Fuser Coating Composition for Low Gloss Print Quality
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Solution Overview
Problem
Manufacturing fuser topcoats for low gloss prints is challenging due to the difficulty in maintaining homogeneity and preventing voids in aerogel and fluorine-containing polymer blends during the powder coating process, leading to inconsistent print quality.
Innovation Solution
A powder coating composition comprising fluorine-containing particles, aerogel particles, and a transient binder like poly(alkylene carbonate) is used, along with a fluorinated surfactant to improve wetting and bonding, ensuring a uniform and textured surface when heated to form a continuous film with low surface energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If aerogel particles and fluorine-containing polymer particles are blended for powder coating, then low gloss print quality is achieved, but homogeneity and void formation become problematic
Solution Approach 1:
The patent creates a composite powder coating system where hydrophobic aerogel particles are surface-modified with silane coupling agents to improve compatibility with fluorine-containing polymer particles. This composite approach allows the disparate materials to bond uniformly, achieving both low gloss print quality and coating homogeneity without void formation
Solution Approach 2:
The patent modifies the surface properties of aerogel particles through silane coupling agent treatment, changing their surface energy and chemical composition. This parameter change enables better interfacial adhesion between aerogel and fluorine-containing polymer particles, ensuring homogeneous mixing and preventing voids during the powder coating process
2Reliability
If fluorine-containing polymer is used for release layer, then low surface energy is achieved, but manufacturing homogeneity is difficult
Solution Approach 1:
The patent introduces silane coupling agents as intermediary substances that bridge the hydrophobic aerogel particles and the fluorine-containing polymer particles. This intermediary layer improves the wettability and bonding between components, making the powder coating process more controllable and manufacturable while preserving the low surface energy properties of the fluorine-containing polymer
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 method produces a homogeneously mixed aerogel and fluorine-containing particle topcoat with a surface energy less than 20 mN/m2, achieving uniform and low gloss prints by maintaining the properties of the fluorine-containing polymer while ensuring good release and robustness.
Implementation Method 1
The coating composition is heated to a temperature sufficient to melt the fluorine-containing particles and the poly(alkylene carbonate)
Implementation Method 2
wherein a surface energy of the outer layer is less than about 20 mN/m2
Data Source
AI summary
The present teachings include a coating composition of a powder of fluorine containing particles, aerogel particles and poly(alkylene carbonate). A method of making a fuser member and the fuser member resulting therefrom is also provided.