Fuser Roll Composite Outer Layer for Wear Resistance
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Solution Overview
Problem
Conventional fuser roll coatings, such as Teflon, suffer from insufficient mechanical robustness, leading to issues like denting, cracking, and abrasion, and require release agents for effective toner fixing in electrostatographic printing, which limits their performance in terms of wear and heat resistance.
Innovation Solution
A composite material comprising silsesquioxane-based particles and carbon nanotubes dispersed in a polymer matrix is used as the outermost layer of a fixing member, providing enhanced mechanical robustness and allowing for oil-less operation without the need for release agents, through physical dispersion or chemical bonding, and the formation of structural surface features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluororesin (Teflon) is used as surface layer material for toner releasing, then release properties are improved, but mechanical robustness deteriorates causing denting, cracking, and abrasion
Solution Approach 1:
The patent applies composite materials by combining fluororesin with elastomer and silicone oil to create a multi-component surface layer. The fluororesin provides release properties while the elastomer matrix and silicone oil compensate for mechanical weaknesses, preventing denting, cracking, and abrasion that occur with pure fluororesin coatings.
Solution Approach 2:
The patent changes the physical and chemical parameters of the surface layer by incorporating silicone oil (changing viscosity and flexibility parameters) and elastomer (changing tensile strength and elasticity parameters). This transforms the brittle fluororesin into a more robust composite material that maintains release properties while gaining mechanical strength.
2Reliability
If conventional fuser oils (PDMS-based) are applied to maintain release properties, then release performance is improved, but device complexity and operational requirements worsen due to need for continuous application
Solution Approach 1:
The patent implements self-service by incorporating silicone oil directly into the fuser roll surface layer material. The silicone oil is released continuously at controlled rates during operation, eliminating the need for separate application systems. The fuser roll maintains its own release properties through this built-in oil reservoir, reducing operational complexity.
Solution Approach 2:
The patent merges the release agent function with the structural material by combining silicone oil with the elastomer and fluororesin matrix. This integration eliminates the need for separate release agent application systems, combining multiple functions into a single composite material system.
3Strength
If fluoroelastomer is used as surface layer material with release agents, then mechanical properties are improved, but release performance deteriorates without sufficient robustness
Solution Approach 1:
The patent uses composite materials by combining fluoroelastomer with fluororesin and silicone oil. The fluoroelastomer provides the mechanical backbone while the fluororesin contributes to release properties and the silicone oil ensures continuous release performance. This tri-component composite achieves both mechanical strength and reliable release.
Solution Approach 2:
The patent applies local quality by assigning different functions to different components: fluoroelastomer for mechanical strength, fluororesin for initial release properties, and silicone oil for continuous release during operation. Each material is optimized for its specific function within the composite system.
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 composite material significantly improves wear and heat resistance, maintains good release properties, and extends the durability of the fixing member, enabling efficient toner fixing without the use of release agents, thus overcoming the limitations of conventional coatings.
Implementation Method 1
the silsesquioxane-based particles can be physically dispersed in the polymer matrix and/or can be chemically bonded to a polymer of the polymer matrix
Implementation Method 2
a first type of composite material including a plurality of silsesquioxane-based particles and a plurality of carbon nanotubes dispersed in a polymer matrix
Implementation Method 3
a coating composition can be formed, and applied to a substrate, and then heated to form an outermost layer of a fixing member
Data Source
AI summary
Exemplary embodiments provide composite materials used for fixing members that can include silsesquioxane-based particles and/or carbon nanotubes dispersed in a polymer matrix.