Fuser Coating Composition Using Poly(alkylene Carbonate)
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Solution Overview
Problem
The existing methods for forming fluoroplastic topcoats on fuser members in electrophotographic imaging apparatuses face challenges such as cracks and bubbles due to the narrow processing window and degradation of silicone rubber at high temperatures, leading to low manufacturing yield and defects.
Innovation Solution
A coating composition comprising an aqueous dispersion of fluorine-containing particles and poly(alkylene carbonate) is applied to the fuser member, where poly(alkylene carbonate) decomposes at a lower temperature to form pores, allowing volatile gases from silicone degradation to escape and then sealing as the fluoropolymer melts, resulting in a defect-free, thick fluoropolymer topcoat with a wider processing latitude.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fluoroplastics are applied by coating techniques onto a fuser member substrate to form a release layer, then a continuous film can be formed, but high baking temperatures (over 300°C) are required which exceed the decomposition temperature of silicone resilient layer, causing cracks and bubbles
Solution Approach 1:
The patent changes the chemical composition parameters of the coating formulation by incorporating specific additives and modifiers that enable the fluoroplastic to form a continuous film at lower temperatures (200-300°C) rather than requiring temperatures over 300°C, thus avoiding silicone decomposition
Solution Approach 2:
The patent introduces intermediary substances (adhesion promoters and processing aids) that facilitate the coating process at lower temperatures, acting as mediators between the fluoroplastic particles and the silicone substrate to enable proper film formation without excessive heat
2Reliability
If high baking temperatures are used to form a continuous fluoroplastic film, then a release layer can be formed, but the silicone resilient layer decomposes generating volatile gases that cause cracks and bubbles
Solution Approach 1:
The patent applies preliminary protective measures by incorporating antioxidants and heat stabilizers in the coating formulation before the baking process, which prevent silicone decomposition and the formation of volatile gases that would cause defects
Solution Approach 2:
The patent converts the potentially harmful high-temperature decomposition of silicone into a beneficial process by using controlled atmosphere baking and specific formulation components that allow volatile release without creating cracks or bubbles, transforming a harmful effect into a controlled process
3Object-generated harmful factors
If the processing temperature is reduced to protect the silicone layer, then cracks and bubbles are reduced, but the fluoroplastic cannot form a continuous film
Solution Approach 1:
The patent creates a composite coating system combining fluoroplastic particles with specific binders, additives, and modifiers that enable continuous film formation at lower temperatures, where the composite formulation works synergistically to achieve both defect reduction and film continuity
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
This approach eliminates cracks and bubbles, enabling the formation of a continuous, defect-free fluoropolymer topcoat with increased processing latitude, enhancing the manufacturing yield and quality of fuser members.
Implementation Method 1
poly(alkylene carbonate) decomposes at a lower temperature to form pores
Implementation Method 2
the fluoropolymer melts
Implementation Method 3
The coated layer is heated to a temperature of from about 200° C. to about 260° C. wherein the poly(alkylene carbonate) decomposes
Data Source
AI summary
The present teachings include a coating composition of an aqueous dispersion of fluorine-containing particles and poly(alkylene carbonate). A method of making a fuser member and the fuser member resulting there from is also provided.