Self-Releasing Fuser Member Coating with Fluorocarbon Chains

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Solution Overview

Problem

Existing fuser members in electrostatographic apparatuses require release agents like silicone oils to prevent toner offset, but these agents deteriorate over time, leading to mechanical failures and contamination, and new materials are needed for low-oil or oil-less machines that can maintain high performance in thermal fusing applications.

Innovation Solution

A self-releasing fuser member with a topcoat comprising fluorocarbon chains bonded to a fluoropolymer layer, which provides a high degree of fluorination at the fusing surface, reducing or eliminating the need for fusing oil and preventing toner offset, while maintaining mechanical properties and adhesion requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If release agents like silicone oils are applied to prevent toner offset, then release properties are improved, but the system deteriorates over time leading to mechanical failures and contamination

Engineering Contradiction:

Improverelease propertiesVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The invention extracts and eliminates the release agent (silicone oil) from the fuser member system. The fluoropolymer coating with fluorocarbon chains provides inherent release properties without requiring external release agents, thereby removing the source of contamination and mechanical failure while maintaining reliable toner release throughout the service life

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention uses a composite material structure consisting of a fluoropolymer base layer with bonded fluorocarbon chains on the surface. This composite provides both the mechanical durability of the fluoropolymer and the release properties of the fluorocarbon chains, achieving long-term reliability without release agents

Inventive Principle:

Principle #40Composite materials

2Reliability

If release agents are used to maintain release properties, then toner offset is prevented, but contamination and mechanical failures increase

Engineering Contradiction:

Improverelease propertiesVSAvoidcontamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention removes the release agent (silicone oil) that causes contamination. The fluoropolymer coating with fluorocarbon chains provides inherent low surface energy and release properties without requiring external agents, eliminating the source of contamination while maintaining effective toner release

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the need for release agents into a benefit by using the inherent low surface energy of fluorocarbon chains in the coating. This eliminates contamination from release agent degradation while maintaining release properties, turning a harmful dependency into an inherent advantage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If fluoropolymer material with fluorocarbon chains is used, then release properties are improved and fusing oil is eliminated, but manufacturing complexity increases

Engineering Contradiction:

Improverelease propertiesVSAvoidcoating structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges the release agent function and the coating material into a single integrated fluoropolymer coating with fluorocarbon chains. This eliminates the need for separate release agent delivery systems and maintenance mechanisms, reducing overall system complexity while providing reliable release properties

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fluoropolymer coating with fluorocarbon chains is self-releasing, providing inherent release properties without requiring external release agents or complex delivery systems. The coating serves its own release function through its chemical structure, simplifying the overall fuser member design

Inventive Principle:

Principle #25Self-service

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 self-releasing fuser member effectively facilitates the release of toner and contaminants without fuser oil, reducing contamination and mechanical failures, and lowering manufacturing costs by eliminating the need for oil delivery systems, while maintaining high performance in thermal fusing applications.

Implementation Method 1

fluorocarbon chains in the topcoat layer are bonded to the fluoropolymer or fluoroelastomer layer via siloxane functionalities

Methodology Applied

Scientific EffectSiloxane bonding: Chemical Bonding

Implementation Method 2

the fluoropolymer material comprises a fluoroelastomer that is cured via a siloxane curing system

Methodology Applied

Scientific EffectSiloxane curing: Chemical Bonding

Data Source

PatentUS8288004B2Fuser member coating having self-releasing fluoropolymer-fluorocarbon layer

Publication Date: 2012.10.16 XEROX CORP

AI summary

A self-releasing fuser member and image apparatus having the fuser member, and wherein the fuser member includes a substrate, and thereover an outer layer having a topcoat, wherein the outer layer includes a fluoropolymer material and wherein said topcoat includes an outermost layer of fluorocarbon chains, wherein the fluorocarbon chains are bonded to said fluoropolymer material, and wherein the fuser member decreases or eliminates the need for fusing oils as it is self-releasing.