The present invention is generally directed to composite materials or
charge rolls comprising a sleeved foam charge roll where the sleeve is
interference-fit over the foam core, and methods of constructing them.
The foam core can be made with an outer diameter larger than that of the
sleeve inner diameter. The sleeve can be interference fit over the foam
core to provide a functional charge roll. In some embodiments the charge
roll can be used in an image forming apparatus including, but not limited
to, an electrophotography system, an electrophotographic copying machine,
and a laser printer.