Fuser Release Layer CNT Dispersion via High Shear Mixing

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Solution Overview

Problem

Incorporating carbon nanotubes into a polymer matrix for fuser release layers in electrophotographic systems leads to agglomerates, resulting in non-homogeneous release layers and print defects due to the brittleness of CNT agglomerates under fusing pressures and temperatures.

Innovation Solution

A method involving high shear mixing of a high load fluoropolymer/carbon nanotube composition followed by additional mixing to form a low load composition, which is then coated and cured on a fuser substrate, reducing carbon nanotube fluoropolymer cluster size and amount to enhance dispersion and prevent agglomerates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If carbon nanotubes are incorporated into a fluoropolymer matrix for fuser release layers, then the release layer provides necessary release properties, but carbon nanotube agglomerates occur resulting in non-homogeneous dispersion and print defects

Engineering Contradiction:

Improverelease layer performanceVSAvoidhomogeneity of release layer

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by first creating a high-load fluoropolymer/CNT composition (30-50 wt% CNT) and thoroughly mixing it to achieve uniform CNT distribution before diluting with additional fluoropolymer to the final desired concentration (1-5 wt% CNT). This preliminary high-concentration mixing ensures CNTs are pre-dispersed uniformly, preventing agglomerate formation in the final release layer composition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the manufacturing process into distinct stages: (1) preparing high-load fluoropolymer/CNT composition, (2) mixing the high-load composition multiple times, (3) diluting with fluoropolymer, and (4) final mixing. This segmentation allows each stage to optimize for its specific purpose, particularly the intensive mixing at high concentration before dilution.

Inventive Principle:

Principle #1Segmentation

2Reliability

If carbon nanotubes are used in the release layer, then release properties are enhanced, but print defects occur due to brittleness of CNT agglomerates under fusing pressures and temperatures

Engineering Contradiction:

Improverelease propertiesVSAvoidprint defects

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By preliminarily mixing the CNTs at high concentration in the fluoropolymer matrix before final formulation, the patent ensures CNTs are individually dispersed and uniformly distributed throughout the polymer matrix. This preliminary dispersion prevents the formation of brittle agglomerates that would cause print defects under fusing conditions.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If high load fluoropolymer/carbon nanotube composition is mixed multiple times, then CNT dispersion is improved and agglomerates are reduced, but manufacturing time and process complexity increase

Engineering Contradiction:

ImproveCNT dispersion qualityVSAvoidmixing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent performs the intensive mixing action preliminarily at high CNT concentration where it is most effective at preventing agglomerate formation. By concentrating the mixing effort at the high-load stage rather than attempting multiple mixing cycles at low concentration, the process achieves superior dispersion efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the concentration parameter during the process - starting with high CNT concentration (30-50 wt%) for mixing, then diluting to final concentration (1-5 wt%). This parameter change optimizes the mixing effectiveness, as high concentration facilitates better CNT-polymer interaction and dispersion during the intensive mixing stage.

Inventive Principle:

Principle #35Parameter changes

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 process significantly reduces the size and volume percentage of carbon nanotube fluoropolymer clusters, improving the homogeneity of the release layer and preventing toner buildup, thereby enhancing image quality and extending the life of fuser surfaces.

Implementation Method 1

mixing the high load fluoropolymer/carbon nanotube composition in a high shear mixer for 3 or more times

Methodology Applied

Scientific EffectShear mixing: Shear Stress

Implementation Method 2

The coated fluoropolymer/carbon nanotube composition is cured to form a fuser release layer on the fuser substrate

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS10501659B2Method of making a fuser member

Publication Date: 2019.12.10 XEROX CORP

AI summary

Described herein is a method of manufacturing a fuser member. The method includes mixing a high load fluoropolymer/carbon nanotube composition in a high shear mixer. The method includes mixing the high load fluoropolymer/carbon nanotube composition in the high shear mixer for 3 or more times. A fluoropolymer is added to the high load fluoropolymer/carbon nanotube composition to form a low load fluoropolymer/carbon nanotube composition. The low load fluoropolymer/carbon nanotube composition is mixed in a rubber compounding mixer for 3 or more times. The low load fluoropolymer/carbon nanotube composition is coated on a fuser substrate, cured and polished.