermined speed in a direction B illustrated in FIG. 5 by various rollers. The various rollers include a drive roller 31, a support roller 32, a tension-applying roller 33, a back roller 25, and a cleaning back roller 34. The drive roller 31 is driven by a motor (not illustrated) with good constant velocity property and rotates the intermediate transfer belt 15. The support roller 32 supports the intermediate transfer belt 15 that extends substantially linearly along the array direction of each photoconductor 11. The tension-applying roller 33 applies a predetermined tension to the intermediate transfer belt 15, and functions as a correction roller that prevents meandering of the intermediate transfer belt 15. The back roller 25 is provided in the secondary transfer section 20. The cleaning back roller 34 is provided in a cleaning section that scrapes off toner remaining on the intermediate transfer belt 15.
The first transfer section 10 is configured by the first transfer roller 16 that faces the photoconductor 11 across the intermediate transfer belt 15. The first transfer roller 16 includes a shaft, and a sponge layer as an elastic layer secured around the shaft. The shaft is a cylindrical bar made of metal such as iron or SUS. The sponge layer is formed of a blended rubber of NBR, SBR, and EPDM in which a conductive agent such as carbon black is blended. The sponge layer is a sponge-like cylindrical roller with a volume resistivity of not less than 107.5 Ωcm and not more than 108.5 Ωcm.
The first transfer roller 16 is placed in press contact with the photoconductor 11 across the intermediate transfer belt 15. Further, the first transfer roller 16 is applied with a voltage (a first transfer bias) of a polarity opposite to the polarity of the charge on the toner (hereinafter referred to as “negative polarity”). Therefore, the toner images on the corresponding photoconductors 11 are electrostatically sucked onto the intermediate transfer belt 15 sequentially, forming superimposed toner images on the intermediate transfer belt 15.
The secondary transfer section 20 includes the back roller 25 and a second transfer roller 22. The second transfer roller 22 is an example of transfer section that transfers a toner image formed by the developing section to a recording medium. The second transfer roller 22 is placed on the toner image carrying surface side of the intermediate transfer belt 15.
The surface of the back roller 25 is configured by a tube of blended rubber of EPDM and NBR in which carbon is dispersed. The inside of the back roller 25 is configured by EPDM rubber. The back roller 25 has a surface resistivity of not less than 107.5 Ω/sq. and not more than 1010/sq. The hardness of the back roller 25 is set to, for example, 70° (ASKER C manufactured by Kobunshi Keiki Co., Ltd.; hereinafter the same). The back roller 25 is placed on the back side of the intermediate transfer belt 15, and configures a counter electrode for the second transfer roller 22. A power supply roller 26 is placed in contact with the back roller 25. The power supply roller 26 is made of metal, and stably applied with a second transfer bias.
The second transfer roller 22 includes a shaft, and a sponge layer as an elastic layer secured around the shaft. The shaft is a cylindrical bar made of metal such as iron or SUS. The sponge layer is formed of a blended rubber of NBR, SBR, and EPDM in which a conductive agent such as carbon black is blended. The sponge layer is a sponge-like cylindrical roller with a volume resistivity of not less than 107.5 Ωcm and not more than 108.5 Ωcm.
The second transfer roller 22 is placed in press contact with the back roller 25 across the intermediate transfer belt 15. Further, the second transfer roller 22 is grounded, and a second transfer bias is produced between the second transfer roller 22 and the back roller 25, thereby transferring a toner image onto the paper K transported to the second transfer section 20.
An intermediate transfer belt cleaner 35 is provided on the downstream side of the secondary transfer section 20 of the intermediate transfer belt 15. The intermediate transfer belt cleaner 35 is able to contact and separate from the intermediate transfer belt 15. The intermediate transfer belt cleaner 35 removes toner or paper dust remaining on the intermediate transfer belt 15 after second transfer, thereby cleaning the surface of the intermediate transfer belt 15.
A reference sensor (home position sensor) 42 is arranged on the upstream side of the image forming unit 1Y for yellow. The reference sensor 42 generates a reference signal that serves as a reference for establishing the timing of image formation in each of the image forming units 1Y, 1M, 1C and 1K. An image density sensor 43 for adjusting image quality is arranged on the downstream side of the image forming unit 1K for black. The reference sensor 42 recognizes a predetermined mark provided on the back side of the intermediate transfer belt 15, and generates a reference signal. The image forming units 1Y, 1M, 1C and 1K begin image formation upon instruction from the controller 40 based on the recognition of this reference signal.
Further, the image forming apparatus according to the exemplary embodiment includes a paper storing section 50, a paper feed roller 51, a transport roller 52, a transport guide 53, a transport belt 55, and the entry guide 56, as a transport section that transports the paper K. The paper storing section 50 stores the paper K. The paper feed roller 51 picks up and transports the paper K collected in the paper storing section 50 at predetermined timing. The transport roller 52 transports the paper L paid out by the paper feed roller 51. The transport guide 53 sends the paper K transported by the transport roller 52 to the second transfer section 20. The transport belt 55 transports the paper K transported to the transport belt 55 after second transfer by the second transport roller 22, to the fixing device 60. The entry guide 56 guides the paper K toward the fixing device 60.
Next, a basic image forming process by the image forming apparatus according to the exemplary embodiment is described.
In the image forming apparatus according to the exemplary embodiment, after predetermined image processing is applied by an image processing device (not illustrated) to image data outputted from an image reading device (not illustrated) or a personal computer (PC) (not illustrated), image formation is executed by the image forming units 1Y, 1M, 1C, and 1K.
The image processing device applies predetermined image processing to inputted reflectance data. The predetermined image processing includes various kinds of image editing such as shading correction, misregistration correction, brightness/color space conversion, gamma correction, frame erasure, color editing, and motion editing. The image data applied with the image processing is converted into color material gradation data of the four colors Y, M, C, and K, and then outputted to the laser exposure unit 13.
The laser exposure unit 13 radiates the exposure beam Bm emitted from, for example, a semiconductor laser to the photoconductor 11 of each of the image forming units 1Y, 1Y, 1M, and 1K, in accordance with the inputted color material gradation data. The surfaces of the respective photoconductors 11 of the image forming units 1Y, 1Y, 1M, and 1K are charged by the charging unit 12, followed by scanning and exposure by the laser exposure unit 13, forming electrostatic latent images. The formed electrostatic latent images are developed by the corresponding image forming units 1Y, 1M, 1C, and 1K as toner images of the colors Y, M, C, and Y, respectively.
The toner images formed on the photoconductors 11 of the image forming units 1Y, 1M, 1C and 1K are transferred onto the intermediate transfer belt 15 in the first transfer section 10 where each of the photoconductors 11 and the intermediate transfer belt 15 contact each other. More specifically, in the first transfer section 10, the first transfer roller 16 applies a voltage (a first transfer bias) of a polarity opposite to the polarity of the charge on the toner (negative polarity) to the base material of the intermediate transfer belt 15, and first transfer is performed by sequentially superimposing the toner images on the surface of the intermediate transfer belt 15.
After the toner images are sequentially transferred to the surface of the intermediate transfer belt 15 by first transfer, the intermediate transfer belt 15 moves so that the toner images are transported to the second transfer section 20. When the toner images are transported to the second transfer section 20, in the transport section, the paper feed roller 51 rotates in synchronization with the timing when the toner images are transported to the second transfer section 20, and a sheet of paper K of a predetermined size is supplied from the paper storing section 50. The paper K supplied from the paper feed roller 51 is transported by the transport roller 52, and reaches the second transfer section 20 via the transport guide 53. Before reaching the second transfer section 20, the paper K is stopped once, and a registration roller (not illustrated) rotates in synchronization with the movement timing of the intermediate transfer belt 15 carrying the toner images, thereby performing registration between the paper K and the toner images.
In the second transfer section 20, the second transfer roller 22 is pressed against the back roller 25 via the intermediate transfer belt 15. At this time, the paper K transported to the second transfer section 20 with synchronized timing is nipped between the intermediate transfer belt 15 and the second transfer roller 22. When a voltage (a second transfer bias) of the same polarity as the polarity (negative polarity) of the charge on the toner is applied from the power supply roller 26, a transfer field is formed between the second transfer roller 22 and the back roller 25. Then, the unfixed toner images held on the intermediate transfer belt 15 are electrostatically transferred onto the paper K at once in the second transfer section 20 where pressure is applied by the second transfer roller 22 and the back roller 25.
Thereafter, the paper K with the electrostatically transferred toner images is transported while being peeled from the intermediate transfer belt 15 by the second transfer roller 22, and transported to the transport belt 55 provided on the downstream side in the paper transport direction of the second transfer roller 22. The transport belt 55 transports the paper K to the fixing device 60 at an optimal transport speed for the fixing device 60. As each of the unfixed toner images on the paper K transported to the fixing device 60 undergoes a fixing process with application of heat and pressure by the fixing device 60, the toner image is fixed onto the paper K. Then, the paper K with the fixed image is transported to a paper output storing section (not illustrated) provided in an eject section of the image forming apparatus.
Toner remaining on the intermediate transfer belt 15 after transfer to the paper K is complete is transported to the cleaning section as the intermediate transfer belt 15 rotates. The toner is then removed from the intermediate transfer belt 15 by the cleaning back roller 34 and the intermediate transfer belt cleaner 35.
While the exemplary embodiment of the invention has been described above, the foregoing description is not intended to limit the invention to the above exemplary embodiment. It is needless to mention that various modifications, alterations, and improvements are possible, and the exemplary embodiment can be implemented in a number of ways consistent with the requirements of the invention.
While the exemplary embodiment is directed to the case of an electrophotographic image forming apparatus, the exemplary embodiment is not limited to this. The exemplary embodiment may be applied to an existing image forming apparatus employing a system other than electrophotography (such as an inkjet recording apparatus equipped with an endless belt for transporting paper).
EXAMPLES
While the exemplary embodiment is described in detail below by way of examples, the exemplary embodiment is by no means limited to these examples.
Example 1
A die (80 mm×400 mm) with Ni electrocast cylinders is prepared. The die has two regions arranged parallel to each other. In one of the regions (50 mm×380 mm), cylindrical projections with a diameter of 0.2 mm and a height of 0.1 mm are arranged in a staggered grid form at an array pitch of 0.6 mm in the sliding direction and in a direction orthogonal to the sliding direction. In the other region (10 mm×380 mm), cylindrical projections with a diameter of 0.5 mm and a height of 0.1 mm are arranged in a staggered grid form at an array pitch of 1.0 mm in the sliding direction and at an array pitch of 0.4 mm in the direction orthogonal to the sliding direction. This die is fabricated by electroforming.
Further, a laminate sheet (80 mm×400 mm) is prepared. The laminate sheet is obtained by bonding together a polyimide resin sheet with a thickness of 75 μm that serves as a substrate, and a crosslinked PTFE sheet (Xeron XF-1B) with a thickness of 0.1 mm that serves as a fluororesin layer.
The die is laid over the fluororesin layer surface of the laminate sheet, and embossing is applied by applying pressure under heating at 180° C. with a pressing machine.
As a result, a sheet-like sliding member is obtained. The sheet-like sliding member has a region (1) and a region (2) in the planar sliding surface of the fluororesin layer. In the region (1), circular recesses with a diameter of 0.2 mm are arranged in a staggered grid form at an array pitch of 0.6 mm in the sliding direction and in the direction orthogonal to the sliding direction. In the region (2), circular recesses with a diameter of 0.5 mm are arranged in a staggered grid form at an array pitch of 1.0 mm in the sliding direction and at an array pitch of 0.4 mm in the direction orthogonal to the sliding direction.
Example 2
A die (80 mm×400 mm) with Ni electrocast cylinders is prepared. The die has a region (10 mm×380 mm) arranged on either side of and parallel to a region (50 mm×380 mm). In the former region (10 mm×380 mm), cylindrical projections with a diameter of 0.5 mm and a height of 0.1 mm are arranged in a staggered grid form at an array pitch of 1.0 mm in the sliding direction and at an array pitch of 0.4 mm in a direction orthogonal to the sliding direction. In the latter region (50 mm×380 mm), cylindrical projections with a diameter of 0.2 mm and a height of 0.1 mm are arranged in a staggered grid form at an array pitch of 0.6 mm in the sliding direction and in the direction orthogonal to the sliding direction. This die is fabricated by electroforming.
Further, a laminate sheet (80 mm×400 mm) is prepared. The laminate sheet is obtained by bonding together a polyimide resin sheet with a thickness of 75 μm that serves as a substrate, and a crosslinked PTFE sheet (Xeron XF-1B) with a thickness of 0.1 mm that serves as a fluororesin layer.
The die is laid over the fluororesin layer surface of the laminate sheet in an aligned manner, and embossing is applied by applying pressure under heating at 180° C. with a pressing machine.
As a result, a sheet-like sliding member is obtained. The sheet-like sliding member has a region (1) and a region (2) in the planar sliding surface of the fluororesin layer. The region (2) is located on either side of the region (1). In the region (1), circular recesses with a diameter of 0.2 mm are arranged in a staggered grid form at an array pitch of 0.6 mm in the sliding direction and in the direction orthogonal to the sliding direction. In the region (2), circular recesses with a diameter of 0.5 mm are arranged in a staggered grid form at an array pitch of 1.0 mm in the sliding direction and at an array pitch of 0.4 mm in the direction orthogonal to the sliding direction.
Example 3
A skeet-like sliding member having a region (1) and a region (2) is obtained in the same manner as in Example 1, except that a single-layer body of crosslinked PTFE sheet (Xeron XF-1B manufactured by Hitachi Cable, Ltd.) with a thickness of 0.3 mm is used instead of the laminate sheet used in Example 1. In the region (1), circular recesses with a diameter of 0.2 mm are arranged in a staggered grid form at an array pitch of 0.6 mm. In the region (2), circular recesses with a diameter of 0.5 mm are arranged in a staggered grid form at an array pitch of 1.0 mm in the sliding direction and at an array pitch of 0.4 mm in the direction orthogonal to the sliding direction.
Comparative Example 1
A sliding member (HGF-500-6 manufactured by Chukoh Chemical Industries. Ltd.) is prepared by laminating a PTFE sheet with a thickness of 0.02 mm on glass cloth. The sliding member has irregularities with a height of 0.02 mm in its sliding surface.
Comparative Example 2
A laminate sheet is prepared. The laminate sheet is obtained by bonding together a polyimide resin sheet with a thickness of 75 μm that serves as a substrate, and a crosslinked PTFE sheet (Xeron XF-1B) with a thickness of 0.1 mm that serves as a fluororesin layer.
Cross marks are embossed onto this laminate sheet by using a stainless mesh (30 meshes with a line diameter of 0.22 mm) instead of a die, and applying pressure under heating at 180° C. with a pressing machine.
As a result, a sheet-lie sliding member is obtained. The sheet-like sliding member has, in the sliding surface of the fluororesin layer, patterns arrayed in a grid form with an irregular line width that ranges from 5 μm to 30 μm and becomes greater at the intersection of the cross marks, in such a way that the cross marks are partially contiguous with each other.
Reference Example
A die (80 mm×400 mm) with Ni electrocast cylinders is prepared. This die is fabricated by electroforming. The die has cylindrical projections with a diameter of 0.2 mm and a height of 0.1 mm arranged in a staggered grid form at an array pitch of 0.6 mm.
Further, a laminate sheet (80 mm×400 mm) is prepared. The laminate sheet is obtained by bonding together a polyimide resin sheet with a thickness of 75 μm that serves as a substrate, and a crosslinked PTFE sheet (Xeron XF-1B) with a thickness of 0.1 mm that serves as a fluororesin layer.
The die is laid over the fluororesin layer surface of the laminate sheet, and embossing is applied by applying pressure under heating at 180° C. with a pressing machine.
As a result, a sheet-like sliding member is obtained. The sheet-like sliding member has circular recesses with a diameter of 0.2 mm arranged in a staggered grid form at an array pitch of 0.6 mm in the planar sliding surface of the fluororesin layer.
Evaluation
The sheet-like sliding member obtained in each of the above examples is attached to a belt/roller nip type fixing device in a high speed copier (Color 1000 Press manufactured by Fuji Xerox Co., Ltd.) (see FIG. 4; the inner surface of the heat belt 84 in which the sheet-like sliding member is placed has a surface roughness Ra of 0.6 μm). For the coefficient of friction between the member to be slid (the heat belt 84) and the sliding member, its initial value and its value after continuous operation with the process speed increased to 840 mm/sec are measured. The measured friction coefficients are evaluated. The results are illustrated as Table 1.
The attaching of the sliding member to the high speed copier is performed in such a way that the region (2) is located on the upstream side with respect to the sliding direction in Example 1-1 and Example 3, and that the region (2) is located on the downstream side with respect to the sliding direction in Example 1-2. Also, in Example 2, the sliding member is attached to the high speed copier in such a way that the region (2) is located on the upstream side and on the downstream side with respect to the sliding direction.
Evaluation indices of friction coefficient The criteria for evaluation of the friction coefficient of the sliding member are as follows.

    ⊙: The initial friction coefficient is not more than 1.0, and the friction coefficient after feeding 2,000,000 sheets (2 Mpv) is not more than 1.2.
    ◯: The initial friction coefficient is not more than 1.0, and the friction coefficient after feeding 1,000,000 sheets (1 Mpv) is not more than 1.5.
    Δ: The initial friction coefficient is not more than 1.0, and the friction coefficient after feeding 400,000 sheets (400 kpv) is not more than 1.5.
    x: The initial friction coefficient is more than 1.0, and the friction coefficient after feeding 400,000 sheets (400 kpv) is more than 1.5.














TABLE 1








Position of region
Initial
Evaluation




(2) with respect to
friction
of friction




sliding direction
coefficient
coefficient









Example 1-1
Upstream
0.08
⊚



Example 1-2
Downstream
0.08
⊚



Example 2
Upstream and
0.08
⊚




downstream





Example 3
Upstream
0.08
⊚



Comparative
—
0.07
Δ



Example 1






Comparative
—
0.11
X



Example 2






Reference
—
0.08
◯



Example










From the results in Table 1 mentioned above, it is appreciated that each of the sheet-like sliding members according to Examples 1 to 3 has a low initial friction coefficient, and an increase in friction coefficient after feeding of sheets is minimized in comparison to Comparative Examples.
Also, during the evaluation of friction coefficient mentioned above, for the cases where the sliding members according to Examples 1 to 3 are used, after continuous operation for 92.6 hours corresponding to feeding of 1 Mpv, the recesses in the sliding members are visually observed to make evaluations on the recovery of wear dust by the second recesses and clogging of the first recesses by wear dust. The results indicate that in the sliding members according to Examples 1 to 3, although the second recesses are nearly filled in by wear dust, the first recesses are not clogged but keep their function as recesses intact.
Likewise, clogging of the recesses is also observed for the case where the sliding member according to Reference Example is used. As a result, many recesses filled in by wear dust are observed, indicating a clear difference from the sliding members according to Examples 1 to 3.
Further, it is confirmed by observation that in the case where the region (2) dotted with the second recesses is located on the upstream side with respect to the sliding direction as in Example 1-1, clogging of the first recesses is more effectively reduced in comparison to the case where the region (2) is located on the downstream side as in Example 1-2.
Also, in the case of Reference Example, after clogging of the recesses occurs, the resistance value increases to an extent that renders the sliding member unusable after feeding of 1 million sheets (1 Mpv).
The foregoing description of the exemplary embodiment of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiment was chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.

## Claims

1. A sliding member for a fixing device, comprising at least a fluororesin layer that has a sliding surface, the sliding surface including:
a first region that is dotted with a plurality of first recesses; and
a second region that is dotted with a plurality of second recesses having a diameter larger than the first recesses,
wherein in the first region, the first recesses have a period of not less than approximately 0.2 mm and not more than approximately 2.0 mm, and each one of the first recesses has an area of not less than approximately 7×10−3 mm2 and not more than approximately 3.2mm2.

2. The sliding member for a fixing device according to claim 1, wherein at least one of the second recesses exists over an entire width of the second region, when the sliding surface is viewed along a sliding direction with respect to the second region.

3. The sliding member for a fixing device according to claim 1, wherein the second region is placed in at least one of a front end portion and a rear end portion with respect to a sliding direction.

4. A fixing device comprising:
a first rotary body;
a second rotary body that is placed in contact with an outer surface of the first rotary body;
a pressing member that is placed inside the second rotary body, the pressing member pressing the second rotary body against the first rotary body from an inner surface of the second rotary body;
a sliding member that lies between the inner surface of the second rotary body and the pressing member, the sliding member being the sliding member for a fixing device according to claim 1; and
a heat source that heats at least one of the first rotary body and the second rotary body.

5. The fixing device according to claim 4, wherein the inner surface of the second rotary body has a surface roughness Ra of not less than approximately 0.1 μm and not more than approximately 2.0 μm.

6. The fixing device according to claim 4, wherein in the sliding member for a fixing device, the second region is placed on an upstream side with respect to a sliding direction.

7. The fixing device according to claim 4, wherein in the sliding member for a fixing device, the second region is placed on a downstream side with respect to a sliding direction.

8. The fixing device according to claim 4, wherein in the sliding member for a fixing device, the second region is placed on an upstream side and a downstream side with respect to a sliding direction.

9. An image forming apparatus comprising:
an image carrier;
a charging section that charges a surface of the image carrier;
a latent image forming section that forms a latent image on the surface of the image carrier that has been charged;
a developing section that develops the latent image with a toner to form a toner image;
a transfer section that transfers the toner image to a recording medium; and
a fixing section that fixes the toner image to the recording medium, the fixing section being the fixing device according to claim 4.

10. A sliding member for a fixing device, comprising at least a fluororesin layer that has a sliding surface, the sliding surface including:
a first region that is dotted with a plurality of first recesses; and
a second region that is dotted with a plurality of second recesses having a diameter larger than the first recesses,
wherein in the second region, the second recesses have a diameter of not less than approximately 300 μm and not more than approximately 1.5 mm.

11. The sliding member for a fixing device according to claim 10, wherein at least one of the second recesses exists over an entire width of the second region, when the sliding surface is viewed along a sliding direction with respect to the second region.

12. The sliding member for a fixing device according to claim 10, wherein the second region is placed in at least one of a front end portion and a rear end portion with respect to a sliding direction.

13. A fixing device comprising:
a first rotary body;
a second rotary body that is placed in contact with an outer surface of the first rotary body;
a pressing member that is placed inside the second rotary body, the pressing member pressing the second rotary body against the first rotary body from an inner surface of the second rotary body;
a sliding member that lies between the inner surface of the second rotary body and the pressing member, the sliding member being the sliding member for a fixing device according to claim 10; and
a heat source that heats at least one of the first rotary body and the second rotary body.

14. The fixing device according to claim 13, wherein the inner surface of the second rotary body has a surface roughness Ra of not less than approximately 0.1 μm and not more than approximately 2.0 μm.

15. The fixing device according to claim 13, wherein in the sliding member for a fixing device, the second region is placed on an upstream side with respect to a sliding direction.

16. The fixing device according to claim 13, wherein in the sliding member for a fixing device, the second region is placed on a downstream side with respect to a sliding direction.

17. The fixing device according to claim 13, wherein in the sliding member for a fixing device, the second region is placed on an upstream side and a downstream side with respect to a sliding direction.

18. An image forming apparatus comprising:
an image carrier;
a charging section that charges a surface of the image carrier;
a latent image forming section that forms a latent image on the surface of the image carrier that has been charged;
a developing section that develops the latent image with a toner to form a toner image;
a transfer section that transfers the toner image to a recording medium; and
a fixing section that fixes the toner image to the recording medium, the fixing section being the fixing device according to claim 13.