Process for electrostatographic reproduction
View Patent ↗A process for fusing toner to paper. The toner fusing system for conducting this process includes a fuser roller consisting of a base, and a fusing surface layer that includes both a fluoroelastomer continuous phase, and also a discontinuous phase dispersed through the continuous phase in the form of domains.
1. A process for fusing toner residing on a substrate to the substrate, the process comprising transmitting heat to the toner, and also comprising contacting the toner with the fusing surface layer of a fuser member, comprising:
(a) a base; and
(b) a fusing surface layer comprising:
(i) a fluoroelastomer continuous phase; and
(ii) discontinuous phase dispersed through the fluoroelastomer continuous phase in the form of domains;
wherein, at the temperature of the fusing process:
the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase; and
the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is greater than 1.0;
the viscosity of the toner is at least 100 Kpoise at a temperature of from 120 to 200° C.; and
the modulus of the discontinuous phase is 8×10 6 Pa or less; and
wherein the discontinuous phase comprises one or both of: at least a minimum proportion by volume of the fusing surface layer; and
at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 10 or less; the amount of heat transmitted to the toner being sufficient to fuse the toner to the substrate, and insufficient to raise the gloss number of the image above about 10 or less.
2. The process of claim 1 , wherein at the equilibrium surface of the fusing surface layer:
(a) the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase at the temperature of the fusing process;
(b) the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is greater than 1.0 at the temperature of the fusing process;
(c) the modulus of the discontinuous phase is 8×10 6 Pa or less at the temperature of the fusing process; and
(d) the discontinuous phase comprises one or both of:
(i) at least a minimum proportion by volume of the fusing surface layer; and
(ii) at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 10 or less.
3. The process of claim 1 , wherein the toner comprises crosslinking, and further comprises at least one member selected from the group consisting of styrene-butadiene thermoplastic toner, styrene-butylacrylate thermoplastic toner, and polyester thermoplastic toner.
4. The process of claim 1 , wherein the discontinuous phase comprises at least one elastomer.
5. The process of claim 4 , wherein the elastomer is selected from the group consisting of silicones, fluorosilicones, fluoroelastomers, and perfluoropolyethers.
6. The process of claim 5 , wherein the discontinuous phase comprises a silicone elastomer.
7. The process of claim 6 , wherein the silicone elastomer comprises silicone elastomer particulate.
8. The process of claim 1 , wherein the discontinuous phase has been prepared from at least one curable polyfunctional poly(C 1-6 alkyl)siloxane polymer.
9. The process of claim 1 , wherein, at the temperature of the fusing process, the fluoroelastomer continuous phase has a modulus of about 5×10 8 Pa or less.
10. The process of claim 9 , wherein, at the temperature of the fusing process, the fluoroelastomer continuous phase has a modulus of about 2×10 8 Pa or less.
11. The process of claim 1 , wherein, at the temperature of the fusing process, the fusing surface layer has a modulus of about 2×10 7 Pa or less.
12. The process of claim 11 , wherein, at the temperature of the fusing process, the fusing surface layer has a modulus of about 1×10 7 Pa or less.
13. The process of claim 1 , wherein the domains have a mean diameter of at least about 0.5 microns.
14. The process of claim 1 , wherein the fusing surface layer comprises at least about 20 parts discontinuous phase per 100 parts by weight of the fluoroelastomer continuous phase.
15. The process of claim 1 , wherein the discontinuous phase comprises at least about 10 percent by volume of the fusing surface layer.
16. A process for fusing toner residing on a substrate to the substrate, the process comprising transmitting heat to the toner, and also comprising contacting the toner with the fusing surface layer of a fuser member, comprising:
(a) a base; and
(b) a fusing surface layer comprising:
(i) a fluoroelastomer continuous phase; and
(ii) a discontinuous phase dispersed through the fluoroelastomer continuous phase in the form of domains;
wherein, at the temperature of the fusing process:
the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase; and
the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is at least 1.0;
the viscosity of the toner is at least 100 Kpoise at a temperature of from 120 to 200° C.; and
the modulus of the discontinuous phase is 8×10 6 Pa or less; and
wherein the discontinuous phase comprises one or both of:
at least a minimum proportion by volume of the fusing surface layer; and
at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 8 or less; the amount of heat transmitted to the toner being sufficient to fuse the toner to the substrate, and insufficient to raise the gloss number of the image above about 8 or less.
17. The process of claim 16 , wherein at the equilibrium surface of the fusing surface layer:
(a) the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase at the temperature of the fusing process;
(b) the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is at least 1.0 at the temperature of the fusing process;
(c) the modulus of the discontinuous phase is 8×10 6 Pa or less at the temperature of the fusing process; and
(d) the discontinuous phase comprises one or both of:
(i) at least a minimum proportion by volume of the fusing surface layer; and
(ii) at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 8 or less.
18. The process of claim 16 , wherein the toner comprises crosslinking, and further comprises at least one member selected from the group consisting of styrene-butadiene thermoplastic toner, styrene-butylacrylate thermoplastic toner, and polyester thermoplastic toner.
19. The process of claim 16 , wherein the discontinuous phase comprises at least one elastomer.
20. The process of claim 19 , wherein the elastomer is selected from the group consisting of silicones, fluorosilicones, fluoroelastomers, and perfluoropolyethers.
21. The process of claim 20 , wherein the discontinuous phase comprises a silicone elastomer.
22. The process of claim 21 , wherein the silicone elastomer comprises silicone elastomer particulate.
23. The process of claim 16 , wherein the discontinuous phase has been prepared from at least one curable polyfunctional poly(C 1-6 alkyl)siloxane polymer.
24. The process of claim 16 , wherein, at the temperature of the fusing process, the fluoroelastomer continuous phase has a modulus of about 5×10 8 Pa or less.
25. The process of claim 24 , wherein, at the temperature of the fusing process, the fluoroelastomer continuous phase has a modulus of about 2×10 8 Pa or less.
26. The process of claim 16 , wherein, at the temperature of the fusing process, the fusing surface layer has a modulus of about 2×10 7 Pa or less.
27. The process of claim 26 , wherein, at the temperature of the fusing process, the fusing surface layer has a modulus of about 1×10 7 Pa or less.
28. The process of claim 16 , wherein the domains have a mean diameter of at least about 1 micron.
29. The process of claim 16 , wherein the fusing surface layer comprises at least about 30 parts discontinuous phase per 100 parts by weight of the fluoroelastomer continuous phase.
30. The process of claim 16 , wherein the discontinuous phase comprises at least about 20 percent by volume of the fusing surface layer.
31. A process for fusing toner residing on a substrate to the substrate, the process comprising transmitting heat to the toner, and also comprising contacting the toner with the fusing surface layer of a fuser member comprising:
(a) a base; and
(b) a fusing surface layer comprising:
(i) a fluoroelastomer continuous phase; and
(ii) a discontinuous phase dispersed through the fluoroelastomer continuous phase in the form of domains;
wherein, at the temperature of the fusing process:
the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase; and
the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is at least 1.0;
the viscosity of the toner is at least 100 Kpoise at a temperature of from 120 to 200° C.; and
the modulus of the discontinuous phase is 8×10 6 Pa or less; and
wherein the discontinuous phase comprises one or both of:
at least a minimum proportion by volume of the fusing surface layer; and
at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 6 or less; the amount of heat transmitted to the toner being sufficient to fuse the toner to the substrate, and insufficient to raise the gloss number of the image above about 6 or less.
32. The process of claim 31 , wherein at the equilibrium surface of the fusing surface layer:
(a) the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase at the temperature of the fusing process;
(b) the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is at least 1.0 at the temperature of the fusing process;
(c) the modulus of the discontinuous phase is 8×10 6 Pa or less at the temperature of the fusing process; and
(d) the discontinuous phase comprises one or both of:
(i) at least a minimum proportion by volume of the fusing surface layer; and
(ii) at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 6 or less.
33. The process of claim 31 , wherein the toner comprises at least one member selected from the group consisting of styrene-butadiene thermoplastic toner, styrene-butylacrylate thermoplastic toner, and polyester thermoplastic toner.
34. The process of claim 31 , wherein the discontinuous phase comprises at least one elastomer.
35. The process of claim 34 , wherein the elastomer is selected from the group consisting of silicones, fluorosilicones, fluoroelastomers, and perfluoropolyethers.
36. The process of claim 35 , wherein the discontinuous phase comprises a silicone elastomer.
37. The process of claim 36 , wherein the silicone elastomer comprises silicone elastomer particulate.
38. The process of claim 31 , wherein the discontinuous phase has been prepared from at least one curable polyfunctional poly(C 1-6 alkyl)siloxane polymer.
39. The process of claim 31 , wherein, at the temperature of the fusing process, the fluoroelastomer continuous phase has a modulus of about 5×10 8 Pa or less.
40. The process of claim 39 , wherein, at the temperature of the fusing process, the fluoroelastomer continuous phase has a modulus of about 2×10 8 Pa or less.
41. The process of claim 31 , wherein, at the temperature of the fusing process, the fusing surface layer has a modulus of about 2×10 7 Pa or less.
42. The process of claim 41 , wherein, at the temperature of the fusing process, the fusing surface layer has a modulus of about 1×10 7 Pa or less.
43. The process of claim 31 , wherein the domains have a mean diameter of at least about 2 microns.
44. The process of claim 31 , wherein the fusing surface layer comprises at least about 40 parts discontinuous phase per 100 parts by weight of the fluoroelastomer continuous phase.
45. The process of claim 31 , wherein the discontinuous phase comprises at least about 25 percent by volume of the fusing surface layer.
46. A process for fusing toner residing on a substrate to the substrate, the process comprising transmitting heat to the toner, and also comprising contacting the toner with the fusing surface layer of a fuser member, comprising:
(a) a base; and
(b) a fusing surface layer comprising:
(i) a fluoroelastomer continuous phase; and
(ii) a discontinuous phase dispersed through the fluoroelastomer continuous phase in the form of domains;
wherein, at the temperature of the fusing process:
the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase; and
the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is at least 1.0;
the viscosity of the toner is at least 100 Kpoise at a temperature of from 120 to 200° C.; and
the modulus of the discontinuous phase is 8×10 6 Pa or less; and
wherein the discontinuous phase comprises one or both of:
at least a minimum proportion by volume of the fusing surface layer; and
at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 5 or less; the amount of heat transmitted to the toner being sufficient to fuse the toner to the substrate, and insufficient to raise the gloss number of the image above about 5 or less.
47. The process of claim 46 , wherein at the equilibrium surface of the fusing surface layer:
(a) the modulus of the fluoroelastomer continuous phase is greater than the modulus of the discontinuous phase at the temperature of the fusing process;
(b) the difference between a logarithm of the modulus of the fluoroelastomer continuous phase and a logarithm of the modulus of the discontinuous phase is at least 1.0 at the temperature of the fusing process;
(c) the modulus of the discontinuous phase is 8×10 6 Pa or less at the temperature of the fusing process; and
(d) the discontinuous phase comprises one or both of:
(i) at least a minimum proportion by volume of the fusing surface layer; and
(ii) at least a minimum proportion by weight of the fluoroelastomer continuous phase;
so that the image generated in the process has a gloss number of about 5 or less.