Method of fabricating a microporous surface blotter roll

Abstract

A method of fabricating a controlled and uniform cell size blotter roll for blotting liquid images consisting of toner particles and carrier liquid. The method includes the step of mixing a first grade of salt having first particles of a first uniform size with a polymer material so as to form a first mixture. The method next includes a step of extruding the first mixture to form an extruded sleeve having intimately compacted polymer material and salt particles, an outer surface, and an inner surface defining a hollow interior. The method then includes curing the extruded sleeve until rigid and dry; abrading the outer surface and the inner surface of the extruded sleeve so as to remove any extrusion induced skin layer and to increase a number of open cells on each surface; applying an adhesive layer onto the abraded outer surface; forming a surface layer by coating the adhesive layer with powder particles of a second mixture consisting of a polymer material and a second grade of salt having second particles of a second, uniform size substantially less than the uniform size of the particles of the first grade of salt; leeching the particles of the first and the second grades of salt from the surface layer, and from the extruded sleeve, in order to form a conformable, compound open cell foam sleeve having controlled uniform cells and the desired hollow interior; and inserting into the desired hollow interior a rigid core having connections for connecting to a vacuum system.