Polyphenylsulfone Transfer Member for Conductivity and Toughness

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Solution Overview

Problem

Current intermediate transfer members in electrophotographic printing face issues such as environmental emissions, high manufacturing costs, and limited performance in stain, abrasion, and solvent resistance, with a need for improved toughness and high gloss, as well as size limitations due to extrusion coating processes.

Innovation Solution

A seamless intermediate transfer member is developed using a polymer blend of polyphenylsulfone and cyclic alkylene terephthalate with dispersed carbon black particles, along with a coating composition that includes polyphenylsulfone, cyclic alkylene terephthalate, and a solvent, which enhances the mechanical properties and conductivity of the transfer member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyimide resins are used for intermediate transfer members, then conductivity and basic functionality are achieved, but environmental emissions occur during manufacture and manufacturing cost increases due to complex processes

Engineering Contradiction:

ImproveconductivityVSAvoidenvironmental emissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing polyimide resins with a polymer blend of polyphenylsulfone and cyclic alkylene terephthalate. This substitution maintains the necessary conductivity through carbon black particles while eliminating the environmental emissions and complex manufacturing associated with polyimide production.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite material system consisting of polyphenylsulfone as the base polymer, cyclic alkylene terephthalate as a modifier, and carbon black particles for conductivity. This composite approach achieves the required electrical properties without relying on environmentally harmful polyimide resins.

Inventive Principle:

Principle #40Composite materials

2Reliability

If polyimide resins are used for intermediate transfer members, then basic transfer functionality is achieved, but manufacturing cost increases and performance in stain, abrasion and solvent resistance needs improvement

Engineering Contradiction:

Improvetransfer functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent modifies the material composition by using polyphenylsulfone and cyclic alkylene terephthalate instead of polyimide resins. This change reduces manufacturing cost while simultaneously improving performance characteristics including stain, abrasion, and solvent resistance, along with enhancing break strength and gloss.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If extrusion coating processes are used to manufacture intermediate transfer belts, then production is achieved, but the size of belts is limited due to die size constraints

Engineering Contradiction:

Improveproduction capabilityVSAvoidbelt size

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

The patent extracts the constraint of extrusion die size limitations by adopting alternative coating processes. This allows the manufacture of intermediate transfer belts with larger dimensions that cannot be produced through conventional extrusion methods, thereby expanding the range of achievable belt sizes.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If conventional materials are used for intermediate transfer members, then basic properties are achieved, but toughness and high gloss properties are insufficient

Engineering Contradiction:

Improvebasic propertiesVSAvoidtoughness and gloss

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite formulation of polyphenylsulfone and cyclic alkylene terephthalate that delivers superior mechanical properties. This material combination provides enhanced break strength, improved gloss, and better overall toughness compared to conventional polyimide-based intermediate transfer members.

Inventive Principle:

Principle #40Composite materials

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 significantly improves the break strength, surface resistivity, and mechanical properties of the intermediate transfer member, enabling higher performance and cost-effectiveness while reducing environmental impact and size limitations.

Implementation Method 1

The conductive powder includes carbon blacks, acetylene black, stannic oxide, indium oxide, potassium titanate and other types of conductive and semi-conductive powders that can be employed

Methodology Applied

Scientific EffectConduction (electrical): Conduction (electrical)

Data Source

PatentUS8338521B2Intermediate transfer member and composition

Publication Date: 2012.12.25 XEROX CORP

AI summary

There is described an intermediate transfer member comprising a seamless layer comprising a polyphenylsulfone and a cyclic alkylene terephthalate having dispersed therein carbon black particles. The composition used to manufacture the seamless intermediate transfer member is also described.