WO1994016539A1 - Rouleau chauffant en ceramique et son procede de fabrication - Google Patents
Rouleau chauffant en ceramique et son procede de fabrication Download PDFInfo
- Publication number
- WO1994016539A1 WO1994016539A1 PCT/US1993/007524 US9307524W WO9416539A1 WO 1994016539 A1 WO1994016539 A1 WO 1994016539A1 US 9307524 W US9307524 W US 9307524W WO 9416539 A1 WO9416539 A1 WO 9416539A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- roller
- layer
- heating layer
- ceramic
- ceramic heating
- Prior art date
Links
- 239000000919 ceramic Substances 0.000 title claims abstract description 83
- 238000000034 method Methods 0.000 title claims abstract description 12
- 238000010438 heat treatment Methods 0.000 claims abstract description 56
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 16
- 238000007750 plasma spraying Methods 0.000 claims abstract description 16
- 239000004203 carnauba wax Substances 0.000 claims abstract description 4
- 235000013869 carnauba wax Nutrition 0.000 claims abstract description 4
- 239000010410 layer Substances 0.000 claims description 123
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 36
- 239000004408 titanium dioxide Substances 0.000 claims description 16
- 239000002346 layers by function Substances 0.000 claims description 13
- 239000001257 hydrogen Substances 0.000 claims description 11
- 229910052739 hydrogen Inorganic materials 0.000 claims description 11
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 9
- 238000007751 thermal spraying Methods 0.000 claims description 6
- 239000010935 stainless steel Substances 0.000 claims description 5
- 229910001220 stainless steel Inorganic materials 0.000 claims description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 4
- 239000004020 conductor Substances 0.000 claims description 4
- 239000007769 metal material Substances 0.000 claims description 4
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 claims description 3
- 229910000423 chromium oxide Inorganic materials 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 2
- 239000011195 cermet Substances 0.000 claims description 2
- 239000011810 insulating material Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 125000004435 hydrogen atom Chemical class [H]* 0.000 claims 5
- 230000003247 decreasing effect Effects 0.000 claims 1
- 239000011343 solid material Substances 0.000 claims 1
- 229910052751 metal Inorganic materials 0.000 abstract description 20
- 239000002184 metal Substances 0.000 abstract description 20
- 239000000463 material Substances 0.000 abstract description 16
- 239000007787 solid Substances 0.000 abstract description 2
- 230000035515 penetration Effects 0.000 abstract 1
- 239000011162 core material Substances 0.000 description 26
- 238000000576 coating method Methods 0.000 description 14
- 239000011248 coating agent Substances 0.000 description 13
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- 239000000203 mixture Substances 0.000 description 8
- 239000007921 spray Substances 0.000 description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 5
- -1 Metro 450 or 480 Chemical compound 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 238000010276 construction Methods 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 239000000565 sealant Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 229920002379 silicone rubber Polymers 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000005524 ceramic coating Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000003989 dielectric material Substances 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 239000012634 fragment Substances 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 229910000907 nickel aluminide Inorganic materials 0.000 description 2
- 238000007639 printing Methods 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000004945 silicone rubber Substances 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 239000004634 thermosetting polymer Substances 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000013005 condensation curing Methods 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 239000013536 elastomeric material Substances 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002734 metacrylic acid derivatives Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000012720 thermal barrier coating Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
Classifications
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
- G03G15/00—Apparatus for electrographic processes using a charge pattern
- G03G15/20—Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
- G03G15/2003—Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat using heat
- G03G15/2014—Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat using heat using contact heat
- G03G15/2053—Structural details of heat elements, e.g. structure of roller or belt, eddy current, induction heating
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
- H05B6/14—Tools, e.g. nozzles, rollers, calenders
- H05B6/145—Heated rollers
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
- G03G15/00—Apparatus for electrographic processes using a charge pattern
- G03G15/20—Apparatus for electrographic processes using a charge pattern for fixing, e.g. by using heat
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
- H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
- H05B3/141—Conductive ceramics, e.g. metal oxides, metal carbides, barium titanate, ferrites, zirconia, vitrous compounds
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/40—Heating elements having the shape of rods or tubes
- H05B3/42—Heating elements having the shape of rods or tubes non-flexible
- H05B3/46—Heating elements having the shape of rods or tubes non-flexible heating conductor mounted on insulating base
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
- G03G2215/00—Apparatus for electrophotographic processes
- G03G2215/20—Details of the fixing device or porcess
Definitions
- the invention relates to heater rollers for use in a variety of industrial machines, as well as methods of making such rollers.
- Steam-heated and induction-heated rollers are used in the paper making, printing, paper, film, and foil converting industries. Some examples are: web heating rollers, drying rollers and drums, laminating rollers, embossing rollers, and cast film extrusion rollers.
- Steam-heated rollers are actually pressure vessels, especially at higher temperatures.
- the internal construction of both steam-heated and induction-heated cores can be quite complex and expensive in order to provide the temperature uniformity needed.
- auxiliary equipment is needed to power or heat the roller.
- the fuser roller melts the toner and presses it into the paper.
- the typical fuser roller consists of an aluminum or non-magnetic metal core with an internal quartz heating lamp.
- the inner diameter of the core has a special coating to absorb heat from the lamp.
- the roller is coated with a non-stick elastomeric material (e.g. silicone rubber) to provide a pressure nip with an opposing roller and to release the toner to the paper.
- the core construction is quite complex and expensive.
- the quartz lamp is fragile, has a limited useful life, and does not provide a uniform temperature distribution to the core.
- Heating rollers for xerography and other applications are disclosed in the following U.S. Patents, Satomura, No.4,628,183; Nagaska, et al., No. 4,743,940; Lee, et al., No. 4,791,275; Kogure, et al. , No. 4,813,372; Urban, et al., No. 4,810,858; Urban, No. 4,820,904, Yoshikawa, et al., I ⁇ o. 4,841,154; Landa, et al., No. 5,089,856.
- one side of a voltage supply is applied to one set of conductive fingers in a ceramic heating layer, while the other side of the voltage supply is applied to another set of conductive fingers in the ceramic heating layer.
- the two sets of fingers are interdigitated and electrical current is produced in the heating layer between the two sets of fingers.
- the ceramic material is a baked ceramic material in which the conductive electrodes are sandwiched between two ceramic layers.
- the present invention is directed to improved constructions of heater rollers utilizing a ceramic heating layer and to improved methods of making such heater rollers.
- the invention relates, in one aspect, to a thermal conduction roller having a cylindrical roller core with a ceramic heating layer of predetermined and controlled resistance disposed around and over the core.
- a conductive ground layer is disposed around and over the ceramic heating layer, the conductive ground layer being connectable to an electrical ground.
- a voltage is applied to the core, or to a thin layer of metal on the outer surface of the core. Current flows outwardly from the core through the ceramic heating layer to the outer ground layer, which may be covered with an outer functional layer of elastomeric or other material for durable performance over the life of the roller.
- the invention relates to the method of making a heater roller in which the ceramic heating layer is formed by plasma spraying, which is one type of thermal spraying. This significantly decreases the resistance of a semiconductive ceramic material. The ceramic material is applied in a manner to control electrical resistance of the ceramic heating layer.
- the electrical resistance of the ceramic heating layer can be controlled by blending the first ceramic material with a metallic material or with a second semiconductive ceramic material and applying the ceramic heating layer in a thickness selected to control electrical resistance.
- the ceramic heating layer is formed of a plurality of thinner layers, which are applied one over the other to build up the ceramic heating layer.
- the electrical resistance of the ceramic heating layer can also be controlled by varying the hydrogen secondary plasma gas level during plasma spraying.
- Fig. 1 is a perspective view of a roller of the present invention with parts broken away;
- Fig. 2 is a cross sectional view of a portion of the roller of Fig. 1;
- Fig. 3 is a left end fragment of a longitudinal section of the roller of Fig. 1;
- Fig. 4 is a right end fragment of a longitudinal section of the roller of Fig. 1;
- Fig. 5 is an exploded view of the roller of Fig. 1 showing use of a metallic sleeve to form the metallic layers of the roller.
- Fig. 1 shows a preferred embodiment of a heater roller 10 of a type for use in copying machines, or in other industrial applications, such as steam-heated or induction- heated rollers for the paper making, printing, paper, film, and foil converting industries.
- the finished roller 10 includes a hollow cylindrical core 11 with suitable journal shafts 25 for disposition in suitable machine bearing structures of a type known in the art.
- the core material in the preferred embodiment is glass, but stainless steel, brass, some steels, aluminum, or an FRP composite type material can also be used. If a non- insulating core is used, the shafts 25 or their bearings must be insulated from the rest of the machine.
- This metal layer 12 can be formed by plasma spraying a bond coating over the full outer surface of the core 11, or as shown in Fig. 5, this layer can be formed by an expandable metal sleeve 13, which is placed over the non ⁇ conducting material 11 as shown in Fig. 5. A bond coating may then be sprayed on the metal sleeve 13 to assist the formation of a bond to the next layer.
- a ceramic layer 14 from 1 to 100 mils in thickness is formed over the full outer surface of the bonding layer 12.
- This layer 15 can be formed by an expandable metal sleeve similar to the sleeve 13, which is shown in Fig. 5.
- the outer surface of the roller 10 is provided by a functional layer 16 of ceramic, alloy, tungsten carbide, or elastomeric/polymeric material. If the outer functional layer 16 is formed of a metal, such as stainless steel, nickel, or tungsten carbide/cobalt composite, this outer layer 16 is connected to a grounded negative (-) side of the power supply. If the outer functional layer 16 is formed of a ceramic, the ceramic is applied by plasma spraying.
- the inner metal layer 12 forms a ring-shaped band 18 extending from one end of the roller 10 (Fig. 4) .
- the outer metal layer 15 forms a ring-shaped band 21 extending from an opposite end of the roller 10 (Fig. 3).
- the voltage source 20 may supply either alternating current or direct current. ith this arrangement, current flows in a radial direction between layers 12 and 15 relative to a longitudinal axis 23 of the roller 10 seen in Figs. 1 and 2.
- a metallic bonding layer 12 of nickel-aluminide such as Metro 450 or 480, or nickel-chrome, such as Metro 43C, is applied in a layer 3 mils to 5 mils thick or more.
- the bonding layer 12 provides the surface roughness Ra of 300 microinches or greater.
- the heater layer 14 is electrically and (optionally) thermally isolated from the metallic core by an insulating layer (not shown) of plasma sprayed ceramic such as alumina, Metco 101 or 105, or preferably zirconia, Metco 201 or 204.
- insulating layer (not shown) of plasma sprayed ceramic such as alumina, Metco 101 or 105, or preferably zirconia, Metco 201 or 204.
- Zirconia can be used as an electrically insulating barrier coating a few mils thick. In thicker layers, zirconia is an effective thermal barrier coating due to its low thermal conductivity. It can be plasma sprayed in layers of 250 mils thick (1/4 inch) or greater.
- the insulating layer does not need to be any thicker than what is required to resist the voltage applied to the heater layer.
- the dielectric strength of plasma-sprayed alumina for example can be up to 300 volts per mil of coating thickness.
- the preferred material for the ceramic heating layer 14 is titanium dioxide, such as Metco 102 ceramic powder. This is commercially available from Metco Corp., Westbury, New York, USA. Titanium dioxide (Ti ⁇ 2) is normally an electrical insulating material. However, when the material is plasma-sprayed, some of the dioxide form is chemically reduced to a conductive sub-oxide (mono-oxide) form, rendering the deposited coating electrically semi ⁇ conductive.
- the term "insulating" material shall mean a material with a volume resistivity of 10 10 ohm- centimeters or greater. As used herein, the term
- “semiconductive” material shall mean a material with a volume resistivity between 10 3 ohm-centimeters and 10 10 ohm-centimeters. Titanium dioxide (T-j.0 2 ) and chromium oxide (Cr 2 ⁇ 4 ) are examples of semiconductive or lower resistance ceramics. These ceramics have volume resistivities typically of 10 8 ohm-centimeters or lower.
- Titanium dioxide can be used as the only component of the heater layer or it can be blended with other ceramics or metals to increase or decrease the volume resistivity of the final coating.
- insulating ceramics such as zirconia or alumina can be blended with semiconductive ceramics such as chromium oxide, or with conductive metals such as nickel, milled steel, stainless steel or other alloys, or aluminum.
- Plasma spraying of a ceramic-metal mixture changes the porosity of the ceramic coating to reduce thermally induced stress during its service life, and minimizes thermal expansion differences between the metallic core and ceramic layers over the useable temperature range of the roller.
- Plasma spraying which is one type of thermal spraying, is advantageous in adjusting the thickness of the coating to a suitable range independent of the electrical resistance of the titanium dioxide portion of the heater layer.
- the resistance of the layer is also affected by the spraying conditions. Titania can be partially reduced to a suboxide by the presence of hydrogen or other reducing agents in the plasma flame. It is the suboxide (probably TiO rather than 3. O 2 ) that is the semiconductor in the ceramic layer 14. Titanium dioxide is normally a dielectric material. The typical average chemical composition of titanium dioxide is 1.8 oxygen per molecule rather ' than 2.0 in a plasma sprayed coating.
- This level (and thus the coating properties) can be adjusted to some extent by raising or lowering the percent of hydrogen in the plasma flame.
- the normal primary gas is nitrogen or argon while the secondary gas is hydrogen or helium.
- the secondary gas raises the ionization potential of the mixture, thus increasing the power level at a given electrode current.
- the hydrogen level is adjusted to maintain the electrode voltage in the gun between 74 and 80 volts.
- the plasma spray parameters should be suitably adjusted to insure that the blend of materials in the finished ceramic layer 14 is the same as intended. All of the powders mentioned do not require the same power levels, spray distance, and other parameters. Thus, adjustment of spray distance, for example, may increase the deposit efficiency of one powder over the other and change the material blend in the finished coating.
- Plasma sprayed ceramic coatings can be applied in one pass (layer) of the plasma gun or in multiple passes.
- the normal method for most types of coating applications is to apply multiple thin coatings of ceramic and build up to the required thickness.
- the ceramic layer described above has a uniform ceramic composition, the sublayers of ceramic in the resulting layer 14 do not have to have the same composition.
- the hydrogen level can be varied during the application of each spray pass to apply a titanium dioxide layer that has a non-uniform electrical resistance from end to end of the roller. This would normally be done to apply more heat to the ends of the roller, where the heat losses are greater, to achieve a uniform temperature across the roller face in its functional environment.
- the thickness of the heater layer 14 can be adjusted to provide the appropriate resistance for the application.
- the heater layer 14 may vary in total thickness from about 1 mil to about 100 mils depending on the roller diameter and length, operating temperature, wattage throughput and power supply voltage. In the preferred embodiment, the heater layer 14 is in a range from 5 mils to 10 mils thick.
- Plasma-sprayed ceramic can be applied in very thin layers (at least as low as 0.1 mil per spray pass). For many heating applications, the heater layer formed by plasma-spraying thin layers will provide a minimal temperature variation due to thickness variation of the resulting layer.
- the temperature uniformity depends primarily on the thickness uniformity of the heater layer. Since the heater layer is composed of many, thin layers or spray passes, material variation is generally not an issue.
- the outer functional layer 16 is then applied.
- This may be any material that can be applied by thermal spraying, any elastomer, thermoplastic or thermoset resin, suitable for the roller application.
- the outer metal layer can be applied by electroplating, if the ceramic is sealed, with the outer functional layer, preferably silicone rubber, bonded to the electroplate.
- the electroplate must not contact the core.
- the outer layer 16 can be plasma sprayed metal, if the ceramic is not sealed or ground, with the outer functional layer plasma sprayed and bonded to the sprayed metal layer 15.
- Such outer metallic layer 16 would preferably be a nickel alloy, stainless steel, or low resistance cermet. If the ceramic is ground, it can be sealed. This increases the dielectric strength of the heater layer 14 and prevents moisture and humidity from changing the effective ceramic resistance and causing short circuits. While the roller is still hot from the plasma or thermal spraying of the ceramic layer 14, a seal coat 24 is applied to the ceramic layer 14 using a dielectric organic material such as Carnauba wax or Loctite 290 weld sealant.
- the sealant 24 is cured, if necessary, (Loctite 290) , with heat, ultra violet light, or spray-on accelerators.
- the ceramic porosity level is generally less than 5% by weight (usually on the order of 2%) . Once sealed, the porosity level has a minimal effect on the coating properties for this application.
- the preferred types of materials are 100 percent solids and low viscosity. These include various kinds of waxes, condensation cure silicone elastomers, and epoxies, methacrylates, thermoset resins and polymerizing weld sealants, such as Loctite 290.
- the sealer will generally be a high resistance material, although the electrical properties of the sealer affect the overall properties of the sealed ceramic layers 14, 24. For example, sealing with Carnauba wax will result in a higher resistance of the sealed ceramic layer 14, 24 than Loctite 290 weld sealant because it is a better dielectric material.
- a finishing step is to grind and polish the sealed ceramic layer 14, 24 to the proper dimensions and surface finish (diamond, silicon carbide abrasives, etc.).
- the outer metallic layer 15 can be a metallic sleeve of nickel, steel, or aluminum, that is removeable and replaceable.
- the outer functional layer 16 is then bonded to the replaceable sleeve.
- the ceramic heater layer 14 would be ground and sealed in this case. If the outer functional layer 16 is damaged or wears out, the roller can be returned to service simply by installing a new sleeve.
- the surface of the core 11 can be crowned positive or negative, to provide a variable ceramic heater layer thickness to compensate for non-uniform heat losses. This could be used to provide a certain temperature profile across the face of the roller 10 in its application.
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- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- General Physics & Mathematics (AREA)
- Fixing For Electrophotography (AREA)
- Control Of Resistance Heating (AREA)
- Rolls And Other Rotary Bodies (AREA)
Abstract
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1019950702877A KR960700548A (ko) | 1993-01-12 | 1993-08-11 | 세라믹 가열기 롤러 및 그의 제조 방법 |
JP6515947A JPH08507636A (ja) | 1993-01-12 | 1993-08-11 | セラミックヒータローラとその製法 |
EP93919959A EP0679324A1 (fr) | 1993-01-12 | 1993-08-11 | Rouleau chauffant en ceramique et son procede de fabrication |
AU50045/93A AU678391B2 (en) | 1993-01-12 | 1993-08-11 | Ceramic heater roller and methods of making same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US315693A | 1993-01-12 | 1993-01-12 | |
US08/003,156 | 1993-01-12 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1994016539A1 true WO1994016539A1 (fr) | 1994-07-21 |
Family
ID=21704451
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1993/007524 WO1994016539A1 (fr) | 1993-01-12 | 1993-08-11 | Rouleau chauffant en ceramique et son procede de fabrication |
Country Status (6)
Country | Link |
---|---|
EP (1) | EP0679324A1 (fr) |
JP (1) | JPH08507636A (fr) |
KR (1) | KR960700548A (fr) |
AU (1) | AU678391B2 (fr) |
CA (1) | CA2153598C (fr) |
WO (1) | WO1994016539A1 (fr) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2302841A (en) * | 1995-07-04 | 1997-02-05 | Samsung Electronics Co Ltd | Fixing rollers for electrophotography |
US5821499A (en) * | 1995-03-31 | 1998-10-13 | D & K Custom Machine Design, Inc. | Heated roller assembly |
WO1999041646A1 (fr) * | 1998-02-12 | 1999-08-19 | American Roller Company | Revetements non collants pour rouleaux d'impression et de couchage |
WO1999051064A1 (fr) * | 1998-03-30 | 1999-10-07 | American Roller Company | Rouleau chauffant en ceramique avec blindage de mise a la terre et detection de defauts |
WO2001043506A1 (fr) * | 1999-12-10 | 2001-06-14 | Bdsb Holdings Limited | Procede de fabrication d'elements chauffants a resistance electrique composes d'oxydes metalliques semi-conducteurs et elements a resistance ainsi fabriques |
WO2004040380A1 (fr) * | 2002-10-31 | 2004-05-13 | Hot Tech Ab | Fabrication d'un rouleau de thermofixage |
US9752007B2 (en) | 2012-07-30 | 2017-09-05 | Dow Corning Corporation | Thermally conductive condensation reaction curable polyorganosiloxane composition and methods for the preparation and use of the composition |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3107290A1 (de) * | 1980-03-03 | 1982-01-07 | Canon K.K., Tokyo | Heizvorrichtung |
JPS5821279A (ja) * | 1981-07-30 | 1983-02-08 | Matsushita Electric Ind Co Ltd | 複写機のトナ−定着用ロ−ルヒ−タ− |
JPS59149385A (ja) * | 1983-02-17 | 1984-08-27 | Hitachi Metals Ltd | 加熱定着装置 |
EP0527576A2 (fr) * | 1991-08-08 | 1993-02-17 | Kabushiki Kaisha TEC | Dispositif de fixage |
US5191381A (en) * | 1991-08-12 | 1993-03-02 | Jie Yuan | PTC ceramic heat roller for fixing toner image |
-
1993
- 1993-08-11 WO PCT/US1993/007524 patent/WO1994016539A1/fr not_active Application Discontinuation
- 1993-08-11 KR KR1019950702877A patent/KR960700548A/ko active IP Right Grant
- 1993-08-11 JP JP6515947A patent/JPH08507636A/ja active Pending
- 1993-08-11 CA CA002153598A patent/CA2153598C/fr not_active Expired - Fee Related
- 1993-08-11 AU AU50045/93A patent/AU678391B2/en not_active Ceased
- 1993-08-11 EP EP93919959A patent/EP0679324A1/fr not_active Ceased
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3107290A1 (de) * | 1980-03-03 | 1982-01-07 | Canon K.K., Tokyo | Heizvorrichtung |
JPS5821279A (ja) * | 1981-07-30 | 1983-02-08 | Matsushita Electric Ind Co Ltd | 複写機のトナ−定着用ロ−ルヒ−タ− |
JPS59149385A (ja) * | 1983-02-17 | 1984-08-27 | Hitachi Metals Ltd | 加熱定着装置 |
EP0527576A2 (fr) * | 1991-08-08 | 1993-02-17 | Kabushiki Kaisha TEC | Dispositif de fixage |
US5191381A (en) * | 1991-08-12 | 1993-03-02 | Jie Yuan | PTC ceramic heat roller for fixing toner image |
Non-Patent Citations (2)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 7, no. 96 (P - 193)<1241> 22 April 1983 (1983-04-22) * |
PATENT ABSTRACTS OF JAPAN vol. 8, no. 286 (P - 324)<1723> 27 December 1984 (1984-12-27) * |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6069346A (en) * | 1993-01-12 | 2000-05-30 | American Roller Company | Ceramic heater roller with ground shield and fault detection |
US5821499A (en) * | 1995-03-31 | 1998-10-13 | D & K Custom Machine Design, Inc. | Heated roller assembly |
GB2302841A (en) * | 1995-07-04 | 1997-02-05 | Samsung Electronics Co Ltd | Fixing rollers for electrophotography |
GB2302841B (en) * | 1995-07-04 | 1997-09-17 | Samsung Electronics Co Ltd | Heating rollers for electrophotographic apparatus |
WO1999041646A1 (fr) * | 1998-02-12 | 1999-08-19 | American Roller Company | Revetements non collants pour rouleaux d'impression et de couchage |
US5997456A (en) * | 1998-02-12 | 1999-12-07 | American Roller Company | High release coatings for printing and coating rollers |
WO1999051064A1 (fr) * | 1998-03-30 | 1999-10-07 | American Roller Company | Rouleau chauffant en ceramique avec blindage de mise a la terre et detection de defauts |
WO2001043506A1 (fr) * | 1999-12-10 | 2001-06-14 | Bdsb Holdings Limited | Procede de fabrication d'elements chauffants a resistance electrique composes d'oxydes metalliques semi-conducteurs et elements a resistance ainsi fabriques |
WO2004040380A1 (fr) * | 2002-10-31 | 2004-05-13 | Hot Tech Ab | Fabrication d'un rouleau de thermofixage |
US9752007B2 (en) | 2012-07-30 | 2017-09-05 | Dow Corning Corporation | Thermally conductive condensation reaction curable polyorganosiloxane composition and methods for the preparation and use of the composition |
Also Published As
Publication number | Publication date |
---|---|
KR960700548A (ko) | 1996-01-20 |
AU5004593A (en) | 1994-08-15 |
CA2153598A1 (fr) | 1994-07-21 |
AU678391B2 (en) | 1997-05-29 |
CA2153598C (fr) | 1998-12-15 |
JPH08507636A (ja) | 1996-08-13 |
EP0679324A1 (fr) | 1995-11-02 |
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