US4196256A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Long life fuser roll
Assignee: Xerox Corp
•
Filing: 1978-08-28
•
Granted: 1980-04-01
•
Expires: 1998-08-28
Abstract
Abstract A method of depositing and affixing a layer of a copolymer of perfluoroalkyl perfluorovinyl ether and tetrafluoroethylene upon a metal surface and the article prepared thereby, is disclosed. A flame sprayed metal surface having an optional fluoropolymer primer thereon is powder coated with the copolymer of perfluoroalkyl perfluorovinyl ether and tetrafluoroethylene and the powder is fused thereon. An improved long life fuser member for use in a fusing apparatus for fixing toner images to copy sheets by the application of heat and pressure is described.
Inventors
- 👤 Clifford O. Eddy
- 👤 George J. Safford
- 👤 Edward F. Bowler, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 11:01
CPC Classifications
G; G03; G03G; G03G15/00; G03G15/20; G03G15/2003; G03G15/2014; G03G15/2053; G03G15/2057; B; B05; B05D; B05D5/00; B05D5/08; B05D5/083; B05D2350/00; B05D2350/30; B05D2350/33; B05D2350/40; B05D2350/60; B05D2350/65; B05D2401/00; B05D2401/30; B05D2401/32; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/3154; Y10T428/31544; Y10T428/31678; Y10T428/31692
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
98 words
A method for manufacturing a laminated article having a support member and a surface layer of a resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprising: (a) providing a support member; (b) applying a porous metal plate on the support member by a flame spraying process; (c) applying fluoropolymer primer to the porous metal plate; (d) drying the fluoropolymer primer; (e) applying powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether to the dried primer-coated metal plate; and (f) heating the powder resin copolymer at a temperature sufficient to fuse the powder resin copolymer until fusion is complete.
Claim 2
Independent Claim
98 words
A method for manufacturing a laminated article having a support member and a surface layer of a resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprising: (a) providing a support member; (b) applying a porous metal plate on the support member by a flame spraying process; (c) applying fluoropolymer primer to the porous metal plate; (d) drying the fluoropolymer primer; (e) applying powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether to the dried primer-coated metal plate; and (f) heating the powder resin copolymer at a temperature sufficient to fuse the powder resin copolymer until fusion is complete.
Claim 3
Dependent Claim
25 words
The method of claim 1 wherein the flame sprayed metal plate is from about 0.15 mil (0.004 mm) to about 1.25 mil (0.032 mm) thick.
Claim 4
Dependent Claim
18 words
The method of claim 1 wherein the fluoropolymer primer is applied to the porous metal plate by spraying.
Claim 5
Dependent Claim
22 words
The method of claim 1 wherein the fluoropolymer primer is heated at a temperature from about 87° C. to about 110° C.
Claim 6
Dependent Claim
24 words
The method of claim 1 wherein the powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether is applied by an electrostatic powder coating process.
Claim 7
Dependent Claim
34 words
The method of claim 1 wherein the powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether is applied in a thickness of from about 0.5 mil (0.013 mm) to about 5 mils (0.13 mm).
Claim 8
Dependent Claim
25 words
The method of claim 1 wherein powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether is heated at about 300° C. to about 425° C.
Claim 9
Dependent Claim
35 words
The method of claim 1 wherein the powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprises substantially spherical beads with a diameter from about 5 microns (0.005 mm) to about 150 microns (0.15 mm).
Claim 10
Dependent Claim
22 words
The method of claim 1 further comprising the step of grit blasting the metal substrate prior to applying the porous metal substrate.
Claim 11
Dependent Claim
11 words
The method of claim 1 wherein the fluoropolymer primer is acidic.
Claim 12
Independent Claim
169 words
A method for manufacturing a laminated fuser member having a metal substrate and a surface layer of a resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprising: (a) providing a metal substrate as a support member; (b) applying a porous, stainless steel plate on the metal substrate by a flame spraying process using a low oxidizing flame and an inert gas as an atomizing gas; (c) applying acid fluoropolymer primer to the flame sprayed, porous stainless steel plate; (d) drying the acid fluoropolymer primer until the primer is dried upon the flame sprayed, porous stainless steel plate; (e) applying sufficient powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether to the dried primer-coated stainless steel plate so that the fused resin copolymer has a thickness of about 0.006 mm to about 0.032 mm, said powder resin copolymer being applied by an electrostatic powder coating process; and (f) heating the powder resin copolymer at a temperature of about 300° C. to about 425° C. to fuse the powder resin copolymer.
Claim 13
Independent Claim
169 words
A method for manufacturing a laminated fuser member having a metal substrate and a surface layer of a resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprising: (a) providing a metal substrate as a support member; (b) applying a porous, stainless steel plate on the metal substrate by a flame spraying process using a low oxidizing flame and an inert gas as an atomizing gas; (c) applying acid fluoropolymer primer to the flame sprayed, porous stainless steel plate; (d) drying the acid fluoropolymer primer until the primer is dried upon the flame sprayed, porous stainless steel plate; (e) applying sufficient powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether to the dried primer-coated stainless steel plate so that the fused resin copolymer has a thickness of about 0.006 mm to about 0.032 mm, said powder resin copolymer being applied by an electrostatic powder coating process; and (f) heating the powder resin copolymer at a temperature of about 300° C. to about 425° C. to fuse the powder resin copolymer.
Claim 14
Dependent Claim
34 words
The method of claim 11 wherein the powder resin copolymer is applied in the form of substantially spherical beads having a diameter from about 5 microns (0.005 mm) to about 150 microns (0.15 mm).
Claim 15
Dependent Claim
10 words
The fuser member made by the method of claim 11.
Claim 16
Dependent Claim
76 words
A laminated article comprising: a support member having a porous flame sprayed metal surface layer; a fluoropolymer primer dried upon the flame sprayed metal surface; and an outer layer over said primer, said outer layer comprising a copolymer resin of perfluoroalkyl perfluorovinyl ether with tetrafluoroethylene, said ether having the formula C n F 2n+1 --O--CF═CF 2 , said outer layer being placed upon the dried primer in the form of a powder coating and fused thereon.
Claim 17
Dependent Claim
76 words
A laminated article comprising: a support member having a porous flame sprayed metal surface layer; a fluoropolymer primer dried upon the flame sprayed metal surface; and an outer layer over said primer, said outer layer comprising a copolymer resin of perfluoroalkyl perfluorovinyl ether with tetrafluoroethylene, said ether having the formula C n F 2n+1 --O--CF═CF 2 , said outer layer being placed upon the dried primer in the form of a powder coating and fused thereon.
Claim 18
Dependent Claim
16 words
An article according to claim 14 wherein n is a number from 1 to 5 inclusive.
Claim 19
Dependent Claim
24 words
The article of claim 14 wherein the outer layer has a thickness of about 0.2 mil (0.005 mm) to about 5 mils (0.13 mm).
Claim 20
Dependent Claim
18 words
The article of claim 14 wherein the flame sprayed metal layer is deposited by a low oxidizing flame.
Claim 21
Dependent Claim
17 words
The article of claim 14 wherein the flame sprayed metal upon the support member is stainless steel.
Claim 22
Dependent Claim
15 words
The article of claim 18 wherein the chromium content of the stainless steel is high.
Claim 23
Dependent Claim
26 words
The article of claim 14 wherein the flame sprayed metal layer is deposited by a flame spray process using an inert gas as an atomizing gas.
Claim 24
Dependent Claim
22 words
The article of claim 14 wherein the flame sprayed layer is about 0.15 mil (0.004 mm) to about 1.25 mil (0.032 mm).
Claim 25
Dependent Claim
13 words
The article of claim 14 wherein the support member is a fuser roll.
Claim 26
Dependent Claim
13 words
The article of claim 14 wherein the support member is a fuser plate.
Claim 27
Dependent Claim
13 words
The article of claim 14 wherein the support member is a fuser belt.
Claim 28
Dependent Claim
23 words
The article of claim 14 wherein the thickness of the flame sprayed metal surface is from about 0.004 mm to about 0.032 mm.
Claim 29
Independent Claim
83 words
A method for manufacturing a laminated article having a support member and a surface layer of a resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprising: (a) providing a support member; (b) applying a porous metal plate on the support member by a flame spraying process; (c) applying powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether to the porous metal plate; and (d) heating the powder resin copolymer at a temperature sufficient to fuse the powder resin copolymer until fusion is complete.
Claim 30
Independent Claim
83 words
A method for manufacturing a laminated article having a support member and a surface layer of a resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether comprising: (a) providing a support member; (b) applying a porous metal plate on the support member by a flame spraying process; (c) applying powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether to the porous metal plate; and (d) heating the powder resin copolymer at a temperature sufficient to fuse the powder resin copolymer until fusion is complete.
Claim 31
Dependent Claim
22 words
The method of claim 26 wherein the flame sprayed metal plate is from about 0.004 mm to about 0.032 mm in thickness.
Claim 32
Dependent Claim
24 words
The method of claim 26 wherein the powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether is applied by an electrostatic powder coating process.
Claim 33
Dependent Claim
30 words
The method of claim 26 wherein the powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether is applied in a thickness of from about 0.025 mm to about 0.13 mm.
Claim 34
Dependent Claim
26 words
The method of claim 26 wherein the powder resin copolymer of tetrafluoroethylene and perfluoroalkyl perfluorovinyl ether is heated at about 300° C. to about 425° C.
Claim 35
Dependent Claim
10 words
The fuser member made by the method of claim 26.
Claim 36
Dependent Claim
74 words
A laminated article comprising: a support member having a porous flame sprayed metal surface layer; an outer layer over said porous flame sprayed metal surface layer, said outer layer comprising a copolymer resin of perfluoroalkyl perfluorovinyl ether with tetrafluoroethylene, said ether having the formula: C n F 2n+1 --O--CF═CF 2 , said outer layer being placed upon the porous flame sprayed metal surface layer in the form of a powder coating and fused thereon.
Claim 37
Dependent Claim
74 words
A laminated article comprising: a support member having a porous flame sprayed metal surface layer; an outer layer over said porous flame sprayed metal surface layer, said outer layer comprising a copolymer resin of perfluoroalkyl perfluorovinyl ether with tetrafluoroethylene, said ether having the formula: C n F 2n+1 --O--CF═CF 2 , said outer layer being placed upon the porous flame sprayed metal surface layer in the form of a powder coating and fused thereon.
Claim 38
Dependent Claim
16 words
An article according to claim 32 wherein n is a number from 1 to 5 inclusive.
Claim 39
Dependent Claim
24 words
The article of claim 32 wherein the outer layer has a thickness of about 1 mil (0.025 mm) to about 5 mils (0.13 mm).
Claim 40
Dependent Claim
18 words
The article of claim 32 wherein the flame sprayed metal layer is deposited by a low oxidizing flame.
Claim 41
Dependent Claim
17 words
The article of claim 32 wherein the flame sprayed metal upon the support member is stainless steel.
Claim 42
Dependent Claim
15 words
The article of claim 36 wherein the chromium content of the stainless steel is high.
Claim 43
Dependent Claim
26 words
The article of claim 32 wherein the flame sprayed metal layer is deposited by a flame spray process using an inert gas as an atomizing gas.
Claim 44
Dependent Claim
18 words
The article of claim 32 wherein the flame sprayed layer is about 0.004 mm to about 0.032 mm.
Claim 45
Dependent Claim
13 words
The article of claim 32 wherein the support member is a fuser roll.
Claim 46
Dependent Claim
13 words
The article of claim 32 wherein the support member is a fuser plate.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-04-01 | 1983-10-01 | 1984-04-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-04-01 | 1987-10-01 | 1988-04-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-04-01 | 1991-10-01 | 1992-04-01 | $7700.00 | Window Closed / Lapsed |