Heat fixing roller having powder metal gudgeon

Claim 2

A fixing mechanism for electrostatographic reproduction apparatus including a heated roller, the heated roller comprising: (a) a core, said core being made from a high thermally conductive metallic material; and (b) a gudgeon for supporting said core, said gudgeon being made from an austenitic stainless steel powder metal part having an interconnected porosity of 20%.

Claim 3

The fixing mechanism of claim 1 wherein said heated roller further includes a heat conducting and compliant outer layer.

Claim 4

The fixing mechanism of claim 1 wherein said heated roller includes a pair of said gudgeons, one at each end of said core.

Claim 5

The fixing mechanism of claim 1 wherein said gudgeon is made from minus one hundred mesh particle size powder.

Claim 6

The fixing mechanism of claim 1 wherein said gudgeon has a sintered density of 6.0 gm/cc.

Claim 7

The fixing mechanism of claim 1 wherein said gudgeon has an interconnected porosity of about 20%.

Claim 8

The fixing mechanism of claim 1 wherein said gudgeon has a generally cylindrical head including a face portion, a shoulder portion, and an angularly shaped journal body portion smaller in diameter than said head portion, said body portion having a plurality of narrow corner flats forming bearing surfaces thereto.

Claim 9

The fixing mechanism of claim 1 wherein said gudgeon has a thermal conductivity of about 5.0 BTU-FT/HR-FT 2 -°F. at 400° F.

Claim 10

The fixing mechanism of claim 1 including means for mounting said heated roller to the frame of such copier or printer, said mounting means including: (a) a bearing for said gudgeon; (b) a thermally insulative sleeve mounted between said bearing and said gudgeon for thermally insulating said bearing from said gudgeon; (c) a sprocket mounted on said gudgeon adjacent said bearing for driving said gudgeon; and (d) a retaining ring mounted in a groove adjacent said sprocket for axially retaining said sprocket on said gudgeon.

Claim 11

The fixing mechanism of claim 1 wherein said gudgeon has a sintered density of about 6.0 gm/cc.

Claim 12

The fixing mechanism of claim 4 wherein said gudgeon is made from AISI type 316 stainless steel powder.

Claim 13

The fixing mechanism of claim 9 wherein said head and journal portions of said gudgeon include a generally cylindrical internal bore.

Claim 14

The fixing mechanism of claim 9 wherein said head of said gudgeon includes a nose portion defining a first outer diameter of said head, a flange portion defining a second and larger outer diameter to said head, and an undercut groove between said nose and said flange portions.

Claim 15

The gudgeon of claim 12 wherein said bore therein has an angular cross-section at the tail end of said gudgeon.

Claim 16

The fixing mechanism of claim 13 wherein said first outer diameter of said gudgeon head is barely less than the inner diameter of said core.

Claim 17

The fixing mechanism of claim 13 wherein said shoulder of said gudgeon includes a recessed area therein for forming an insulative air pocket between said shoulder and said bearing.

Claim 18

The heated roller of claim 13 wherein said second outer diameter of said gudgeon head is less than said outer diameter of said core.

Claim 19

The fixing mechanism of claim 13 wherein the bottom or base of said undercut groove forms a third outer diameter of said head, said third outer diameter of said head being less than said first outer diameter thereof.

Claim 20

The fixing mechanism of claim 13 wherein said undercut groove is filled by a contracted weld upset of the material of said core; said upset being created by means of friction welding.

Claim 21

A process for making stainless steel powder metal gudgeons to be connected to a heated roller of an electrostatographic fixing mechanism, the process including the steps of: (a) molding austenitic stainless steel powder so as to produce a gudgeon having a green density of 5.7 gm/cc; and (b) sintering the molded gudgeon at a temperature within the range 2200°-2500° F. so as to achieve an interconnected porosity of about 20%.

Claim 22

A process for making stainless steel powder metal gudgeons to be connected to a heated roller of an electrostatographic fixing mechanism, the process including the steps of: (a) molding austenitic stainless steel powder so as to produce a gudgeon having a green density of 5.7 gm/cc; and (b) sintering the molded gudgeon at a temperature within the range 2200°-2500° F. so as to achieve an interconnected porosity of about 20%.

Claim 23

The process of claim 20 wherein the stainless steel powder being molded is -100 mesh AISI 316 stainless steel powder.

Claim 24

The process of claim 20 wherein the density of the gudgeon after sintering is 6.0 gm/cc.

Claim 25

The process of claim 20 wherein the stainless steel powder being molded includes 1-5% by weight of molybdenium disulfide for increased machinability.

Claim 26

The process of claim 20 wherein said molded gudgeon is sintered at a temperature of 2,325° F.

Claim 27

A process for making and connecting a stainless steel powder metal gudgeon to a metallic core heated roller of an electrostatographic fixing mechanism, the process including the steps of: (a) molding the stainless steel powder metal into a gudgeon having a generally cylindrical head including a nose portion and a shoulder flange portion; (b) sintering the molded gudgeon at a temperature within the range 2200°-2500° F. so as to achieve an interconnected porosity of about 20%; and (c) friction welding the head of the gudgeon to the metalic core of the heated roller such that the nose portion of the gudgeon forced-fits into an end of such core.

Claim 28

A process for making and connecting a stainless steel powder metal gudgeon to a metallic core heated roller of an electrostatographic fixing mechanism, the process including the steps of: (a) molding the stainless steel powder metal into a gudgeon having a generally cylindrical head including a nose portion and a shoulder flange portion; (b) sintering the molded gudgeon at a temperature within the range 2200°-2500° F. so as to achieve an interconnected porosity of about 20%; and (c) friction welding the head of the gudgeon to the metalic core of the heated roller such that the nose portion of the gudgeon forced-fits into an end of such core.

Claim 29

The process of claim 25 further including the step of machining an undercut groove, between the nose and shoulder flange portions of the sintered gudgeon, for receiving a welding upset during friction welding.