Fuser Roller Annealing for Adhesion and Durability
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Solution Overview
Problem
Existing fuser members in electrostatographic fixing systems face issues with toner offset, poor abrasion resistance, and heat resistance due to the degradation of silicone rubber layers during high-temperature sintering processes, leading to delamination and wrinkling artifacts.
Innovation Solution
A multi-layer coating for fuser members comprising a fluoropolymer resin layer, a resilient elastomer layer, a tie layer of fluoropolymers or fluoroelastomers, and a primer layer, with an annealing process applying heat and pressure to enhance adhesion and durability, preventing delamination and improving heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fluoropolymer resin layer is sintered to a silicone rubber layer at high temperature (approximately 500°C), then the fluoropolymer resin layer achieves good adhesion to the silicone rubber layer, but the silicone rubber layer degrades causing smoking, depolymerization, and reduced durability
Solution Approach 1:
A fluoroelastomer layer is introduced as an intermediary between the fluoropolymer resin layer and the silicone rubber layer. This fluoroelastomer layer can be processed at lower temperatures (below 500°C) while still providing strong adhesion, thus protecting the silicone rubber layer from thermal degradation during the sintering process. The fluoroelastomer acts as a buffer that allows bond formation without subjecting the silicone rubber to excessive heat.
Solution Approach 2:
The invention uses a composite structure combining fluoropolymer resin, fluoroelastomer, and silicone rubber in specific layers. This composite material approach allows each layer to perform its function optimally: the fluoropolymer resin provides non-stick properties, the fluoroelastomer provides adhesion at moderate temperatures, and the silicone rubber provides compliance and cushioning without thermal degradation.
2Area of moving object
If a single compliant rubber layer is used on a fuser member, then the contact area between fuser member and toner-bearing receiver is increased, but the fuser member absorbs release oils and degrades leading to wrinkling artifacts and non-uniform nip width
Solution Approach 1:
The rubber layer is segmented into multiple functional layers: a silicone rubber base cushion layer for compliance, a fluoroelastomer intermediate layer for adhesion and stability, and a fluoropolymer resin top layer for non-stick properties. This segmentation allows each layer to address specific requirements without compromising the others, preventing oil absorption and degradation while maintaining contact area.
Solution Approach 2:
The invention employs a composite structure where the fluoroelastomer layer is bonded to the silicone rubber base cushion layer. This composite material combination provides the compliance needed for good contact area while the fluoroelastomer component resists oil absorption and degradation, preventing wrinkling artifacts and maintaining uniform nip width.
3Reliability
If dielectric heating is used to avoid high temperature sintering effects on silicone rubber, then the silicone rubber layer is protected from degradation, but the process becomes complicated and expensive and the fluoropolymer resin layer may still delaminate in high-pressure fuser systems
Solution Approach 1:
The fluoroelastomer layer serves as a mediator that enables adhesion formation at lower temperatures (below 500°C), eliminating the need for complex dielectric heating processes. This intermediate layer allows the fluoropolymer resin to bond to the silicone rubber without subjecting the silicone rubber to high temperatures, thereby protecting it from degradation while simplifying the manufacturing process.
Solution Approach 2:
The invention changes the processing temperature parameter from high temperature (500°C) to lower temperature (below 500°C) by introducing the fluoroelastomer layer. This parameter change simplifies the heating process and eliminates the need for complex dielectric heating equipment while still achieving strong adhesion between layers.
4Object-generated harmful factors
If a fluoropolymer resin sleeve layer is used on a fuser member, then the non-stick property is achieved, but the abrasion resistance and heat resistance are poor
Solution Approach 1:
The invention uses a composite structure with a fluoropolymer resin outer layer for non-stick properties, a fluoroelastomer intermediate layer for adhesion and durability, and a silicone rubber base cushion layer for compliance. This composite material approach provides both the non-stick property needed to prevent toner offset and the abrasion/heat resistance required for durability, as each layer contributes different properties that complement each other.
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 solution provides fuser members with improved adhesion between layers, enhanced abrasion and heat resistance, and economic production, reducing toner offset and maintaining layer integrity under harsh conditions.
Implementation Method 1
annealing the outer surface of the outer layer through contacting the outer layer by means of heat and pressure
Implementation Method 2
annealing the outer surface of the outer layer through contacting the outer layer by means of heat and pressure
Implementation Method 3
uniquely bonded to a silicone base cushion layer by means of a fluoroelastomer layer
Data Source
AI summary
A method of making a fuser roller comprising: providing a fuser roller an outer layer comprising a fluorothermoplastic polymer; and annealing the outer surface of the outer layer through contact the outer layer by means of heat and pressure.