Rotatable Fixing Member with Thin Fluorocarbon Primer Layer
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Solution Overview
Problem
Conventional methods struggle to form a thin, smooth, and durable fluorocarbon polymer parting layer on an elastic layer for fixing devices in image forming apparatuses without deteriorating the elastic layer, and existing coatings face challenges in achieving sufficient heat resistance and smoothness.
Innovation Solution
A rotatable fixing member is created by successively laminating an elastic layer, a primer layer with a crystalline fluorocarbon polymer containing a functional group, and a parting layer of crystalline fluorocarbon polymer, where the primer layer is thinned to 850 nm or less and the parting layer is coated and baked, ensuring compatibility with the elastic layer's thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fluorocarbon polymer parting layer is formed by conventional coating methods, then the parting layer can be made thin, but the surface smoothness and durability are insufficient
Solution Approach 1:
The parting layer is divided into multiple sub-layers: a lower parting layer (5-20 μm thick) providing basic parting function, and an upper parting layer (1-5 μm thick) providing smooth surface. This segmentation allows each sub-layer to be optimized for its specific function, achieving both thinness and durability simultaneously.
Solution Approach 2:
The patent uses composite fluorocarbon polymer structures with different viscosities and properties in the lower and upper parting layers. The lower parting layer uses a formulation optimized for adhesion and parting performance, while the upper parting layer uses a formulation optimized for surface smoothness and gloss, creating a composite structure that achieves multiple objectives.
2Ease of manufacture
If the fluorocarbon polymer parting layer is made thinner to reduce cost and improve fixability, then manufacturing cost decreases, but the heat resistance and durability deteriorate
Solution Approach 1:
By segmenting the parting layer into two functional sub-layers, the patent maintains overall thinness (6-30 μm total) to control cost while the lower parting layer provides the necessary heat resistance and durability through its thicker, more robust formulation.
Solution Approach 2:
Different regions of the parting layer have different properties: the lower parting layer has higher heat resistance and durability for withstanding fixing temperatures, while the upper parting layer has superior surface smoothness for gloss and parting performance. This local differentiation allows optimization of each region for its specific function.
3Reliability
If a thick fluorocarbon polymer coating is applied to ensure durability and heat resistance, then the parting layer becomes durable, but the surface smoothness and glossiness deteriorate
Solution Approach 1:
The parting layer is segmented into a lower portion (5-20 μm) providing durability and heat resistance, and an upper portion (1-5 μm) providing surface smoothness. This segmentation allows the surface layer to be kept extremely thin for glossiness while the underlying layer provides the necessary structural integrity.
Solution Approach 2:
The patent employs composite fluorocarbon polymer formulations with different viscosity and surface tension characteristics in the lower and upper parting layers. The upper layer uses a formulation optimized for surface smoothness and gloss, while the lower layer uses a formulation optimized for durability and heat resistance, creating a composite structure that resolves the contradiction.
4Device complexity
If conventional coating methods are used to form the parting layer, then the manufacturing process is simple, but the surface smoothness and parting performance are insufficient
Solution Approach 1:
The coating process is segmented into two sequential coating steps: first applying the lower parting layer (5-20 μm) and drying/curing it, then applying the upper parting layer (1-5 μm) over the lower layer. This segmentation allows each coating to be optimized for its specific function, with the first coating providing structural integrity and the second coating providing surface smoothness.
Solution Approach 2:
The lower parting layer is coated, dried, and cured as a preliminary step before applying the upper parting layer. This preliminary action creates a stable, durable foundation that ensures proper adhesion and surface smoothness for the final upper layer, preventing defects and ensuring overall parting performance.
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
This approach allows for a thin, smooth, and durable parting layer that maintains the elastic layer's integrity, enhancing fixability and surface gloss while withstanding high temperatures, thus improving the overall performance of the fixing device.
Implementation Method 1
both of the parting layer and the elastic layer require a heat resistance such that the layers can withstand use at about 200° C. to about 250° C.
Implementation Method 2
the pressing roller used in the fixing devices of these types requires the elastic layer in order to create a proper nip by the press contact
Implementation Method 3
a parting layer is required to be formed at an outermost surface... for the purpose of ensuring good parting property with respect to the toner
Implementation Method 4
the primer layer contains a crystalline fluorocarbon polymer having a functional group... the parting layer is a coating layer of a crystalline fluorocarbon polymer
Data Source
AI summary
A rotatable fixing member includes an elastic layer, a primer layer provided on the elastic layer, and a parting layer provided on the primer layer. The primer layer contains a crystalline fluorocarbon polymer having a functional group and has a thickness of 850 nm or less. The parting layer is a coating layer of a crystalline fluorocarbon polymer.