US5869808A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Ceramic heater roller and methods of making same
Assignee: American Roller Co LLC
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Filing: 1996-08-14
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Granted: 1999-02-09
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Expires: 2016-08-14
Abstract
Abstract A thermal conductive roller for use in copying machines, steam-heated and induction-heated applications includes a ceramic heating layer formed by plasma spraying a ceramic material to form an electrically conductive heating layer of preselected and and controlled resistance. Several methods of controlling the resistance of the ceramic heating layer are disclosed. The ceramic heating layer is sealed with a solid, low viscosity sealer such as Carnauba wax to protect the ceramic layer from moisture penetration. Electrical current is applied at or near the core and is conducted radially outward through the heating layer to an outer grounded metallic layer. An outer contact layer of metal, ceramic, or polymeric material can be added.
Inventors
- 👤 Bruce E. Hyllberg
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 22:38
CPC Classifications
G; G03; G03G; G03G15/00; G03G15/02; G03G15/0208; G03G15/0216; G03G15/0233; G03G15/20; G03G15/2003; G03G15/2014; G03G15/2053; H; H05; H05B; H05B3/00; H05B3/10; H05B3/12; H05B3/14; H05B3/141; H05B3/40; H05B3/42; H05B3/46; H05B6/00; H05B6/02; H05B6/10; H05B6/14; H05B6/145; B; B29; B29C; B29C48/00; B29C48/03; B29C48/07; B29C48/08; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49082; Y10T29/49099
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
150 words
A three-layer thermal conduction roller in which a voltage is applied to the roller to cause heating within a heating layer, the roller comprising: a cylindrical roller core; a first layer of an electrical insulating material disposed around the cylindrical roller core; a second layer of a semiconductive heating ceramic disposed around the insulating layer and the cylindrical roller core; and an outermost layer, which forms the outer surface of the roller, the outermost layer being disposed around and over the semiconductive heating layer for conducting and carrying heat to a work object, the outermost layer being electrically insulative; wherein the second layer is formed of at least one plasma-sprayed coating of ceramic material; and wherein a resulting composition of the ceramic material and volume resistivity of the second layer are controlled by controlling the hydrogen secondary plasma gas level as the ceramic material is plasma-sprayed longitudinally alone the roller.
Claim 2
Dependent Claim
150 words
A three-layer thermal conduction roller in which a voltage is applied to the roller to cause heating within a heating layer, the roller comprising: a cylindrical roller core; a first layer of an electrical insulating material disposed around the cylindrical roller core; a second layer of a semiconductive heating ceramic disposed around the insulating layer and the cylindrical roller core; and an outermost layer, which forms the outer surface of the roller, the outermost layer being disposed around and over the semiconductive heating layer for conducting and carrying heat to a work object, the outermost layer being electrically insulative; wherein the second layer is formed of at least one plasma-sprayed coating of ceramic material; and wherein a resulting composition of the ceramic material and volume resistivity of the second layer are controlled by controlling the hydrogen secondary plasma gas level as the ceramic material is plasma-sprayed longitudinally alone the roller.
Claim 3
Dependent Claim
16 words
The roller of claim 1, wherein the ceramic material further comprises titanium dioxide and titanium mono-oxide.
Claim 4
Dependent Claim
29 words
The roller of claim 1, wherein the layer of semiconductive heating ceramic is a plasma-sprayed blend of a first ceramic material, including titanium dioxide, and a second ceramic material.
Claim 5
Dependent Claim
17 words
The roller of claim 1, further comprising a sealant that seals the layer of semiconductive heating ceramic.
Claim 6
Dependent Claim
13 words
The roller of claim 4, wherein the sealant is a 100% solid material.
Claim 7
Dependent Claim
11 words
The roller of claim 4, wherein sealant is a Carnauba wax.
Claim 8
Dependent Claim
129 words
A three-layer thermal conduction roller for use in industrial applications in which a voltage is applied to the roller to cause heating within a heating layer, the roller comprising: a cylindrical roller core; a first layer of an electrical insulating material disposed around the cylindrical roller core; a second layer of a semiconductive heating ceramic disposed around the insulating layer and the cylindrical roller core; and an outermost layer, which forms the outer surface of the roller, the outermost layer being disposed around and over the semiconductive heating layer for conducting and carrying heat to a work object, the outermost layer being electrically insulative; wherein the second layer is formed of at least one plasma-sprayed coating of ceramic material; and wherein the outermost layer is a plasma-sprayed ceramic material.
Claim 9
Dependent Claim
129 words
A three-layer thermal conduction roller for use in industrial applications in which a voltage is applied to the roller to cause heating within a heating layer, the roller comprising: a cylindrical roller core; a first layer of an electrical insulating material disposed around the cylindrical roller core; a second layer of a semiconductive heating ceramic disposed around the insulating layer and the cylindrical roller core; and an outermost layer, which forms the outer surface of the roller, the outermost layer being disposed around and over the semiconductive heating layer for conducting and carrying heat to a work object, the outermost layer being electrically insulative; wherein the second layer is formed of at least one plasma-sprayed coating of ceramic material; and wherein the outermost layer is a plasma-sprayed ceramic material.
Claim 10
Dependent Claim
40 words
The roller of claim 7, wherein a resulting composition of the ceramic material and volume resistivity of the second layer are controlled by controlling the hydrogen secondary plasma gas level as the ceramic material is plasma-sprayed longitudinally along the roller.
Claim 11
Dependent Claim
25 words
The roller of claim 7, wherein the layer of semiconductive heating ceramic is a plasma-sprayed blend of the ceramic material and a second ceramic material.
Claim 12
Dependent Claim
18 words
The roller of claim 7, further comprising a sealant that seals the layer of the semiconductive heating ceramic.
Claim 13
Dependent Claim
13 words
The roller of claim 10, wherein the sealant is a 100% solid material.
Claim 14
Dependent Claim
11 words
The roller of claim 10, wherein sealant is a Carnauba wax.
Claim 15
Independent Claim
117 words
A method of making a thermal conduction roller in which a voltage is applied to cause heating within a heating layer disposed between an inner insulating layer and an outer contact surface, the method comprising: plasma spraying a ceramic material in one or more sublayers to form an electrically semiconductive ceramic heating layer of controlled resistance between the insulating layer and the outer contact surface; selecting the hydrogen secondary plasma gas level as the ceramic material is plasma-sprayed along the length of the roller to control the volume resistivity and composition of the one or more sublayers of ceramic material; and applying an outer functional layer of an elastomeric material around and over the ceramic heating layer.
Claim 16
Independent Claim
117 words
A method of making a thermal conduction roller in which a voltage is applied to cause heating within a heating layer disposed between an inner insulating layer and an outer contact surface, the method comprising: plasma spraying a ceramic material in one or more sublayers to form an electrically semiconductive ceramic heating layer of controlled resistance between the insulating layer and the outer contact surface; selecting the hydrogen secondary plasma gas level as the ceramic material is plasma-sprayed along the length of the roller to control the volume resistivity and composition of the one or more sublayers of ceramic material; and applying an outer functional layer of an elastomeric material around and over the ceramic heating layer.
Claim 17
Dependent Claim
16 words
The method of claim 13, wherein the ceramic material further comprises titanium dioxide and titanium mono-oxide.
Claim 18
Dependent Claim
23 words
The method of claim 13, wherein the ceramic heating layer is a plasma-sprayed blend of the ceramic material and a second ceramic material.
Claim 19
Dependent Claim
18 words
The method of claim 15, further comprising the step of sealing the ceramic heating layer with a sealant.
Claim 20
Dependent Claim
13 words
The method of claim 16, wherein the sealant is a 100% solid material.
Claim 21
Dependent Claim
12 words
The method of claim 16, wherein the sealant is a Carnauba wax.
Claim 22
Independent Claim
107 words
A method of making a thermal conduction roller for use in industrial applications in which a voltage is applied to cause heating within a heating layer disposed between an inner insulating layer and an outer contact surface, the method comprising: plasma spraying a ceramic material in one or more sublayers to form an electrically semiconductive ceramic heating layer of controlled resistance between the insulating layer and the outer contact surface; and applying an outermost functional layer of ceramic material around and over the ceramic heating layer; wherein the outermost functional layer is applied by plasma spraying a ceramic outer layer around and over the ceramic heating layer.
Claim 23
Independent Claim
107 words
A method of making a thermal conduction roller for use in industrial applications in which a voltage is applied to cause heating within a heating layer disposed between an inner insulating layer and an outer contact surface, the method comprising: plasma spraying a ceramic material in one or more sublayers to form an electrically semiconductive ceramic heating layer of controlled resistance between the insulating layer and the outer contact surface; and applying an outermost functional layer of ceramic material around and over the ceramic heating layer; wherein the outermost functional layer is applied by plasma spraying a ceramic outer layer around and over the ceramic heating layer.
Claim 24
Dependent Claim
40 words
The method of claim 19 wherein a resulting composition of the ceramic material and volume resistivity of the second layer are controlled by controlling the hydrogen secondary plasma gas level as the ceramic material is plasma-sprayed longitudinally along the roller.
Claim 25
Dependent Claim
23 words
The method of claim 19, wherein the ceramic heating layer is a plasma-sprayed blend of the ceramic material and a second ceramic material.
Claim 26
Dependent Claim
18 words
The method of claim 19, further comprising the step of sealing the ceramic heating layer with a sealant.
Claim 27
Dependent Claim
13 words
The method of claim 22, wherein the sealant is a 100% solid material.
Claim 28
Dependent Claim
11 words
The method of claim 22, wherein sealant is a Carnauba wax.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2002-02-08 | 2002-08-10 | 2003-02-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-02-08 | 2006-08-10 | 2007-02-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-02-08 | 2010-08-10 | 2011-02-09 | $7700.00 | Window Closed / Lapsed |