Aluminized roll including anodization layer

Details Aluminized roll including anodization layer Aluminized roll including anodization layer

2000-04-20

2001-12-11

Chen, Sophia S. (Department: 2852)

Electrophotography

Image formation

Development

C492S048000

Reexamination Certificate

active

06330417

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to a printing apparatus and, more particularly, to a printer including a roll having an aluminum core with a mirror-like finish on the exterior surface prior to an anodization layer being formed on the exterior surface, and a sealant associated with the anodization layer, and a method of making the same.
BACKGROUND OF THE INVENTION
Reference is made to copending application, Ser. No. 09/553,369 entitled, Method of Making an Aluminized Roll, filed currently herewith, and the disclosure of which is totally incorporated herein by reference.
Electrophotographic marking is a well-known, commonly used method of copying or printing documents. Electrophotographic marking is performed by exposing a charged photoreceptor with a light image representation of a desired document. The photoreceptor is discharged in response to that light image, creating an electrostatic latent image of the desired document on the photoreceptor's surface. Toner particles are then deposited onto the latent image, forming a toner image, and then transferred onto a substrate, such as a sheet of paper. The transferred toner image is then fused to the substrate, usually using heat and/or pressure, thereby creating a permanent record of the original representation. The surface of the photoreceptor is then cleaned of residual developing material and recharged in preparation for the production of other images. Other marking technologies, for example, electrostatographic marking and ionography are also well-known.
Many electrostatographic marking machines include a developer having a developer housing, a transport roll, a donor roll, and an electrode structure. In such a developer, the transport roll advances carrier and toner to a loading zone adjacent the donor roll. The transport roll is electrically biased relative to the donor roll such that toner is attracted from the carrier to the donor roll. The donor roll then advances toner from the loading zone to a development zone adjacent the photoreceptor. In general, a donor roll includes a conductive core and a partially conductive surface. In hybrid scavengeless development, the donor roll provides an electrostatic “intermediate” between the photoreceptor and the transport roll.
While existing rolls are generally suitable, improvements in development quality and performance are desired. However, previous attempts to improve quality and performance have included additional machining and grinding of the outer periphery of the core of the roll. These additional steps increase the cost of the rolls. Therefore, an improved cost-effectiveroll providing excellent electrical properties, cost effectiveness, smaller pinholes and inclusions, high conductivity/time constant, and tolerances would be beneficial.
Reference is made to the following United States patents relating, for example, to reproduction machines, development apparatus, and components.
U.S. Pat. No. 3,950,089 relates to a development apparatus in which a surface for the direct conveyance of electrically-conductive toner comprises a dielectric sheath.
U.S. Pat. No. 4,034,709 relates to a development apparatus in which a surface for the direct conveyance of toner comprises styrenebutadiene.
U.S. Pat. No. 4,774,541 relates to discloses a development apparatus in which a surface for the direct conveyance of toner is doped with carbon black.
U.S. Pat. No. 4,868,600 relates to a scavengeless development system in which toner detachment from a donor and the concomitant generation of a controlled powder cloud is obtained by AC electric fields supplied by self-spaced electrode structures.
U.S. Pat. No. 4,893,151 relates to a single component image developing apparatus including a developing roller coated with a chemical vapor deposition ceramic and an elastic blade coated with a ceramic.
U.S. Pat. No. 4,984,019 relates to an apparatus in which contaminants are removed from an electrode positioned between a donor roller and a photoconductive surface.
U.S. Pat. No. 5,010,367 relates to a scavengeless
on-interactive development system for use in highlight color imaging.
U.S. Pat. No. 5,032,872 relates to an apparatus for developing a latent image recorded on a photoconductive member in an electrophotographic printing machine.
U.S. Pat. No. 5,043,768 relates to a rotating release liquid applying device for a fuser including an outer porous ceramic material.
U.S. Pat. No. 5,063,875 relates to an apparatus which develops an electrostatic latent image. A transport roll advances developer material from a chamber to a donor roll.
U.S. Pat. No. 5,128,723 relates to an apparatus which develops an electrostatic latent image recorded on a photoconductive member with toner.
U.S. Pat. No. 5,245,392 and RE 35698 relate to a phenolic resin coated on a donor roll.
U.S. Pat. No. 5,322,970 relates to a donor roll for the conveyance of toner in a development system for an electrophotographic printer includes an outer surface of ceramic.
U.S. Pat. No. 5,341,197 relates to a method and apparatus involving the stopping and starting of the development of images, using hybrid development, to insure proper charging of the donor toner layer.
U.S. Pat. No. 5,384,627 relates to a developer unit adapted to develop a latent image with toner particles.
U.S. Pat. No. 5,420,375 relates to a method and apparatus involving the stopping and starting of the development of images, using hybrid development, to insure proper charging of the donor toner layer.
All documents cited herein, including the foregoing, are incorporated herein by reference in their entireties.
SUMMARY OF THE INVENTION
The principles of the present invention provide for a roll with a core comprised of aluminum and method thereof. The core comprises an outer surface that is prepared to a substantially mirror-like finish prior to anodization. The mirror-like finish may be formed using an industrial grade diamond and a lathe turning operation. Alternatively, the mirror-like finish may be formed by polishing. An anodization layer having a thickness ranging from about 1 to 100 microns is then formed on the mirror-like outer surface and on the ends of the roll. A sealant is then applied on the anodization layer such that it substantially seals the roll. The sealant may include nickel acetate, hot water, polytetrafluorethylene (PTFE), NITUFF™, sodium dichromate, equivalent sealants, and combinations thereof. The sealant, NITUFF™, is presently commercially available from Nimet Industries, Inc. of South Bend Indiana.
The aluminum material for the core of the roll is commercially available in a variety of grades from, for example, VAW of America, St. Augustine, Fla. and from Alcoa. The Aluminum Association, Inc. (AAI) promulgates the American National Standard (ANSI) alloy designation systems for aluminum wrought and cast alloys and for other aluminum products. AAI registers chemical composition limits of alloys, assigns alloy designations and publishes registration records. Other designation systems than AAI are envisioned which correlate to grades of generally high purity aluminum alloy, and the other designation systems and corresponding grades are interchangeable as a core material. For example, equivalent aluminum alloy grading systems and compositions having other aluminum alloy grades of a generally higher purity are interchangeable as a base material for the core. The chemical composition of the aluminum alloy may be tested using the ASTM method E
34
Spectrochemical Analysis.
This invention relates generally to a roll with a core made of high purity aluminum such as from about 90% to about 100% pure aluminum. The core exterior surface may be prepared using a diamond turning operation prior to formation of an anodization layer thereon. A sealant may be applied over the anodization layer or be associated with the anodization layer via an anodization bath process. Various grades of generally high purity aluminum, mirror-like finish processes, anodization processes, and sealants are envisioned.
One aspect of the invention relates to a roll

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