Method of manufacture of multi-layer roll having compliant PTFE top layer from a fibrillated PTFE membrane

A method for forming a compliant multi-layer roll having a compliant PTFE top layer on an elastic layer which is bonded to a substantially rigid core, comprising:

• providing a substantially rigid cylindrical core and a cylindrical mold sleeve having two open ends;
• wrapping a fibrillated PTFE membrane over and extending beyond the full length of the core to form a cylinder having two open ends and forming a top coat and core assembly;
• placing the top coat and core assembly into the cylindrical mold sleeve with the ends of the top coat membrane extending beyond the ends of the mold sleeve;
• placing the mold sleeve with top coat and core assembly into a book mold cavity and closing the book;
• injecting flowable elastomeric material into the space between the membrane and core;
• heating the book mold to cure the elastomeric material;
• removing the multi-layer roll from the molding sleeve;
• heating the PTFE roll surface of roll under pressure to a temperature below the crystalline melting point;
• and
• quenching the roll.