Fixing Roller Resin Layer Detachment Prevention
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Solution Overview
Problem
Existing fixing rollers with a PFA tube thickness of 30 μm experience wrinkles and detachment issues at high speeds due to mechanical and thermal stress, while increasing the thickness to 40 μm or more leads to detachment from the silicone rubber layer due to reduced flexibility and increased shearing stress.
Innovation Solution
A fixing roller design with a resin layer made of fluorine resin and a thickness of 40 μm or more, where the peripheral velocity is set to 300 mm/s or more, meeting the condition Tr≧Tc+60 or Tr≧Tc+75 in a detachment test to prevent detachment, involves a core, an elastic layer of silicone rubber, and a specific manufacturing process including etching treatment and controlled primer application to enhance adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the PFA tube thickness is increased to 40 μm or more to prevent wrinkles at high speed, then mechanical strength is improved, but the resin layer becomes more likely to detach from the silicone rubber layer due to reduced flexibility and increased shearing stress
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness of the silicone rubber elastic layer to 1.5 mm or more, which increases the flexibility and deformation capacity of the elastic layer. This allows the thicker PFA tube (40 μm or more) to follow the deformation of the elastic layer without generating excessive shearing stress, thereby preventing detachment while maintaining mechanical strength
Solution Approach 2:
The patent uses composite materials by combining PFA (fluorine resin) with silicone rubber in a specific configuration. The PFA tube is coated on the silicone rubber elastic layer, creating a composite structure where the fluorine resin provides mechanical strength and the silicone rubber provides elasticity and flexibility, resolving the contradiction between strength and adhesive reliability
2Reliability
If the PFA tube thickness is kept at 30 μm to maintain flexibility and prevent detachment, then adhesive strength is improved, but wrinkles occur on the PFA tube at high process speeds due to insufficient mechanical strength
Solution Approach 1:
The patent changes the parameter of elastic layer thickness to 1.5 mm or more, which provides sufficient deformation capacity to accommodate the thicker PFA tube (40 μm or more) without causing wrinkles. The increased thickness of the elastic layer allows it to absorb mechanical stress and thermal expansion differences at high speeds, preventing wrinkle formation while maintaining adhesive strength
3Adaptability or versatility
If the silicone rubber layer thickness is increased or hardness is reduced to improve elasticity, then deformation capacity is improved, but shearing stress between the PFA tube and silicone rubber increases, leading to detachment
Solution Approach 1:
The patent optimizes the thickness parameter of the silicone rubber elastic layer to 1.5 mm or more, which provides adequate deformation capacity. This specific thickness range ensures that the elastic layer can follow the deformation requirements at high speeds without generating excessive shearing stress that would cause detachment of the PFA tube
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents detachment of the resin layer from the elastic layer at high speeds, ensuring stable operation and extended lifespan of the fixing roller, even with a thicker resin layer, by maintaining a higher limit detachment temperature and improving adhesive strength.
Implementation Method 1
a PFA tube whose internal surface has been subjected to an etching treatment
Implementation Method 2
application of primer is fixed to the inside of a cylindrical mold
Implementation Method 3
silicone rubber is heated and cured
Data Source
AI summary
A fixing roller includes: a core; an elastic layer made of an elastic material, formed around the core; and a resin layer made of fluorine resin, formed around the elastic layer. The fixing roller is designed such that the resin layer has a thickness of 40 μm or more, and the fixing roller meets a relation Tr≧Tc+60 or Tr≧Tc+75 where Tr (° C.) is a limit temperature obtained in a predetermined peeling test and Tc (° C.) is a temperature of the fixing roller at which a fixing process is performed. This allows the fixing roller used in an image forming apparatus with a high process speed to secure that the resin layer is less likely to be detached from the elastic layer.