Method of making a fuser member

A surface layer comprising:

• a fluoropolymer, a plurality of carbon nanotubes, each carbon nanotube having an aspect ratio ranging from about 10 to about 1,000,000, each carbon nanotube having a diameter of from 1 nanometer to about 20 nanometers;
• and carbon nanotube fluoropolymer clusters having a size ranges from about 5 micron to about 250 micron;
• and wherein the carbon nanotube fluoropolymer clusters are from about 0.01 volume percent to about 15 volume percent of the surface layer, wherein the surface layer is formed by mixing a high load fluoropolymer/carbon nanotube composition in a high shear mixer and mixing the high load fluoropolymer/carbon nanotube composition for 3 or more times wherein the high load fluoropolymer/carbon nanotube composition comprises from about 8 weight percent to about 30 weight percent of the high load composition;
• adding more of the fluoropolymer to the high load fluoropolymer/carbon nanotube composition to form a low load fluoropolymer/carbon nanotube composition wherein the carbon nanotubes comprise from about 0.1 weight percent to about 7 weight percent of the low load composition;
• mixing the low load fluoropolymer/carbon nanotube composition in a rubber compounding mixer for 3 or more times;
• and coating the low load composition and curing to form the surface layer, wherein the surface layer has a surface roughness of from about 0.6 microns to about 1.2 microns.

A fuser member comprising:

• a substrate layer;
• an intermediate layer disposed on the substrate layer;
• and
• a release layer disposed on the intermediate layer, the release layer comprising;
• a fluoropolymer, a plurality of carbon nanotubes, each carbon nanotube having an aspect ratio ranging from about 10 to about 1,000,000, each carbon nanotube having a diameter of from 1 nanometer to about 20 nanometers;
• and carbon nanotube fluoropolymer clusters having a size ranges from about 5 micron to about 250 micron;
• and wherein the carbon nanotube fluoropolymer clusters are from about 0.01 volume percent to about 15 volume percent of the release layer, wherein the release layer is formed by mixing a high load fluoropolymer/carbon nanotube composition in a high shear mixer and mixing the high load fluoropolymer/carbon nanotube composition for 3 or more times wherein the high load fluoropolymer/carbon nanotube composition comprises from about 8 weight percent to about 30 weight percent of the high load composition;
• adding more of the fluoropolymer to the high load fluoropolymer/carbon nanotube composition to form a low load fluoropolymer/carbon nanotube composition wherein the carbon nanotubes comprise from about 0.1 weight percent to about 7 weight percent of the low load composition;
• mixing the low load fluoropolymer/carbon nanotube composition in a rubber compounding mixer for 3 or more times;
• and coating the low load composition and curing to form the release layer, wherein the release layer has a surface roughness of from about 0.6 microns to about 1.2 micron.