Fluoroelastomer Fuser Coating for Uniform Toner Fusion
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Solution Overview
Problem
Electrophotographic imaging apparatuses often experience visual banding defects during the fixing or fusing of toner images, particularly in full solid blacks, which need to be eliminated to improve image quality.
Innovation Solution
A fuser member with a fluoroelastomer layer is created using a flow coating solution containing a fluoroelastomer, a nucleophilic crosslinking agent, and non-functional polydimethylsiloxane, applied in a spiral pattern onto a substrate, utilizing solvents like N-methyl 2-pyrrolidone, dimethyl formamide, or dimethyl sulfoxide, to enhance adhesion and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used to apply fluoroelastomer layer, then manufacturing process is simple, but visual banding defects occur in toner image fusion
Solution Approach 1:
The patent applies preliminary action by preparing the fluoroelastomer coating solution with specific additives (nucleophilic crosslinking agent and polydimethylsiloxane) before application. This pre-formulation ensures uniform coating and eliminates visual banding defects during toner image fusion, resolving the contradiction between manufacturing precision and process complexity.
Solution Approach 2:
The patent changes the chemical parameters of the coating solution by incorporating nucleophilic crosslinking agents and polydimethylsiloxane additives. These parameter changes in the coating formulation improve the uniformity of the fluoroelastomer layer, thereby eliminating visual banding defects while maintaining a relatively simple coating process.
2Reliability
If fluoroelastomer layer is applied without crosslinking agent, then manufacturing process is simple, but adhesion and uniformity are poor causing visual banding
Solution Approach 1:
The patent uses nucleophilic crosslinking agents as intermediaries that facilitate strong adhesion between the fluoroelastomer layer and the substrate. These crosslinking agents form chemical bonds that improve reliability of adhesion while maintaining ease of manufacture, as the crosslinking process occurs automatically during coating without requiring additional manufacturing steps.
Solution Approach 2:
The patent creates a composite coating system by combining fluoroelastomer with nucleophilic crosslinking agents and polydimethylsiloxane. This composite material approach enhances adhesion and uniformity of the fluoroelastomer layer, resolving the contradiction between reliability and ease of manufacture.
3Manufacturing precision
If conventional coating solution is used, then formulation is simple, but visual banding defects occur especially in full solid blacks
Solution Approach 1:
The patent applies local quality by adding specific functional additives (nucleophilic crosslinking agents and polydimethylsiloxane) to the coating solution at controlled concentrations. These additives locally improve the coating properties in critical areas, ensuring uniformity in full solid black regions without requiring large quantities of materials.
Solution Approach 2:
The patent changes the chemical composition parameters of the coating solution by incorporating small amounts of nucleophilic crosslinking agents and polydimethylsiloxane. These parameter changes in the formulation significantly improve manufacturing precision and eliminate visual banding defects while using minimal quantities of additives.
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 minimizes visual banding defects, ensuring a smoother and more uniform toner image fusion, thereby improving the overall quality of printed images.
Implementation Method 1
a fluoroelastomer layer... prepared by flow coating a flow coating solution... including a fluoroelastomer, a nucleophilic crosslinking agent
Implementation Method 2
applying the flow coating solution from an applicator to the substrate in a spiral pattern in a controlled amount so that substantially all the coating from the applicator adheres to said substrate
Implementation Method 3
The flow coating solution includes an effective solvent selected from the group consisting of N-methyl 2-pyrrolidone, dimethyl formamide, and dimethyl sulfoxide
Data Source
AI summary
The present teachings include a flow coating solution, a fuser member and an image forming apparatus. The fuser member includes a substrate and flow coating solution applied onto the substrate. The outer layer includes a flow coating solution including a fluoroelastomer, a nucleophilic crosslinking agent and a non-functional polydimethylsiloxane having the formula:wherein n is from 100 to 20,000. The flow coating solution includes an effective solvent selected from the group consisting of N-methyl 2-pyrrolidone, dimethyl formamide, and dimethyl sulfoxide.