# Patent

## Title
Fixing device, image forming apparatus including the fixing device, and fixing method

## Abstract

A fixing device for fixing an image formed on a recording material in an image forming apparatus includes a fixing member, a heating part that heats the fixing member to fix an image formed on the recording material by heat, a storage unit that is charged by an external power source to supply power to the heating part, and a control unit that controls the external power source to supply power to the heating part and determines whether to start to supply power to the heating part from the storage unit. The control unit controls the external power source to charge the storage unit during a period from when power supply from the storage unit to the heating part is completed at the time of warming-up the fixing member by the heating part until when the power supply from the storage unit to the heating part is started.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/220,686 filed Sep. 8, 2005, now U.S. Pat. No.7,343,113 which claims priority to Japanese Patent Application No. 2004-260985 filed in the Japanese Patent Office on Sep. 8, 2004, the entire contents of each of which is herein incorporated by reference.


BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fixing device and a fixing method in which an image is fixed onto a recording material while supplying power to a heating part of a fixing roller from a storage unit, and to an image forming apparatus including the fixing device.
2. Description of the Related Art
A fixing device that fixes a toner image formed on a recording material, such as a recording sheet, via a heating part having a main heating element and an auxiliary heating element has been widely used. In this fixing device, the main heating element is powered by a main power supply unit, and the auxiliary heating element is powered by an auxiliary power supply unit including a capacitor. The auxiliary power supply unit is charged by an external power source through the main power supply unit when the main power supply unit does not supply power to the main heating element, and the auxiliary power supply unit is not charged by the external power source through the main power supply unit when the main power supply unit supplies power to the main heating element.
Published Japanese patent application No. 2003-257590 describes the above fixing device. The fixing device enhances the power-saving effect with a simple configuration. Further, an installation space is reduced by reducing the size of the auxiliary power supply unit.
In a fixing device using a main power supply unit and an auxiliary power supply unit including a capacitor that supply power to a heating part, it is desirable to charge the auxiliary power supply unit acting as a storage unit by effective use of electric power of an external power source; and to enhance the quality of an image fixed on a recording material even if the fixing device is in a low temperature condition.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, a fixing device for fixing an image formed on a recording material includes a fixing member disposed on a recording material conveyance path, a heating part configured to heat the fixing member to fix an image formed on the recording material by heat, and a storage unit configured to be charged by an external power source to supply power to the heating part. The fixing device further includes a control unit configured to control the external power source to supply power to the heating part and to determine whether to start to supply power to the heating part from the storage unit. The control unit is configured to control the external power source to charge the storage unit during a period from when power supply from the storage unit to the heating part is completed at the time of warming-up the fixing member by the heating part to when the power supply from the storage unit to the heating part is started.
According to another aspect of the present invention, an image forming apparatus includes an image forming device configured to form an image on a recording material, and the above-described fixing device.
According to yet another aspect of the present invention, the method of fixing an image formed on a recording material includes charging a storage unit by an external power source; supplying power to a heating part from the storage unit; heating a fixing member by the heating part; and controlling the external power source to charge the storage unit during a period from when power supply from the storage unit to the heating part is completed at the time of warming-up the fixing member by the heating part to when the power supply from the storage unit to the heating part is started.



BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description of non-limiting embodiments when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic cross sectional view of an image forming apparatus including a fixing device according to an embodiment of the present invention;
FIG. 2 is a schematic cross sectional view of the fixing device according to an embodiment of the present invention;
FIG. 3 is a block diagram of an exemplary power supply control circuit structure of the fixing device according to an embodiment of the present invention;
FIG. 4A is a graph showing a variation of a temperature of a fixing roller with time when warming-up the fixing roller according to an embodiment of the present invention;
FIG. 4B is a graph showing a variation of the temperature of the fixing roller with time during a sheet passing operation according to an embodiment of the present invention;
FIG. 5 is a time chart for explaining a power supply operation of the fixing device according to an embodiment of the present invention;
FIG. 6 is a graph showing a variation of the temperature of the fixing roller with time when warming-up the fixing roller according to an embodiment of the present invention;
FIG. 7 is a flowchart of AC power supply control operation steps of a control unit when warming-up the fixing roller according to an embodiment of the present invention;
FIG. 8 is a flowchart of DC power supply control operation steps of the control unit when warming-up the fixing roller according to an embodiment of the present invention;
FIG. 9 is a time chart for explaining a power supply operation of the fixing device according to another embodiment of the present invention; and
FIG. 10 is a time chart for explaining a power supply operation of the fixing device according to another embodiment of the present invention.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Non-limiting embodiments of the present invention are now described with reference to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.
FIG. 1 is a schematic cross sectional view of an image forming apparatus including a fixing device according to an embodiment of the present invention. The image forming apparatus may be a copying machine, a printer, a facsimile machine, or other similar image forming apparatuses. The image forming apparatus includes a drum-shaped photoreceptor 41 acting as an image carrier. Arranged around the photoreceptor 41 are a charging device 42, a mirror 43, a developing device 44, a transfer device 48, and a cleaning device 46 in the order of the rotational direction of the photoreceptor 41 indicated by an arrow A in FIG. 1. Specifically, the charging device 42 includes a charging roller. The mirror 43 constitutes part of an exposure device 40. The developing device 44 includes a developing roller 44a. The transfer device 48 transfers a developed image to a recording material P such as a transfer sheet. The cleaning device 46 includes a blade 46a in sliding-contact with the circumferential surface of the photoreceptor 41. Reference numeral 150 in FIG. 1 indicates an exposure portion of the circumferential surface of the photoreceptor 41 located between the charging device 42 and the developing roller 44a. The exposure portion 150 is exposed to a laser light beam Lb emitted from the exposure device 40 and reflected by the mirror 43.
The transfer device 48 is disposed opposite the lower circumferential surface of the photoreceptor 41. Reference numeral 47 in FIG. 1 indicates a transfer section where the transfer device 48 faces the photoreceptor 41. Further, a pair of registration rollers 49 are provided on an upstream side of the transfer section 47 in the rotational direction of the photoreceptor 41. The recording material P is fed out from a sheet feeding cassette 70 by a sheet feeding roller 110 toward the registration rollers 49 while being guided by a sheet conveyance guide plate (not shown). Moreover, a fixing device 10 is disposed on a downstream side of the transfer section 47 in the rotational direction of the photoreceptor 41.
The image forming operation of the image forming apparatus is performed as follows. First, the charging device 42 uniformly charges the rotating photoreceptor 41. Then, the exposure device 40 emits the laser light beam Lb corresponding to image data to the exposure portion 150 of the circumferential surface of the photoreceptor 41, thereby writing a latent image on the surface of the photoreceptor 41. The latent image moves to the developing device 44 by the rotation of the photoreceptor 41, and is developed with toner by the developing device 44. As a result, a toner image is formed on the surface of the photoreceptor 41.
The recording material P, which has been fed out from the sheet feeding cassette 70 by the sheet feeding roller 110, is conveyed through a sheet conveyance path 80 (indicated by dotted lines in FIG. 1) to the registration rollers 49 and stops at a nip part between the registration rollers 49. Then, the registration rollers 49 feed the recording material P toward the transfer section 47 with appropriate timing so that the recording material P is aligned with the toner image on the photoreceptor 41. Subsequently, the toner image is transferred from the surface of the photoreceptor 41 onto the surface of the recording material P under the influence of the transfer electric field produced in the transfer section 47 by the transfer device 48. In the above-described image forming apparatus, for example, the exposure device 40, the photoreceptor 41, the charging device 42, the developing device 44, and the transfer device 48 act as an image forming device that forms a toner image on the recording material P. The recording material P having a transferred toner image is conveyed through the sheet conveyance path 80 to the fixing device 10. The fixing device 10 fixes the toner image onto the recording material P by the application of heat and pressure while the recording material P passes through the sheet conveyance path 80 in the fixing device 10. The recording material P having a fixed toner image is discharged to a sheet discharging section (not shown) of the image forming apparatus.
The residual toner which has not been transferred from the photoreceptor 41 to the recording material P is moved to the cleaning device 46 by rotation of the photoreceptor 41, and is removed from the surface of the photoreceptor 41 by the blade 46a. Subsequently, the charging device 42 uniformly charges the surface of the photoreceptor 41 to prepare for the next image forming operation. Reference numeral 120 in FIG. 1 indicates a power switch that turns on and off power to the image forming apparatus.
FIG. 2 is a schematic cross sectional view of the fixing device 10 according to an embodiment of the present invention. As illustrated in FIG. 2, the fixing device 10 includes a fixing member such as a fixing roller 14 and a pressing member such as a pressing roller 15. The fixing roller 14 has a hollow cylindrical base. In view of the issues of the durability and the possible deformation caused by pressure, the base of the fixing roller 14 is preferably formed from a metallic material, such as aluminum, or iron, for example. Further, it is preferable that the circumferential surface of the fixing roller 14 include a releasing layer covering the circumference of the base to prevent toner from being adhered onto the surface of the fixing roller 14. Moreover, the inner circumferential surface of the fixing roller 14 may be blackened to efficiently absorb the heat of heating members 1a and 1b (described below).
The pressing roller 15 includes a core metal and an elastic layer made of rubber or the like overlying the core metal. The pressing roller 15 is press-contacted against the fixing roller 14 with a predetermined pressing force by a pressing device (not shown). While the recording material P passes through a nip part between the fixing roller 14 and the pressing roller 15, a toner image is fixed onto the recording material P under the influence of heat and pressure. The pressing roller 15 may include a foamed layer overlying the core metal. In this case, because the heat of the fixing roller 14 does not tend to be transferred to the pressing roller 15 due to the insulation effectiveness of the foamed layer of the pressing roller 15, the fixing roller 14 can be quickly heated up. The fixing device 10 of the present embodiment uses the fixing roller 14 as the fixing member and the pressing roller 15 as the pressing member. Alternatively, the fixing device 10 may use an endless belt or a film for at least one of the fixing member and the pressing member.
The fixing device 10 further includes a heating part 1 having an AC heating element 1a (hereafter referred to as a main heating member 1a) and DC heating elements 1b (hereafter referred to as auxiliary heating members 1b). As a non-limiting example, the heating part 1 includes one main heating member 1a and two auxiliary heating members 1b. The main heating member 1a and auxiliary heating members 1b may be disposed at any desired position where the main heating member 1a and the auxiliary heating members 1b heat the fixing roller 14. In this embodiment, the main heating member 1a and auxiliary heating members 1b are disposed in the fixing roller 14 to heat the fixing roller 14 from inside. The fixing device 10 of FIG. 2 has a construction wherein the fixing roller 14 acts as a heat roller heated by a radiation heater from inside and also acts as a sheet conveyance roller disposed on the sheet conveyance path 80.
With reference to FIGS. 1 and 2, the fixing device 10 further includes a fixing temperature detecting unit 8, a local ambient temperature detecting unit 90, and a control unit 60. The fixing temperature detecting unit 8 may be formed by any temperature detecting unit capable of detecting the surface temperature of the fixing roller 14, and the temperature detecting unit does not need to make direct contact with the outer circumferential surface of the fixing roller 14 as long as it can detect the surface temperature of the fixing roller 14. Therefore, various contact type sensors and non-contact type sensors, including a thermistor, a thermocouple, an infrared temperature detector, or the like, may be used for the fixing temperature detecting unit 8. The fixing temperature detecting unit 8 transmits data of temperature information to the control unit 60. The local ambient temperature detecting unit 90 detects a local ambient temperature in the vicinity of the fixing roller 14. A thermistor, a thermocouple, or the like may be used for the local ambient temperature detecting unit 90. The local ambient temperature detecting unit 90 also transmits data of temperature information to the control unit 60. The control unit 60 controls the start of the power supply, stopping of the power supply, and an increase or decrease in the amount of power supplied to the heating part 1 of the fixing device 10 based on temperature information obtained by the fixing temperature detecting unit 8 and the local ambient temperature detecting unit 90.
FIG. 3 is a block diagram of an exemplary power supply control circuit structure of the fixing device 10 according to an embodiment of the present invention. In FIG. 3, only a circuit portion involved in power supply to the heating part 1 is illustrated. With reference to FIG. 3, the control circuit of the fixing device 10 includes a main power supply unit 2, a storage unit 3 acting as an auxiliary power supply unit, a charger 4, a charge/discharge switching unit 5, a main switching element 6a, auxiliary switching elements 6b, and the control unit 60.
The main power supply unit 2 is powered by an external power source such as a commercial power source to feed electric power to each unit of the image forming apparatus when the power switch 120 of the image forming apparatus is turned on. The main power supply unit 2 is configured to feed electric power to each unit of the image forming apparatus by being connected to an outlet 50 of the commercial power source via a plug 51 (shown in FIG. 1). In Japan, the commercial power source is limited to about 100V and 15 A, and the maximum power of the main power supply unit 2 is generally set to about 1500 W. The main power supply unit 2 may have the functions of adjusting the voltage, commutating an alternating current and a direct current, and stabilizing the voltage. The main heating member 1a heats up by being supplied with power from the main power supply unit 2.
The storage unit 3 acting as an auxiliary power supply unit is formed from an electric double layer capacitor, and is powered by the main power supply unit 2 to supply power to the auxiliary heating members 1b. That is, each of the auxiliary heating members 1b is heated via power derived from the storage unit 3. Instead of the electric double layer capacitor, the storage unit 3 may be formed from a lithium-ion secondary battery, a nickel metal hydride secondary battery, or a pseudocapacitor using redox. As illustrated in FIG. 3, the storage unit 3 is connected to the charger 4, and the charger 4 is connected to the main power supply unit 2. The charger 4 is configured to subject the power supplied from the main power supply unit 2 to a voltage adjustment and an AC/DC conversion, and to supply the power to the storage unit 3. The storage unit 3 supplies the stored power (auxiliary power) to the auxiliary heating members 1b via the charge/discharge switching unit 5. The charge/discharge switching unit 5 selectively allows one of the supplying of power from the storage unit 3 to the auxiliary heating members 1b and the charging of the storage unit 3 by the charger 4. The control unit 60 controls the main switching element 6a to switch ON and OFF the power supply from the main power supply unit 2 to the main heating member 1a, and controls the auxiliary switching elements 6b to switch ON and OFF the power supply from the storage unit 3 to the auxiliary heating members 1b. 
As a non-limiting example, the storage unit 3 is formed by a capacitor module made up of a plurality (for example, forty) of electric double-layer capacitor cells connected in series. Each capacitor cell may have a capacitance of approximately 800 F at a rated voltage of 2.5 V, so as to realize a high output voltage of approximately 100V from the capacitor module. Each capacitor cell may have an internal resistance of about 5 m.OMEGA. or less, a diameter of about 35 mm, and a length of about 120 mm. Stable operation of the storage unit 3 can be achieved for a long period of time by providing a voltage balance circuit (not shown) to keep a voltage balance among capacitor cells connected in series. If the internal resistance of each capacitor cell is set to about 5 m.OMEGA. or less, the decrease of the voltage between terminals of the storage unit 3 can be less than that of the secondary battery, such as a lithium-ion battery, and a nickel metal hydride battery, even if a large electric current over 20 A flows to the auxiliary heating members 1b at the time of warming-up the fixing roller 14. Further, as a large amount of electric power can be obtained from a relatively small number of capacitor cells, the cost and size of the storage unit 3 can be decreased.
The storage unit 3 is chargeable and dischargeable. Because the storage unit 3 uses an electric double-layer capacitor which has a large capacity and is not accompanied by chemical reactions, the storage unit 3 can be rapidly charged and its useful lifetime is longer than a secondary battery. In the case of using a nickel-cadmium battery as an auxiliary power supply, which is generally used as a secondary battery, several tens of minutes to several hours may be necessary for charging the nickel-cadmium battery, even if a boosting charge is provided. For this reason, a large power can be supplied to units of an apparatus only several times a day, so that the use of the nickel-cadmium battery as an auxiliary power supply is not practical. In contrast, the storage unit 3 using an ultra capacitor can be charged in about several tens of seconds to several minutes. Thus, the time for charging the storage unit 3 can be lessened. For example, the storage unit 3 using an ultra capacitor can be charged when the main power supply unit 2 can afford to charge the storage unit 3, for example, during a non-image forming state of the image forming apparatus. Thus, the number of heating operations, by using the storage unit 3 as the auxiliary power supply unit, can be increased to a practical number.
The useful lifetime of the nickel-cadmium battery is short because the number of allowable charge-discharge iteration times of the nickel-cadmium battery is about 500 to 1000 times. Accordingly, it may be necessary to replace the nickel-cadmium battery very frequently, thereby resulting in a corresponding replacement task and increasing costs for battery replacement. In contrast, the number of allowable charge-discharge iteration times of the capacitor is about 10,000 times or more. Further, the capacitor is not easily deteriorated even if the capacitor is charged and discharged repeatedly. Maintenance of the capacitor is rarely required because the capacitor does not need any liquid exchange or supplement otherwise used in a lead-acid battery.
A capacitor which can store a large amount of electric energy has been developed, so that the use of the capacitor in an electric car is under review. For example, the electric double-layer capacitor developed by Nippon Chemicon Co. has an electrostatic capacitance of about 2000 F at a rated voltage of 2.5 V, which is sufficient for power supply for several seconds to several ten seconds. Further, a capacitor named HYPER CAPACITOR (trade name) manufactured by NEC Corp. has an electrostatic capacitance of about 80 F. Moreover, JEOL Ltd. discloses a NANOGATE CAPACITOR (trade name) which has a voltage proof of about 3.2 to 3.5V and an electric energy density of about 50 to 75 wh/kg.
The main heating member 1a and the auxiliary heating members 1b may be formed from halogen heaters. The halogen heater heats by flowing electric current through a filament formed in a glass tube. Instead of the halogen heater or halogen lamp, the main heating member 1a and the auxiliary heating members 1b may be formed from induction heaters or ceramic heaters. For example, the main heating member 1a, which is powered by the main power supply unit 2, may be formed from a halogen heater, which can provide a 1200 W output at the voltage of 100V. For example, the auxiliary heating members 1b, which are powered by the storage unit 3, may be formed from two halogen heaters connected in parallel. One of the halogen heaters can provide a 1000 W output at the voltage of 100V, and the other halogen heater can provide a 700 W output at the voltage of 100V, for example.
As described above, the heating part 1 of the fixing roller 14 receives power such that the main heating member 1a is supplied with power from the main power supply unit 2 and the auxiliary heating members 1b are supplied with power from the storage unit 3. The power from the main power supply unit 2 is supplied to the storage unit 3 through the charger 4, and the storage unit 3 supplies stored power to the auxiliary heating members 1b at an arbitrary timing.
FIG. 4A is a graph showing a variation of the temperature of the fixing roller 14 with time when warming-up the fixing roller 14 according to an embodiment of the present invention. By supplying power from the storage unit 3 to the heating part 1 in addition to the power supplied from the main power supply unit 2 to the heating part 1, an amount of power greater than the amount of power supplied by the main power supply unit 2 can be supplied to the heating part 1 of the fixing roller 14. Therefore, the warm-up time for raising the temperature of the fixing roller 14 from a room temperature to a target temperature can be decreased by heating the heating part 1 with both the main power supply unit 2 and the storage unit 3, instead of by heating the heating part 1 with only the main power supply unit 2, as illustrated in the graph of FIG. 4A.
FIG. 4B is a graph showing a variation of the temperature of the fixing roller 14 with time during a sheet passing operation according to an embodiment of the present invention. If a plurality of the recording materials P pass through the fixing device 10 consecutively (i.e., a sheet passing operation), the recording material P absorbs heat from the fixing roller 14. In this condition, if the heating part 1 is supplied with power from only the main power supply unit 2, the temperature of the fixing roller 14 falls below a predetermined lower limit temperature as illustrated in FIG. 4B. In contrast, by supplying power to the heating part 1 from both the main power supply unit 2 and the storage unit 3, the drop in temperature of the fixing roller 14 can be controlled as illustrated in FIG. 4B. By this control, the number of recording materials P passing through the fixing device 10 per unit time can be increased, allowing the image forming apparatus to make copies or prints at a high speed.
FIG. 5 is a time chart for explaining a power supply operation of the fixing device 10 according to an embodiment of the present invention.
Before warming-up the fixing roller 14 at a startup of the fixing device 10 (i.e., an initial state), the storage unit 3 including the electric double-layer capacitor having a large capacity is charged by the main power supply unit 2 through the charger 4. At the time of warming-up the fixing roller 14, the temperature of the fixing roller 14 is rapidly raised from a room temperature to a target temperature by supplying power to the main heating member 1a from the main power supply unit 2, and by supplying power to the auxiliary heating members 1b from the storage unit 3. The present inventors carried out experiments under the following conditions:
(1) The fixing roller 14 made of aluminum has a diameter of about 40 mm and a thickness of about 0.7 mm;
(2) The power of about 1200 W is supplied to the main heating member 1a from the main power supply unit 2 and the power of about 1700 W is supplied to the auxiliary heating members 1b from the storage unit 3. So, a total of about 2900 W power is supplied to the heating part 1 of the fixing roller 14.
According to the experimental results, when the fixing roller 14 was heated by supplying power only to the main heating member 1a from the main power supply unit 2, the temperature of the fixing roller 14 was raised from room temperature to a target temperature in about 30 seconds (i.e., a warm-up time). In contrast, when the fixing roller 14 was heated by supplying power to the heating part 1 from both the main power supply unit 2 and the storage unit 3, the warm-up time was reduced to about 10 seconds.
Because the storage unit 3 is constructed from a capacitor, the power supplied from the storage unit 3 to the auxiliary heating members 1b is gradually decreased from about 1700 W due to the decrease of voltage during supplying power to the auxiliary heating members 1b. With this characteristic of the capacitor, the power supplied from the storage unit 3 becomes small after a predetermined time has elapsed. Therefore, even if the temperature of the fixing roller 14 is raised to about 500 degrees centigrade at which the recording material P may ignite, the temperature of the fixing roller 14 gradually decreases due to the above-described characteristic of the capacitor. By using the capacitor as the storage unit 3, the temperature of the fixing roller 14 can be safely raised in a short period of time.
To ensure safety, a safety device is provided in case that the system goes out of control. For example, the safety device may terminate the power supply by cutting off a power supply circuit with a safety circuit, such as a temperature fuse or a thermostat.
The supply of power to the heating part 1 can be increased by using two series of commercial power sources or by using a secondary battery or a fuel battery. However, in this case, a large amount of power is continuously supplied to the heating part 1, so that the warm-up time for raising the temperature of the fixing roller 14 to a target fixing temperature is reduced and the temperature elevation is sharper. In this condition, a safety circuit cannot follow the temperature elevation. When the safety circuit starts to operate, the temperature of the heating part 1 may get too high and cause a recording sheet to ignite. In contrast, in a configuration using a capacitor, even if the system goes out of control and the power supply is not stopped, heating of the heating member is stopped after a predetermined amount of power stored in the capacitor is used up, and the temperature rise of the heating member is automatically stopped. Thus, the warm-up time for raising the temperature of the fixing roller 14 to a target fixing temperature can be safely reduced by using a capacitor as a power supply.
As the fixing roller 14 is a thin-layered roller, if the number of recording materials passing through the nip part between the fixing roller 14 and the pressing roller 15 per unit time increases, the surface temperature of the fixing roller 14 typically decreases. However, in the fixing device 10 of the present embodiment, the surface temperature of the fixing roller 14 is prevented from dropping by supplying power to the auxiliary heating members 1b from the storage unit 3 in addition to the supply of power from the main power supply unit 2 to the main heating member 1a during a sheet passing operation as shown in the time chart of FIG. 5. Thus, even if the image forming apparatus is a high-speed machine, the fixing device 10 can achieve a short warm-up time of the fixing roller 14; and can prevent an undesirable drop of the temperature of the fixing roller 14 during a sheet passing operation, while using the thin-layered fixing roller 14.
If only one of the auxiliary heating members 1b capable of providing a 700 W output is heated during the sheet passing operation, the heating part 1 of the fixing roller 14 may be supplied with a power output of about 500 W from the storage unit 3, in addition to the power from the main power supply unit 2 during the sheet passing operation. In this configuration, because the drop of the temperature of the fixing roller 14 after the sheet passage through the fixing device 10 can be prevented, the image forming apparatus according to the embodiment of the present invention can achieve a high-speed image formation, for example, 75 copies per a minute (CPM). In a background image forming apparatus using a thin-layered fixing roller without performing the power supply from a capacitor during a sheet passing operation, the image formation speed is about 60 CPM at most.
Both of the two auxiliary heating members 1b may be used during the sheet passing operation, or the heating part 1 of the fixing roller 14 may include only one auxiliary heating member 1b. Employing a plurality of (e.g., two) auxiliary heating members 1b and one of the auxiliary heating members 1b increases the supply of power and enhances temperature control performance.
As shown in the time chart of FIG. 5, after performing image forming operations (i.e., the sheet passing operation), the image forming apparatus is put into a stand-by state if a next image forming operation is not performed during a predetermined time interval. In the stand-by state, that is, a non-operational state of the image forming apparatus in which the fixing device 10 is not used, charging of the storage unit 3 is performed. In the stand-by state, the main power supply unit 2 can afford to supply power to the storage unit 3, and the storage unit 3 formed from a capacitor is charged within several minutes. Therefore, the storage unit 3 can be quickly charged for a subsequent warming-up operation, so that a user need not wait for a long time until a next image forming operation becomes ready. The stand-by state of the image forming apparatus of this embodiment may employ any save-mode, such as an off-mode and a low power mode.
As described above, by using a capacitor as the storage unit 3 for heating the heating part 1 of the fixing device 10, an advantage which cannot be obtained from a secondary battery can be obtained.
FIG. 6 is a graph showing a variation of the temperature of the fixing roller 14 with respect to time when warming-up the fixing roller 14 according to an embodiment of the present invention.
As shown by a line “a” (both the main power supply unit and the auxiliary power supply unit) of FIG. 6, when a local ambient temperature Ta detected by the local ambient temperature detecting unit 90 is a room temperature, for example, about 23 degrees centigrade, the temperature of the fixing roller 14 rises to a target temperature “T0” by supplying power to the heating part 1 from both the main power supply unit 2 and the storage unit 3 in a target time “t0”, for example, about 10 seconds.
In a low temperature condition in which the local ambient temperature Ta detected by the local ambient temperature detecting unit 90 is less than a low threshold temperature “T1”, for example, about 15 degrees centigrade, the temperature T of the fixing roller 14 may be lower than the low threshold temperature “T1”. This low temperature condition occurs when the fixing roller 14 is heated in a colder environment. In this low temperature condition, as shown by a line “b” of FIG. 6, it takes time longer than the target time “t0” to raise the temperature of the fixing roller 14 to the target temperature “T0”. In this case, the power supplying time of the storage unit 3 becomes longer and the amount of consumed power of the storage unit 3 increases, so that the remaining amount of the stored power of the storage unit 3 to be used for supplying to the heating part 1 of the fixing roller 14 during the sheet passing operation decreases. In such a low temperature condition, the temperature of the recording material P is low as well, and power greater than usual needs to be supplied to the heating part 1 during the sheet passing operation. However, the voltage of the storage unit 3 is lower than usual and the power supplied from the storage unit 3 becomes smaller. Consequently, a fixing failure typically occurs due to insufficient heating of the fixing roller 14.
If the local ambient temperature Ta detected by the local ambient temperature detecting unit 90 is lower than the low threshold temperature T1 before warming-up the fixing roller 14, the fixing roller 14 may be warmed-up by using only the main power supply unit 2 without using the storage unit 3 or by using the main power supply unit 2 and using the storage unit 3 with its power supply reduced. By lowering power consumption at the time of warming-up the fixing roller 14 and by using the saved power of the storage unit 3 during the sheet passing operation, a fixing failure can be prevented even in a low temperature condition.
For example, in the case of using the auxiliary heating member 1b rated at 700 W at 100V, the voltage between terminals of the auxiliary heating member 1b decreases from 100V to 85V due to the power supply of the storage unit 3 at the time of warming-up the fixing roller 14, and the auxiliary heating member 1b provides about a 500 W output during the sheet passing operation. If the storage unit 3 does not supply power to the auxiliary heating member 1b at the time of warming-up, the auxiliary heating member 1b can provide a 700 W output at the voltage of 100V during the sheet passing operation. In this condition, the fixing roller 14 can apply a sufficient amount of heat to the recording material P having a low temperature, and the power supplying time of the storage unit 3 can be extended during the sheet passing operation.
FIG. 7 is a flowchart of AC power supply control operation steps of the control unit 60 when warming-up the fixing roller 14 according to an embodiment of the present invention. First, the fixing temperature detecting unit 8 detects the temperature T of the fixing roller 14 before warming-up the fixing roller 14 in step S1. Then, the control unit 60 determines whether the detected temperature T of the fixing roller 14 is less than or equal to the target temperature “T0” (T.1toreq.T0) in step S2. For example, the target temperature “T0” is set about 180 degrees centigrade. If the answer is NO in step S2, the control operation proceeds to step S6. In step S6, the control unit 60 switches OFF the power supply from the main power supply unit 2 to the main heating member 1a. If the answer is YES in step S2, the control unit 60 switches ON the power supply from the main power supply unit 2 to the main heating member 1a in step S3. Subsequently, the fixing temperature detecting unit 8 detects the temperature T of the fixing roller 14 during warming-up the fixing roller 14 in step S4. Then, the control unit 60 determines whether the temperature T of the fixing roller 14 is greater than or equal to the target temperature “T0” (T.gtoreq.T0) in step S5. If the answer is NO in step S5, the control operation returns to reexecute step S4. If the answer is YES in step S5, the control unit 60 switches OFF the power supply from the main power supply unit 2 to the main heating member 1a in step S6.
In the time chart of FIG. 5, the storage unit 3 is charged by the main power supply unit 2 during a period from when the power supply from the storage unit 3 to the auxiliary heating members 1b is completed at the time of warming-up the fixing roller 14 (indicated by a reference character “t1” in FIG. 5) to when the power supply from the storage unit 3 to the auxiliary heating members 1b is started at the time of the sheet passing operation (indicated by a reference character “t2” in FIG. 5). Immediately after the temperature of the fixing roller 14 is raised to the target temperature “T0” in the warming-up operation, the remaining power of the storage unit 3 is reduced, so that the voltage of the storage unit 3 is lowered. In this condition, even if a halogen heater rated at the same power is used, the output of the power of the halogen heater decreases. So, in this embodiment, the storage unit 3 is charged by the main power supply unit 2 during a period between the “t1” and “t2” in which the power supplied from the main power supply unit 2 to the main heating member 1a is small. By charging the storage unit 3 in this period, the power supplied from the storage unit 3 to the heating part 1 of the fixing roller 14 can be increased at the time of sheet passing operation.
For example, in the case of using the auxiliary heating member 1b rated at 700 W at 100V, the voltage between terminals of the auxiliary heating member 1b decreases from 100V to 85V due to the power supply of the storage unit 3 at the time of warming-up the fixing roller 14, and the auxiliary heating member 1b provides about a 500 W output during the sheet passing operation. If the storage unit 3 is charged by the main power supply unit 2 immediately before the sheet passing operation, the auxiliary heating member 1b can provide a 700 W output at the voltage of 100V during the sheet passing operation. In a low temperature condition such as occurs on a winter morning, the amount of heat absorbed by the recording material P from the fixing roller 14 is relatively large during the sheet passing operation. However, the decrease of temperature of the fixing roller 14 can be prevented during the sheet passing operation by charging the storage unit 3 by the main power supply unit 2 before performing the sheet passing operation. The level of the charging of the storage unit 3, that is, the value of the voltage of the charged storage unit 3 may be set depending on environmental conditions.
FIG. 8 is a flowchart of DC power supply control operation steps of the control unit 60 when warming-up the fixing roller 14 according to an embodiment of the present invention. First, the fixing temperature detecting unit 8 detects the temperature T of the fixing roller 14 before warming-up the fixing roller 14 in step S11. Then, the control unit 60 determines whether the detected temperature T of the fixing roller 14 is greater than or equal to the target temperature T0 (T.gtoreq.T0) in step S12. If the answer is NO in step S12, the control unit 60 switches ON the power supply from the storage unit 3 to the auxiliary heating members 1b at the time of warming-up the fixing roller 14 in step S13. By supplying power to the heating part 1 of the fixing roller 14 from the storage unit 3 at the warming-up time, the temperature of the fixing roller 14 can be raised to the target temperature “T0” in the target time “t0” as indicated by the graph “a” of FIG. 6. Then, the control operation returns to reexecute step S11.
If the answer is YES in step S12, the control unit 60 switches OFF the power supply from the storage unit 3 to the auxiliary heating members 1b in step S14. In this condition, as the initial temperature of the fixing roller 14 is high, the fixing roller 14 can be rapidly warmed-up without using the storage unit 3. Then, in step S15, the storage unit 3 starts to be charged from the main power supply unit 2 (from the commercial power source) through the charger 4 during a period between the time “t1” and “t2” in FIG. 5. When the voltage of the storage unit 3 reaches a predetermined value, charging of the storage unit 3 is stopped in step S16.
Subsequently, in step S17, the fixing temperature detecting unit 8 detects the temperature T of the fixing roller 14 at the time of sheet passage. Then, the control unit 60 determines whether the temperature T of the fixing roller 14 is greater than or equal to the target temperature “T0” (T.gtoreq.T0) in step S118. If the answer is NO in step S18, the control unit 60 switches ON the power supply from the storage unit 3 to the auxiliary heating members 1b in step S19. Then, the control operation returns to reexecute step S17. If the answer is YES in step S18, the control unit 60 switches OFF the power supply from the storage unit 3 to the auxiliary heating members 1b in step S20.
As a non-limiting example, the control unit 60 may control the main power supply unit 2 (the commercial power source) so as not to charge the storage unit 3 based on operation information of the image forming apparatus during the period between the time “t1” and “t2” in FIG. 5. For example, the operation information of the image forming apparatus may be a size of the recording material P to be passed through the nip part between the fixing roller 14 and the pressing roller 15. In the fixing device 10 according to the embodiment of the present invention, the auxiliary heating member 1b rated at 700 W at 100V heats the entire area of the circumferential surface of the fixing roller 14 in its longitudinal direction where the recording material P of any size contacts. If the storage unit 3 is charged by the main power supply unit 2 after the power supply from the storage unit 3 to the auxiliary heating members 1b is completed at the time of warming-up the fixing roller 14 and if the auxiliary heating member 1b provides a 700 W output at the voltage of 100V during a plurality of the small-sized recording materials P consecutively pass through the nip part between the fixing roller 14 and the pressing roller 15, the end areas of the circumferential surface of the fixing roller 14 in its longitudinal direction where the small-sized recording material P does not contact (i.e., sheet non-contact areas) tend to be over-heated. In contrast, if the storage unit 3 is not charged by the main power supply unit 2 after the power supply from the storage unit 3 to the auxiliary heating members 1b is completed at the time of warming-up the fixing roller 14 and if the auxiliary heating member 1b provides a 500 W output at the voltage of 85V during a plurality of the small-sized recording materials P consecutively pass through the nip part between the fixing roller 14 and the pressing roller 15, overheating of the sheet non-contact areas of the circumferential surface of the fixing roller 14 can be prevented.
Instead of using the size of the recording material P to control operation, the operation information of the image forming apparatus may be the local ambient temperature detected by the local ambient temperature detecting unit 90 or the number of sheets to be printed. Specifically, if the local ambient temperature detected by the local ambient temperature detecting unit 90 is relatively high or the number of sheets to be printed is relatively small, the control unit 60 controls the main power supply unit 2 so as not to charge the storage unit 3 after the power supply from the storage unit 3 to the auxiliary heating members 1b is completed at the time of warming-up the fixing roller 14. By doing so, unnecessary power consumption can be prevented.
FIG. 9 is a time chart for explaining a power supply operation of the fixing device 10 according to another embodiment of the present invention. In this embodiment, as indicated by reference character “X” in FIG. 9, the control unit 60 controls the main power supply unit 2 to charge the storage unit 3 even after a plurality of recording materials P are started to consecutively pass through the nip part between the fixing roller 14 and the pressing roller 15 in the sheet passing operation. In the sheet passing operation period, as indicated by reference character “Y” in FIG. 9, some power of the main power supply unit 2 is supplied to the storage unit 3 for charging the storage unit 3. For example, when the image forming apparatus functions as a printer (i.e., a print mode) to consecutively reproduce images based on image data transmitted from a personal computer, for example, to the image forming apparatus, electric power is not so necessary as compared to the case in which the image forming apparatus functions as a copier (i.e., a copy mode) to consecutively reproduce images based on image data obtained by scanning images of original documents fed by an auto document feeder (not shown) one by one. Therefore, by charging the storage unit 3 in the sheet passing operation period in such a print mode in which the main power supply unit 2 can afford to supply power to the storage unit 3, the time period needed for charging the storage unit 3 in the stand-by state can be lessened. Further, the fixing roller 14 can be quickly warmed-up during a subsequent warming-up operation period because the storage unit 3 has been sufficiently charged in the sheet passing operation period and the stand-by state period. As a result, a user need not wait for a long time until a next image forming operation becomes ready, thereby enhancing users' convenience.
When performing the second sheet passing operation immediately after performing the first sheet passing operation in which a large number of sheets are consecutively passed through the nip part between the fixing roller 14 and the pressing roller 15, the remaining power of the storage unit 3 is small but the main power supply unit 2 can afford to supply power to the storage unit 3 because the main power supply unit 2 need not supply a large power to the main heating member 1a which has been sufficiently heated during the first sheet passing operation period. In this case, the storage unit 3 may be charged by the main power supply unit 2 during the second sheet passing operation period in which a plurality of recording materials P pass through the nip part between the fixing roller 14 and the pressing roller 15.
FIG. 10 is a time chart for explaining the power supply operation of the fixing device 10 according to another embodiment of the present invention. As indicated by reference characters “Ya” and “Z” in FIG. 10, the control unit 60 controls the main power supply unit 2 (the commercial power source) to charge the storage unit 3 during a period from when power supply from the storage unit 3 to the auxiliary heating members 1b is completed at the time of warming-up the fixing roller 14 to when the power supply from the storage unit 3 to the auxiliary heating members 1b is started in the sheet passing operation period in which a plurality of recording materials P pass through the nip part between the fixing roller 14 and the pressing roller 15. Specifically, the storage unit 3 is charged by the main power supply unit 2 even if the main power supply unit 2 supplies power to the main heating member 1a in the sheet passing operation period. When the temperature of the fixing roller 14 detected by the fixing temperature detecting unit 8 is less than or equal to a predetermined value, charging of the storage unit 3 is stopped and the power supply from the storage unit 3 to the auxiliary heating members 1b is started in the sheet passing operation period. As an alternative example, when the temperature of the fixing roller 14 detected by the fixing temperature detecting unit 8 is less than or equal to a predetermined value, the charging of the storage unit 3 is stopped and the power supply from the main power supply unit 2 to the main heating member 1a may be increased in the sheet passing operation period instead of starting the power supply from the storage unit 3 to the auxiliary heating members 1b. 
In the above-described embodiments, the storage unit 3 acting as an auxiliary power supply unit can be charged by effective use of electric power of the external power source during a period from when the power supply from the storage unit 3 to the auxiliary heating members 1b is completed at the time of warming-up the fixing roller 14 to when the power supply from the storage unit 3 to the auxiliary heating members 1b is started at the time of the sheet passing operation.
The present invention has been described with respect to the exemplary embodiments illustrated in the figures. However, the present invention is not limited to these embodiments and may be practiced otherwise.
Numerous additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore understood that within the scope of the appended claims, the present invention may be practiced other than as specifically described herein.

## Claims

1. An image forming apparatus, comprising:
an image forming device configured to form an image on a recording material; and
a fixing device configured to fix the image formed on the recording material, the fixing device comprising:
a fixing member disposed on a recording material conveyance path;
a heating part configured to heat the fixing member during a first period corresponding to warming-up the fixing member, and to heat the fixing member during a second period corresponding to the recording material passing the fixing member, to fix the image formed on the recording material by heat;
a storage unit configured to be charged with power supplied from an external power source; and
a control unit configured to control the power supplied from the external power source to cause the storage unit to be charged during a third period between the first period and the second period.

2. The image forming apparatus according to claim 1, wherein the fixing device further comprises:
a fixing temperature detecting unit configured to detect a temperature of the fixing member,
wherein the control unit is configured to control the storage unit to start supply of power to the heating part at the time of warming-up the fixing member by the heating part and to control the storage unit to stop supply of power to the heating part when the temperature of the fixing member reaches a target temperature.

3. The image forming apparatus according to claim 1, wherein the fixing device further comprises:
a fixing temperature detecting unit for detecting a temperature of the fixing member,
wherein the control unit controls the storage unit to start supply of power to the heating part when the temperature of the fixing member is less than or equal to a predetermined value when a plurality of recording materials consecutively pass through the recording material conveyance path.

4. The image forming apparatus according to claim 1, wherein:
the control unit controls the power supplied from the external power source to cause the storage unit to be charged even after a plurality of recording materials are started to consecutively pass through the recording material conveyance path.

5. The image forming apparatus according to claim 1, wherein:
the control unit controls the power supplied from the external power source to cause the storage unit to be charged even if the external power source supplies power to the heating part during the second period.

6. A method of fixing an image formed on a recording material, comprising:
charging a storage unit with power supplied from an external power source;
heating a fixing member by the heating part during a first period corresponding to warming-up the fixing member, and to heat the fixing member during a second period corresponding to the recording material passing the fixing member; and
controlling the power supplied from the external power source to cause the storage unit to be charged during a third period, between the first period and the second period.

7. The method according to claim 6, further comprising:
detecting a temperature of the fixing member; and
controlling the storage unit to start supply of power to the heating part at the time of warming-up the fixing member by the heating part and controlling the storage unit to stop supply of power to the heating part when the temperature of the fixing member reaches a target temperature.

8. The method according to claim 6, further comprising:
detecting a temperature of the fixing member, and controlling the storage unit to start supply of power to the heating part when the temperature of the fixing member is less than or equal to a predetermined value when a plurality of recording materials consecutively pass through a recording material conveyance path.

9. The method according to claim 6, wherein:
the controlling comprises controlling the power supplied from the external power source to cause the storage unit to be charged even after a plurality of recording materials are started to consecutively pass through a recording material conveyance path.

10. The method according to claim 6, wherein:
the controlling comprises controlling the power supplied from the external power source to cause the storage unit to be charged even if the external power source supplies power to the heating part during the second period.

11. The method according to claim 6, further comprising:
controlling the power supplied from the external power source so as not to cause the storage unit to be charged based on operation information of an image forming apparatus during the third period.