U.S. patent application number 10/687751 was filed with the patent office on 2005-04-21 for high capacity leak resistant release agent delivery system for use in printer devices.
This patent application is currently assigned to BMP AMERICA, INC.. Invention is credited to Doell, Carl E., Lebold, Alan, Milicia, Peter A., Whitehead, Patrick M..
Application Number | 20050085360 10/687751 |
Document ID | / |
Family ID | 34377664 |
Filed Date | 2005-04-21 |
United States Patent
Application |
20050085360 |
Kind Code |
A1 |
Lebold, Alan ; et
al. |
April 21, 2005 |
HIGH CAPACITY LEAK RESISTANT RELEASE AGENT DELIVERY SYSTEM FOR USE
IN PRINTER DEVICES
Abstract
A toner release agent delivery system for a printing device
utilizes a roller which has a plurality of layers of a non-woven
textile web. The textile web is comprised of substantially all
sub-denier fibers. The release agent delivery system with
predominately sub-denier fibers has a very high release agent
retention capability with a very low leak rate.
Inventors: |
Lebold, Alan; (Niagara
Falls, NY) ; Milicia, Peter A.; (Youngstown, NY)
; Whitehead, Patrick M.; (Youngstown, NY) ; Doell,
Carl E.; (Darien, NY) |
Correspondence
Address: |
Douglas R. Hanscom
JONES, TULLAR & COOPER, P.C.
P.O. Box 2266 Eads Station
Arlington
VA
22202
US
|
Assignee: |
BMP AMERICA, INC.
|
Family ID: |
34377664 |
Appl. No.: |
10/687751 |
Filed: |
October 20, 2003 |
Current U.S.
Class: |
492/56 ;
29/895.211; 399/326; 492/44; 492/50; 492/51 |
Current CPC
Class: |
G03G 15/2025 20130101;
Y10T 29/49551 20150115; G03G 2215/2093 20130101 |
Class at
Publication: |
492/056 ;
492/050; 492/051; 492/044; 029/895.211; 399/326 |
International
Class: |
F16C 013/00; B25F
005/02; G03G 015/20 |
Claims
What is claimed is:
1. A toner release agent application roller comprising: a roller
shaft; textile web wound in a plurality of layers on said roller
shaft, said textile web being formed of greater than 55% sub-denier
fibers, said layers including an outer layer defining an outer
surface of said roller, said outer surface being directly
engageable with a surface of a fuser roller, said textile web
having a high void volume per unit volume and a high surface area
per unit volume and a high capillary force; means securing an end
of said outer layer to a second, underlying layer of said plurality
of layers of said textile web; and a release agent impregnated in
said textile web to a level of between 2.5 and 500 grams/square
meter, said release agent being impartable to the fuser roller
during said contact of said outer surface of said roller formed by
said outer layer of said plurality of layers of said textile web,
wound on said roller shaft, with the fuser roller, said high
capillary force providing a high release agent retention capacity
for said roller.
2. The toner release agent application roller of claim 1 wherein
said textile web includes a majority of splitable fibers.
3. The toner release agent application roller of claim 2 wherein
splitable fibers are ultra-fine.
4. The toner release agent application roller of claim 3 wherein
said ultra-fine fibers are between 0.05 denier and 0.35 denier.
5. The toner release agent application roller of claim 1 wherein
said textile web is formed of 100% sub-denier fibers.
6. The toner release agent application roller of claim 2 wherein
said splitable fibers have a linear density of no greater than 1
gram weight per 9000 meters of length.
7. The toner release agent application roller of claim 1 wherein
said textile web is a non-woven textile web.
8. The toner release agent application roller of claim 7 wherein
said non-woven textile web is a spunbond/hydroentangled non-woven
textile web.
9. The toner release agent application roller of claim 1 wherein
said textile web has an area weight of between 30 and 450 grams per
square meter.
10. The toner release agent application roller of claim 4 wherein
at least 80% of said ultra-fine fibers are below 0.35 denier.
11. The toner release agent application roller 1 wherein said
release agent includes silicone oil.
12. The toner release agent application roller of claim 1 of claim
11 wherein said silicone oil has a viscosity between 10 and 100,000
centistoke.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed generally to a release
agent delivery system for use in a printing process. More
particularly, the present invention is directed to a non-woven
textile fabric web roller for use as a release agent delivery
device in a release agent delivery system. Most specifically, the
present invention is directed to a non-woven textile fabric web
roller of essentially sub-denier fibers for use in a release agent
delivery system. The use of a textile web of sub-denier fibers in a
roller construction provides a release agent delivery system with
the provision of very high oil holding capacity through the
provision of increased textile capillary force which is a result of
the textile web's inherent high surface area to volume ratio.
BACKGROUND OF THE INVENTION
[0002] In printing processes such as Phase Change ink printing
("PC") and Electrostatic toner Printing ("EP") there typically
exists a point in the process where pressure is applied to marking
or printing substances, thereby pressing those marking or printing
substances onto a substrate, which marking or printing substances
then form a visual image. The marking substance in PC is typically
a wax-based ink while the marking substance in EP is typically
toner particles. The substrate in both PC and EP is typically
paper. The pressure is typically formed between the "nip" of two
rollers.
[0003] The permanent fixing or "fusing" of the marking or printing
substances onto the substrate includes a warming process of the
marking substances prior to, or upon their reaching the nip point.
The warming process allows the wax or toner to become flowable and
tacky. When the warmed marking or printing substances and the
substrate reach the nip point, the nip pressure causes the wax or
toner to flow into the fibers or pores of the paper. When the wax
or toner cools, solidification of the wax or toner occurs thus
causing the wax or toner to be bonded firmly to the paper.
[0004] The methods of thermally fusing wax or toner onto the paper
inherently include some drawbacks. One such drawback of these fuser
systems is that since the wax or toner particles are tackified by
heat, part of the heated wax or toner particles forming the image
are often inadvertently retained by the fuser roller rather than
penetrating the paper's surface. This tackified wax or toner often
sticks to the surface of the fuser roller and then gets deposited
onto the following paper or onto the mating pressure roller. This
unintended depositing of wax or toner onto the following paper is
known as "offsetting". Offsetting is an undesirable occurrence,
which lowers the sharpness and quality of the immediate print and
also contaminates the following prints with offset wax or
toner.
[0005] To alleviate the wax or toner-offsetting problem, it is
common practice to utilize release agents such as silicone oils,
which are applied to the fuser roll surface and which act as wax or
toner release agents. These wax or toner release agents possess a
relatively low surface energy and are suitable for use in the fuser
roll environment. In practice, a thin layer of silicone oil is
applied to the surface of the fuser roll to form an interface
between the fuser roll surface and the wax or toner particles.
Thus, a low surface energy, easily parted layer is presented to the
wax or toners that pass through the nip. This low surface energy
layer of release agent thereby prevents wax or toner from adhering
to the fuser roll surface.
[0006] Numerous systems have been used to deliver wax or toner
release agents to the fuser roll. These systems sometimes
incorporate a textile as the release agent fluid holding and
delivery medium. Such textiles also serve an additional role in
that they are utilized as a fuser roller cleaning mechanism. With
each rotation of the fuser roller, there may be some non-released
wax or toner particles remaining on the surface of the fuser
roller. These non-released wax or toner particles are captured in
the interstices of the textile fibers used to deliver the release
agents to the fuser roll.
[0007] Some of the release agent delivery textiles, which are more
commonly used in printing machines, are known as non-woven
textiles. Some of the more commonly used non-woven textiles are
known as hydroentangled non-woven textiles, needle felts, thermal
bonds, and spun bonds. Many of the non-woven textiles used in
printing machines are typically made of fibers with some content of
polyesters, nylons, amides, aramids, imides, polyphenylene sulfide
(PPS), PTFE, and/or viscose rayons. The textiles are typically
impregnated with a silicone oil such as those sold by the Dow
Corning Corporation. Many of these silicone oil impregnated
textiles are manufactured at BMP America Incorporated located in
Medina, N.Y. or at BMP Europe Limited located in Accrington,
Lancashire, United Kingdom.
[0008] Although these oil impregnated non-woven textiles meet a
number of application requirements, many applications demand still
higher oil holding capabilities with low oil leak rates. In an
effort directed to providing a printer which is as small as
feasible, and thus having an oil delivery system which is as small
as possible, every step towards reducing the size of the oil
delivery system is critical in today's market. Certain oil holding
issues still exist with the presently used textile materials. Under
many conditions, current textile materials leak oil when saturated
to high levels. These oil leaks are very undesirable and can
decrease print quality because they can form oil blotches. They can
also decrease the expected oil delivery life of the textile
roller.
[0009] Every step towards increasing an oil delivery roller's oil
holding capacity is a step towards increased oil delivery life
while at the same time not sacrificing print quality.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a
release agent delivery system for use in a printer.
[0011] Another object of the present invention is to provide a
non-woven textile fabric web roller useable as a release agent
delivery device.
[0012] A further object of the present invention is to provide a
non-woven textile fabric web roller of essentially sub-denier
fibers useable as a release agent delivery device.
[0013] Still another object of the present invention is to provide
a release agent delivery web roller which will increase the oil
holding capacity of a given size textile fabric web oil delivery
device.
[0014] Yet a further object of the present invention is to provide
a release agent delivery web roller which will increase the oil
holding capacity of a textile oil delivery device while maintaining
a low to zero oil leaking rate under normal printer operating
conditions.
[0015] In accordance with the present invention, a release agent is
delivered to a fuser roller by the use of a roller that includes a
roller shaft which has been wrapped with a multiplicity of layers
of a non-woven textile web of essentially sub-denier fibers. These
sub-denier fibers in the web which has been wound on the roller
shaft provide much improved oil holding capacity. Instead of
demonstrating substantial oil leaking at a given oil loading when
placed into a simulated printer environment, the oil retention of
the non-woven textile web which contains essentially sub-denier
fibers in accordance with the present invention, and which is wound
in multiple layers on a roller shaft, results in minimal to zero
oil leakage when compared to prior devices subjected to identical
oil loading when placed in identical simulated printer
environments. This increased oil holding capacity provides for
longer life textile oil delivery rollers within a given set of size
and oil retention constraints.
[0016] The sub-denier fibers of the non-woven textile web used in
the release agent delivery system of the present invention provide
a textile with a high surface area per unit volume. A textile's
surface area per unit volume has a strong influence on its
capillary force. The high capillary force of the non-woven textile
web of essentially sub-denier fibers, in accordance with the
present invention, results in a web roller with a high capillary
force. Such a web roller can be impregnated with a higher amount of
oil before displaying any signs of leakage. Thus, the release agent
delivery system of the present invention provides a non-leaking
release agent delivery roller having a higher oil holding capacity
than is provided by other current web rollers.
[0017] The textile fabric web consisting of essentially 100%
sub-denier fibers also has a high void volume per unit volume. This
high void volume results in a large capillary force for the same
unit volume. Again the result is twofold. The non-woven textile web
used in the release agent delivery system, particularly in the form
of a web-wrapped roller, provides a large volume of oil holding
capacity with a minimal or zero leak rate. These two desirable, but
often essentially exclusive characteristics, are a function of the
amount of sub-denier fibers used to form the non-woven textile used
to construct the release agent application roller of the present
invention.
[0018] The higher oil holding capacity of the non-woven textile web
roller of the present invention allows for the less frequent
replacement of the oil delivery system or allows for a smaller
roller size to provide the same life as larger prior art rollers.
Both of these properties are very critical in today's printer
designs. Longer life consumable components and smaller consumable
components are key design features in today's printer consumable
parts.
[0019] To attain these objectives, the high capacity leak resistant
release agent delivery system in accordance with the present
invention utilizes, in one preferred embodiment, a textile web of
substantially sub-denier fibers, with the web weighing in the range
of 10 to 300 grams/square meter and being comprised of greater than
55% fibers which are sub-denier in size. The textile web may be
produced by hydroentangling, thermal bonding, spun bonding, needle
felting, melt blowing, or other non-woven technologies. The textile
web is impregnated with a release agent, which is typically
silicone oil, to a level of 2.5 to 500 grams/square meter. The
textile web is wound in a plurality of layers on a roller core or
shaft and results in a release agent delivery roller with greatly
improved oil delivery and retention capabilities. The resultant
release agent delivery system provides these greatly improved oil
holding capabilities as a result of significantly increased textile
capillary force. This increased capillary force is a function of
the high surface area per unit volume and the high void volume of
the textile web of substantially sub-denier fibers. The present
invention is a substantial advance in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] While the novel features of the release agent delivery
system for printers in accordance with the present invention are
set forth with particularity in the appended claims, a full and
complete understanding of the present invention may be had by
referring to the detailed description of the preferred embodiments,
as presented subsequently, and as illustrated in the accompanying
drawings in which:
[0021] FIG. 1 is a side elevation view of a textile web support
shaft, which is usable to support a textile web of a release agent
delivery system in accordance with the present invention,
[0022] FIG. 2 is an end view of a wound textile release agent
delivery device on a support shaft, in accordance with the present
invention,
[0023] FIG. 3 is a side elevation view, partly in section, of a
wound textile release agent delivery device on a support shaft, in
accordance with the present invention,
[0024] FIG. 4 is an end view of the release agent delivery device
using a wound textile fabric for delivery of a release agent in an
EP printer device in accordance with the present invention,
[0025] FIG. 5 is an end elevation view of a release agent delivery
device using a wound textile fabric for delivery of a release agent
in a PC printer device in accordance with the present invention,
and
[0026] FIG. 6 is a graph of oil leakages of the release agent
delivery system of the present invention in comparison to prior
devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring initially to FIG. 1, there may be seen a roller
shaft, generally at 2, upon which a textile web may be wound in a
circumferential fashion. The roller shaft 2 is typically
constructed of metal but could be produced from plastic or similar
materials. The roller shaft 2 has attachment features 4 such as
knurls or adhesives for use in the mechanical attachment of the
textile web to the shaft 2. The roller shaft 2 typically has
journals 6 on which the roller rotates when the roller is
positioned in a printer's oil supply system housing which is not
specifically shown.
[0028] Referring to FIG. 2, there may be seen an end view of a
wound textile release agent delivery device, generally at 11, in
accordance with the present invention. A non-woven textile 12,
which is comprised of substantially all sub-denier fibers, is wound
on a roller shaft 2, generally of the type depicted in FIG. 1. An
outer layer 13 of wound textile 12 that is wound on the roller
shaft 2 forms a release agent delivery point when the wound textile
release agent delivery device is in use. A second from last textile
wrap 14 is the typical point of textile to textile final binding
which provides the roller's "roll like" integrity. This textile
final binding is typically a strip of adhesive, a non-continuous
pattern of adhesive, a non-continuous pattern of ultrasonic
staking, a non-continuous pattern of thermal binding, or some such
non-continuous mechanical attachment of the outer layer 13 of the
non-woven, substantially sub-denier textile 12 to the second from
last layer 14 of textile 12. An initial wrap 16 of textile 12
around the roller shaft 2 is the point of textile 12 to shaft 2
binding which anchors the textile 12 to the shaft 2. This initial
binding is typically an adhesive attachment or is accomplished by
the use of metal knurls for a mechanical attachment. An end portion
18 of the last wrap 13 is typically bonded down to the top of the
second from last textile wrap 14 with a strip of adhesive, a
non-continuous pattern of adhesive, a non-continuous pattern of
ultrasonic staking, a non-continuous pattern of thermal binding, or
some such non-continuous mechanical attachment.
[0029] As may be seen in FIGS. 2 and 3, the textile 12 is wound on
the roller shaft 2. A plurality of layers of the textile web 12 are
built up on the roller shaft 2. The number of layers of textile 12
is a function of the desired service life and of the space
available in which to position the release agent delivery roller,
generally at 11. The outermost layer 13 of the non-woven textile
web 12 of substantially sub-denier fibers is the surface which
transfers the release agent, such as a silicone oil, that is held
in the textile web 12 wound into a roller shape, onto the surface
of a fuser roller of an EP or PC printer device. The transfer of
the release agent from the uppermost layer 13 of the textile web 12
acts to dry out that outermost layer. The release agent in the
outermost layer 13 of the roller 11 is replenished by the tendency
of the release agent that is retained in all of the layers 12 of
the textile web wound on the roller shaft 2 to stay in equilibrium.
This causes an essentially continuous migration of the release
agent from the inner web layers to the outermost textile web layer
13. While this process of replenishment of the outer web layer 13
on the roller 11 due to the tendency of the release agent to
attempt to maintain an equilibrium condition in all of the textile
layers 12 wound on the web core 2 is not a part of the present
invention, the use of the non-woven textile web of essentially
sub-denier fibers in accordance with the present invention provides
a release agent roller with far superior release agent retention
capability and capacity. Accordingly, as the release agent is
transferred to the fuser roller from the outermost layer 13 of the
textile web 12, there is a large reservoir of release agent in the
inner layers of the non-woven textile web 12 which will move to the
outermost layer 13 in an effort to maintain an equilibrium
condition throughout the entire roller.
[0030] FIG. 3 is a side elevation view, partly in section of a
wound textile release agent delivery device in accordance with the
present invention. The end portion 18 of the outer wrap 13 as seen
in FIG. 3 is shown rotated from its location of FIG. 2. The
internal body of the wound textile 12 contains release agent in the
textile's interstices. The body of the textile 12 is mechanically
supported by the shaft 2 and is attached by the adhesion/knurl
points 4. The wound textile release agent delivery device rotates
on journals 6 which are in a printer device. The wound textile
release agent delivery device 11 exudes release agent to the
printer through the device's outer most layer of textile 13.
[0031] FIG. 4 is a side elevation view of the release agent
delivery device 11 of the present invention and using a wound
textile fabric 12 for delivery of a release agent in a EP printer
device. The release agent delivery device 11 delivers a release
agent 34 to a fuser roller 36 or more specifically to the fuser
roller's surface 38. A substrate, typically paper, with
electrostatically attached toner 40 enters a nip between the fuser
roll 36 and a pressure roll 42. The substrate exits the nip with
"fused" attached toner 44. On occasion, some fused toner 46
unintentionally resides on the fuser drum 36 but is then cleaned by
the textile interstices of the release agent delivery device
11.
[0032] FIG. 5 is a side elevation view of a release agent delivery
device 11 using a wound textile fabric 12 for delivery of a release
agent in a PC printer device in accordance with the present
invention. The release agent delivery device 11 delivers release
agent 50 to the fuser roller 56 or more specifically to the fuser
roller's surface 52. The PC printer delivers a wax ink 54 on top of
the release agent layer 50. A substrate, typically paper, 58 enters
a nip between the fuser roller 56 and a pressure roll 60. The
substrate exits the nip with attached wax ink 62. On occasion, some
wax ink 64 unintentionally resides on the fuser drum 56 but is then
cleaned by the textile interstices of the release agent delivery
device 11 of the present invention.
[0033] In both types of printer devices, such as the EP of FIG. 4
and the PC of FIG. 5, the importance of the release agent delivery
system 11 for metering a very precise amount of release agent per
revolution is critical to print quality and to release agent
delivery system life. The amount of release agent, 34 or 50,
deposited upon the fuser roller 36, or 56, respectively can
dramatically effect print quality. Typical targeted amounts of
release agent deposited per page are 0.01 mg/page (0.00001 g/page)
to 10.00 mg/page (0.01 g/page). Very minor fluctuations in amount
can dramatically affect the printer's intended release
characteristics and print quality. Too little release agent, 34 or
50, will inhibit the intended release of fused toner 46 or wax 64
onto the intend substrate surface 44 or 62. In most of these
printer styles, the release agent amount affects the printed images
appearance. High oil yields a glossy finish appearance while low
oil yields a matte finish appearance. Too little oil can lead to an
undesired matte finish while too much oil can lead to an undesired
glossy finish and to an oil soaked page.
[0034] The capillary force of the textile used for the release
agent delivery system is a very critical driving force in the
release agent delivery system's 11 metering rate and holding
capacity. The metering rate or the printer's intended target
release agent rate per page can be changed by changing one or more
of many variables such as the delivery system's textile capillary
force, the delivery system's force of compression against the fuser
roller, the delivery system's speed relative to the fuser roller,
the release agent's viscosity and surface tension, and the fuser
roller temperature which ranges typically between 20.degree. and
260.degree. C., and more specifically typically between 30.degree.
to 90.degree. C. for wax ink fuser rollers and 160.degree. to
240.degree. C. for toner fusers rollers. The holding capacity of
the release agent delivery system does not have as many available
variables in the metering rate requirement. The holding capacity of
the release agent delivery system is a delicate balance of textile
capillary force, textile void volume, release agent viscosity, and
release agent surface tension. The release agent characteristics
are typically selected based primarily on the required release
characteristics of the toner and of the ink or the wax with little
regard to the holding capacity of the release agent delivery
system. This is understandable since the major function of the
release agent is to release the toner 46 and the ink wax 64. This
being the case, selection of the release agent delivery device has
to be made so as to optimize release agent holding capacity by
maximizing the textile's capillary force while maintaining void
volume. Capillary force is a very strong function of surface area
per unit volume. The release agent delivery system of the present
invention maximizes surface area per unit volume by incorporating
at least 55% microdenier fibers and preferably by incorporating
100% microdenier fibers in the textile web. These are fibers whose
linear density is less than 1 gram weight/9000 meters of length.
More specifically, the present invention's best results come from
incorporating the most fine polymer fibers which are commercially
available in a form suitable to produce the required textile
styles. These fine fibers are known as "splitable" fibers and are
available in linear densities as low as 0.05 grams per 9000 linear
meters.
[0035] Suitable textile styles for use in forming the release agent
delivery system in accordance with the present invention are
non-woven textile that can be produced using various processing
methodologies such as hydroentangleing, spun bonding, thermal
bonding, and needlefelting. Most specifically, best results have
been attained using a product which is a combination
spunbond/hydroentagled product which incorporates splitable fibers.
Such manufacturing processes are known to those skilled in the art.
The fibers of these textiles preferably are nylon, amide, imide,
polyester, aramid, PTFE, PPS, viscose rayon, or a blend of these
fibers or a composite of these chemistries in a fiber that is then
splitable to ultra fine deniers. A splitable fiber is a composite
fiber such as polyester and nylon which, when processed, splits
into much finer fibers. Splitable fibers are well known to those
skilled in the art. The linear density of these fibers ranges
between 0.05 denier and 3 denier, and preferably between 0.05
denier and 0.35 denier. These sub-denier fibers are used to produce
the non-woven textile webs which as useable to form the release
agent delivery system of the present invention. The resultant
textiles' area weight is typically between 30 and 450 grams per
square meter (gsm), and preferably ranges from 60 to 200 gsm. The
textiles' thickness is typically between 0.050 mm and 1.000 mm. The
preferred textile thickness ranges from 0.150 mm to 0.500 mm.
[0036] The non-woven textile webs are first formed using the
processing technologies discussed above. Once they are formed, the
textile webs are then slit into a size suitable for supplying oil
to a fuser apparatus in an EP or PC printing machine. These sizes
range from 0.150 meters wide by 0.5 meter long to 1.1 meters wide
by 200 meters long. The next step is typically one of impregnating
the resultant non-woven textile web with a fuser release fluid such
as a silicone oil. Most commonly, silicone oil with a viscosity
within the range of 5 to 100,000 centistoke is utilized as the
fuser release fluid.
[0037] As discussed above, the utilization of a non-woven textile
web of substantially sub-denier fibers in a roller of a toner
release agent device in accordance with the present invention
facilitates the production of an EP or a PC printer toner release
agent device with increased oil holding capacity through increased
textile capillary force which is a result of the textile web's
inherent higher surface area to volume ratio. This increased oil
holding capacity will increase the oil leak resistance of a toner
or wax release agent device. This increased oil leak resistance
accomplishes the storage of more oil in the textile web based
release agent delivery device without oil leakage concerns which,
in turn, yields longer life due to higher oil holding capacity.
EXAMPLE 1
[0038] A spun bond hydroentangled textile was manufactured using
nylon/polyester composite splitable fibers. The resultant textile
web contained a majority of split fibers of approximately 0.14
denier. These ultra fine split fibers yield a very high capillary
force textile web. A suitable textile web is manufactured by the
Freudenberg Nonwovens company under the name of "Evolon" fabric.
Additionally advantageous of "Evolon" is the fact that it is a
continuous filament textile which leads to very good fiber
retention. Loose fibers are a very negative occurrence in virtually
all printer textile applications.
[0039] The spun-bond hydroentagled textile web was manufactured to
an area weight of 130 grams/square meter with a thickness of 0.59
mm. The material was then slit to a width of 210 mm. The web was
then wound onto a metal shaft to a length of 3.1 meters, forming a
web-wrapped roller with a roller outer diameter of 1.75". The outer
wrap was then adhered to the second from outer wrap using a liquid
adhesive. The adhesive was allowed to dry. The dry web wrapped roll
was then impregnated with various amounts of oil. The amounts of
oil impregnation included 150 grams, 175 grams, 200 grams, 225
grams, and 250 grams. Oil of 50 Centistoke silicone oil as
manufactured by Dow Corning under the brand name 200 fluid, was
used.
[0040] To determine the oil holding capacity of the web wrapped
roller, one common methodology is known as leak testing. The leak
test procedure used for the web in accordance with example 1, and
in accordance the following examples #2, #3, and #4, is as
follows:
[0041] a) Preset a laboratory oven (VWR model 1630) to 60 degrees
Celsius and allow oven temperature to stabilize.
[0042] b) Individually mount rollers vertically in a metal plate
fixture which supports the web roll by holding the bottom most
portion of the shaft without touching any portion of the web. Each
metal plate fixture should be placed on an individual oil
collection pan. Both fixture and pan should be pre-weighed.
[0043] c) Heat rollers at 60 degrees Celsius for 24 hours while
mounted vertically.
[0044] d) Remove rollers with fixture and pan from oven.
[0045] e) Remove roller from fixture and pan. Weigh roller and then
weigh fixture and pan.
[0046] f) The difference between the initial fixture and pan weight
and the final fixture and pan weight is equal to the weight of the
oil that leaked out of the roller.
COMPARATIVE EXAMPLE 2
[0047] The process used to determine the oil leaking by the web of
example 1 was followed with a change of the textile used in
comparative example 2. The comparative example 2 textile was a
needle felt textile manufactured using 80% sub-denier fiber. This
textile was manufactured using 20% 2.0 denier polyester fibers and
80% 0.7 denier polyester fibers, a web formulation typically used
in prior art release agent delivery systems. The web was
manufactured to an area weight of 500 grams/square meter with a
thickness of 1.500 mm. The material was then slit to a width of 210
mm. The web was then wound onto a metal shaft to a length of 1.65
meters, forming a web wrapped roll with an outer diameter of
1.75".
COMPARATIVE EXAMPLE 3
[0048] The process used to determine the oil leaking by the web of
example 1 was followed with a change of the textile used in
comparative example 3. The comparative example 3 textile was a
hydroentangled textile manufactured using 100% 1.35 denier
polyester fiber. The web was manufactured to an area weight of 110
grams/square meter with a thickness of 0.70 mm. The material was
then slit to a width of 210 mm. The web was then wound onto a metal
shaft to a length of 3.46 meters, forming a web wrapped roll with
an outer diameter of 1.75".
[0049] COMPARATIVE EXAMPLE 4
[0050] The process used to determine the oil leaking by the web of
example 1 was followed with a change of the textile used in
comparative example 4. The comparative example 4 textile was a
needle felt textile manufactured using no sub-denier fiber. This
textile was manufactured using 100% 1.5 denier polyester fibers, a
web formulation typically used in prior art release agent delivery
systems. The web was manufactured to an area weight of 235
grams/square meter with a thickness of 1.00 mm. The material was
then slit to a width of 210 mm. The web was then wound onto a metal
shaft to a length of 1.65 meters, forming a web wrapped roller with
an outer diameter.
[0051] Results
[0052] FIG. 6 is a graph which displays the superior release agent
holding capability of a release agent delivery system in accordance
with the present invention. Example #1 shows no oil leakage up to
200 grams loading while all other textiles showed a high degree of
leakage at the same 200 gram loading. The capability of a textile
web with a higher surface area per unit volume to provide higher
capillary force and thus to provide improved oil retention is also
clearly indicated when viewing the results versus the calculated
surface area per unit of web roller volume. The following table
displays this clear trend of improved oil retention with increased
surface area per unit volume; i.e. with decreased fiber size.
1 Fiber Fiber Web Web Web Area Surface Oil Fiber Denier Density
Length Width Area Weight Area Leakage Type (d) (g/cc) (Meters) (mm)
(M{circumflex over ( )}2) (g/M{circumflex over ( )}2)
(cm{circumflex over ( )}2) @ 200 g Example # 1 Polyester 0.14
Approx 3.10 210 0.651 130 647,641 0.0 & Nylon 1.35 Example # 2
Polyester 0.7/2.0 1.38 0.81 210 0.170 500 267,297 10.2 Example # 3
Polyester 1.35 1.38 3.46 210 0.726 110 194,952 29.4 Example # 4
Polyester 1.5 1.38 1.65 210 0.347 235 134,612 54.3
[0053] The splitable fiber non-woven textile webs, which contain
fibers with deniers as low as 0.05 d, and which are identified as
example #1, are the preferred textiles for use with the present
invention. No other textile that is fit for the purpose of an EP or
PC printer web wrap roller, has achieved the oil retention levels
obtained by the release agent delivery system of the present
invention.
[0054] It will thus be seen that the release agent delivery system,
using a non-woven web of substantially sub-denier fibers, in
accordance with the present invention, results in the production of
a more leak resistant web roller release agent delivery system.
[0055] While a preferred embodiment of a release agent delivery
system for EP and PC printers in accordance with the present
invention has been set forth fully and completely hereinabove, it
will be apparent to one of skill in the art that a number of
changes in, for example the specific printer being used, the
non-woven processing method being used, and the like could be made
without departing from the true spirit and scope of the present
invention which is accordingly to be limited only by the following
claims.
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