Process cartridge

Abstract

This invention relates to a processing cartridge. A processing cartridge includes: an electrophotographic photosensitive member having a drum shape; a developing unit for developing an electrostatic latent image on the surface of the electrophotographic photosensitive member using a toner; and a cleaning blade for removing the toner from the surface of the electrophotographic photosensitive member, the cleaning blade contacting the electrophotographic photosensitive member, wherein the electrophotographic photosensitive member includes wrinkles on its surface, and wherein the toner has a flow torque E of 320 mJ or more.

Description

Technical Field

[0001] This disclosure relates to a processing box for electrophotographic equipment. Background Technology

[0002] Electrophotographic photosensitive components used in electrophotographic equipment are typically drum-shaped (hereinafter also described as "electrophotographic photosensitive drum," "photosensitive drum," or simply "electrophotographic photosensitive component"). In electrophotographic equipment, various electrical and mechanical forces are applied to the surface of the electrophotographic photosensitive component (synonymous with the outer surface, and applicable hereinafter as well) during the repetitive steps of charging, exposure, development, transfer, and cleaning. Among these, the friction generated between the surface of the electrophotographic photosensitive component and the cleaning blade during cleaning is significant, and image distortion is affected by the wear and tear on the surface of the electrophotographic photosensitive component or the decrease in cleaning power.

[0003] In order to reduce the wear on the surface of electrophotographic photosensitive components, the improvement of the materials of their surface layer has been promoted, and the improvement techniques to date include improving their wear resistance by using materials with excellent wear resistance, such as curable resins, in the surface layer.

[0004] Electrophotographic photosensitive components are commonly used in electrophotographic image forming methods that include charging, exposure, development, transfer, and cleaning steps. Among these, the cleaning step, which removes residual toner from the electrophotographic photosensitive component after the transfer step, is crucial for obtaining a clear image. Cleaning methods typically involve applying pressure to a rubber-like cleaning blade to scrape away the toner from the electrophotographic photosensitive component.

[0005] Meanwhile, to improve wear resistance, the following improvements have been made: Undulations are formed on the surface of the electrophotographic photosensitive component to reduce the contact area between the surface and the cleaning blade, thereby reducing friction. Reduced friction suppresses wear on the surface of the electrophotographic photosensitive component. Additionally, the contact torque between the surface of the electrophotographic photosensitive component and the cleaning blade can be reduced.

[0006] In Japanese Patent Application Publication No. 2010-26240, an electrophotographic photosensitive component having a specific groove shape in its surface is disclosed for the purpose of improving cleanliness.

[0007] In Japanese Patent Application Publication No. 2010-250355, a toner image carrier member having a specific groove shape in its outer peripheral surface is disclosed for the purpose of simultaneously achieving high cleaning performance and suppressing the wrapping of the cleaning scraper.

[0008] Japanese Patent Application Publication No. 2015-161786 discloses an electrophotographic photosensitive component that has a highly stable surface even in high-temperature environments when the surface of the electrophotographic photosensitive component is processed by the concave and convex shape of the transfer mold component.

[0009] There has been a requirement for recent electrophotographic equipment to further reduce torque without causing cleaning defects. During the cleaning process, a layer of small particles called a barrier layer (which includes, for example, toner additives) forms on the respective surfaces of the cleaning blade and the electrophotographic photosensitive element. Maintaining the barrier layer is crucial during cleaning. Cleaning defects refer to the phenomenon where the barrier layer is damaged by some factor, causing toner or its external additives to escape from the cleaning blade. When cleaning defects occur, streaky image defects appear on the image, or even if they do not appear on the image, the escaped micro-toner or external additives remain on the surface of the electrophotographic photosensitive element and adhere to the charging roller, resulting in defects such as poor charging. Although toner escape can be suppressed by increasing the abutment pressure of the cleaning blade, this increases torque.

[0010] In the techniques disclosed in Japanese Patent Application Publication No. 2010-26240 and Japanese Patent Application Publication No. 2010-250355, a decrease in torque was observed due to reducing the friction between the electrophotographic photosensitive component and the cleaning blade. However, the grooves are processed parallel to the processing direction, thus causing toner or its additives to escape, resulting in poor cleaning in some cases. Summary of the Invention

[0011] Therefore, one aspect of this disclosure is to provide a treatment box that simultaneously achieves a reduction in torque and an improvement in cleanliness.

[0012] The above aspects are achieved by the present disclosure as described below. Specifically, the processing unit according to the present disclosure comprises: an electrophotographic photosensitive member having a drum shape; a developing unit for developing an electrostatic latent image on the surface of the electrophotographic photosensitive member using a toner; and a cleaning blade for removing the toner from the surface of the electrophotographic photosensitive member, the cleaning blade contacting the electrophotographic photosensitive member, wherein the electrophotographic photosensitive member includes wrinkles on its surface, and wherein the fluidity torque E of the toner is 320 mJ or more.

[0013] Further features of this disclosure will become apparent from the following description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0014] Figure 1AThis is a top view of the surface of an electrophotographic photosensitive element, used to illustrate an example of the concave and convex shape of the wrinkles in the electrophotographic photosensitive element.

[0015] Figure 1B A graphic is provided to illustrate height information obtained from surface observation of an electrophotographic photosensitive component, showing an example of the uneven shape of the wrinkles in the electrophotographic photosensitive component.

[0016] Figure 2 The diagram illustrates a schematic configuration of an electrophotographic apparatus including a processing box comprising an electrophotographic photosensitive element.

[0017] Figure 3 A diagram showing the appearance of the propeller blades of a powder flowability analyzer.

[0018] Figure 4 A diagram showing a polishing machine used to polish the surface of an electrophotographic photosensitive component in a comparative example.

[0019] Figure 5 A top view showing an example of the shape of the concave and convex portions of the folds formed on the outer surface of the electrophotographic photosensitive drum according to the invention.

[0020] Figure 6A A diagram showing the two-dimensional power spectrum F(r,θ) obtained by analyzing the frequency of wrinkles formed on the outer surface of the electrophotographic drum according to the invention.

[0021] Figure 6B A graph is shown to illustrate the one-dimensional radial distribution function obtained by integrating in the θ direction using the two-dimensional power spectrum F(r,θ) obtained by analyzing the frequency of the wrinkles formed on the outer surface of the electrophotographic drum according to the invention.

[0022] Figure 6C To illustrate the rate of change of power values ​​over the entire θ range when the angular distribution q(θ) is calculated from the two-dimensional power spectrum F(r,θ) at the frequency rp where the one-dimensional radial distribution function p(r) has a maximum value, the two-dimensional power spectrum F(r,θ) is obtained by integrating in the θ direction using frequency analysis of the wrinkles formed on the outer surface of the electrophotographic photosensitive drum according to the invention. Detailed Implementation

[0023] Preferred embodiments of this disclosure will now be described in detail with reference to the accompanying drawings.

[0024] This disclosure is described in detail below with reference to preferred embodiments.

[0025] In the prior art, which includes arranging grooves in the surface of an electrophotographic photosensitive element having a drum shape, a configuration has been adopted in which the direction of the groove shape is parallel to the rotation direction of the electrophotographic photosensitive element having a drum shape. Therefore, it has been found that, especially when the abutting pressure of the cleaning blade is low, residual toner on the electrophotographic photosensitive element escapes from the abutting portion of the cleaning blade through the groove shape, thereby causing striped image defects or contamination of the charging roller.

[0026] In view of the foregoing, the inventors of this disclosure have conducted in-depth research and have found that the aforementioned disadvantages can be resolved by a processing box having the following configuration.

[0027] Specifically, the processing box according to this disclosure is as follows: an electrophotographic photosensitive member including a support and a photosensitive layer; a developing unit for developing an electrostatic latent image on the surface of the electrophotographic photosensitive member with a toner; and a cleaning blade for removing the toner from the surface of the electrophotographic photosensitive member, the cleaning blade contacting the electrophotographic photosensitive member. The processing box is characterized in that the electrophotographic photosensitive member includes wrinkles on the surface of the electrophotographic photosensitive member, and the toner flow torque E is 320 mJ or more.

[0028] In this document, as described below, for example, it can be recognized that an electrophotographic photosensitive component has wrinkles covering its entire surface. In this invention, wrinkles refer to a pattern of raised and recessed areas where a plurality of mountain-like protrusions (hereinafter, protrusions) are arranged at intervals.

[0029] In the surface of an electrophotographic photosensitive component, observation areas are formed, comprising: 19 line segments dividing the electrophotographic photosensitive component into 20 equal parts along its axial direction, and 76 line segments dividing the photosensitive component into 4 equal parts along its circumference, each serving as a center point. Each observation area is a square region with each side measuring 50 μm, and the orientation of each observation area is set such that one side of the square forming the observation area is parallel to the circumferential direction of the electrophotographic photosensitive component. The following holds true for each of the 76 observation areas.

[0030] A first reference line, L1, is drawn through the center point of any one of the observation areas and is parallel to the circumference of the electrophotographic photosensitive element. Furthermore, 1,799 reference lines, L2 to L1799, are obtained by rotating the first reference line L1 around the center point by 0.1°. In this case, each of the reference lines L1 to L1799 intersects the convex portion of the wrinkle at multiple locations, and at least two of these locations have different angles of intersection.

[0031] <Composition of Electrophotographic Photosensitive Components>

[0032] The electrophotographic photosensitive element of the processing box according to this disclosure is a drum-shaped electrophotographic photosensitive element, characterized in that the surface of the electrophotographic photosensitive element has mountain-shaped folds.

[0033] Figure 1A This is a top view illustrating an example of a square observation area, 50.0 μm on each side, disposed at a chosen location on the surface of an electrophotographic photosensitive element. (See attached image.) Figure 1A As shown, the mountain-like folds in this disclosure are striped, uneven shapes that can be observed when viewing the surface of an electrophotographic photosensitive component from above. The striped shapes are not distributed in a single direction, but include, for example, curved portions, broken portions, and branching portions.

[0034] Furthermore, in this disclosure, the ridges forming the convex portions of each wrinkle refer to straight lines or curves obtained by connecting the apexes of the striped, uneven convex portions when viewed from above on the surface of the electrophotographic photosensitive element, such as those formed by... Figure 1A The figure 1a is indicated by reference numeral 1a.

[0035] Although there are no particular limitations on the method of obtaining ridges by identifying protrusions by observing the upper surface of an electrophotographic photosensitive component, protrusions can be identified, for example, by image analysis of height information measured using a confocal laser microscope. Figure 1B For the reason Figure 1A An example of a cross-sectional profile with a concave-convex shape. (From...) Figure 1A The ridges of the folds indicated by reference numeral 1a in the attached figure can be identified by various free folds. Figure 1B The vertices of the convex shape are obtained by referring to the reference numeral 1b in the attached figure.

[0036] Furthermore, in this invention, the ridges of the folds have multiple curvatures in each ridge. Curvature is a quantity representing the degree of curvature of the curve, and when the neighborhood of any point on the curve is approximated by a circle, the curvature χ is obtained as the reciprocal of the radius R of the circle, as shown in equation (I).

[0037]

[0038] Where s represents the length of the arc portion corresponding to the curve, and r is the position vector of any point on the curve.

[0039] For example, in such Figure 5 At point 5b, the curvature is large, due to the high degree of curvature of the ridge line 5a of the fold, and as shown in Figure 5b... Figure 5 At point 5c, the curvature is small, which is due to the small curvature of the ridge line 5a of the fold.

[0040] Preferably, the ridges of the folds have multiple inflection points within a square observation area with one side measuring 50 μm. An inflection point refers to... Figure 5The point where the curvature changes direction is shown in 5d, and the curvature is zero at the inflection point.

[0041] The detailed mechanism of action of this invention is speculated as follows. First, it is speculated that the folds have a predetermined number or more protrusions within a certain range, thereby reducing the contact area when the cleaning scraper abuts against the electrophotographic photosensitive drum, and thus reducing the friction. Furthermore, it is speculated that because the ridges of the protrusions of the folds point in various directions, toner passing through the concave portions is prevented from sliding during the rotation of the electrophotographic photosensitive drum.

[0042] Preferably, the electrophotographic photosensitive drum according to the present invention satisfies the following conditions.

[0043] That is, when a two-dimensional power spectrum F(r,θ) with a frequency component as r and an angle component as θ is obtained by frequency analysis of the height information of the folds in the observation area, the one-dimensional radial distribution function p(r) obtained by integrating the two-dimensional power spectrum F(r,θ) in the θ direction has at least one maximum value, and when the angular distribution q(θ) is calculated from the two-dimensional power spectrum F(r,θ) at the frequency rp where the one-dimensional radial distribution function p(r) has a maximum value, the rate of change of the power value in the entire θ range is less than 10%.

[0044] As a result of research conducted by the inventors, it was discovered that, in which... Figure 5 and Figure 1B As shown, the effects of the present invention can be highly obtained when the outer surface of the electrophotographic photosensitive drum has wrinkles and the shapes of the concave and convex portions of the wrinkles have a predetermined periodicity.

[0045] There are no particular limitations on the method for obtaining the periodicity of the shape of the concave and convex parts of the folds, but the following method can be used: obtain height information by observing the outer surface of the electrophotographic drum, and then analyze the obtained results by using a two-dimensional Fourier transform.

[0046] Specifically, when the height information of the folds is obtained using the values ​​of N1×N2, the height at any point (n,m) within the surface is h. n,m When the two-dimensional power spectrum P(k,l) obtained by discrete Fourier transform is represented by the following equation (II).

[0047]

[0048] Here, f k,l It is represented by the following equation (III).

[0049]

[0050] Where k and l represent the frequency in the horizontal direction and the frequency in the vertical direction, respectively.

[0051] Furthermore, the spectrum obtained by transforming the two-dimensional power spectrum P(k,l) obtained by equation (II) from the orthogonal coordinate system (k,l) to the polar coordinate system (r,θ) is represented by the two-dimensional power spectrum F(r,θ). Here, r and θ satisfy the following equations (IV) and (V), respectively.

[0052]

[0053] θ=Tan -1 (l / k) (V)

[0054] In this invention, height information obtained by measuring a square observation area with one side of 50 μm at regular intervals of less than 0.25 μm in each of two directions parallel to each side of the square is used for analysis.

[0055] Figures 6A-6C A figure illustrating an example of the results obtained through numerical analysis of the electrophotographic photosensitive drum according to the present invention. Figure 6A A diagram showing the two-dimensional power spectrum F(r,θ) obtained by analyzing the frequencies of wrinkles formed on the outer surface of an electrophotographic photosensitive drum is presented. Additionally, Figure 6B A plot of the one-dimensional radial distribution function obtained by integrating the obtained two-dimensional power spectrum F(r,θ) along the θ direction is shown. Additionally, Figure 6C A graph showing the rate of change of power values ​​over the entire θ range when the angular distribution q(θ) is calculated from the two-dimensional power spectrum F(r,θ) at the frequency rp where the one-dimensional radial distribution function p(r) has a maximum value.

[0056] like Figure 6B As shown, preferably, in the electrophotographic photosensitive drum according to the invention, the radial distribution function p(r) obtained by making the two-dimensional power spectrum F(r,θ) one-dimensional in the radial direction has at least one maximum value. This means that the shapes of the concave and convex portions of the folds formed on the outer surface of the electrophotographic photosensitive drum are distributed at regular intervals.

[0057] In addition, such as Figure 6C As shown, when the angular distribution q(θ) of F(rp,θ) is calculated at the frequency rp where p(r) is maximized, the rate of change of the power value over the entire θ range is preferably within a predetermined range, specifically, preferably less than 10%. This means that the shapes of the concave and convex portions of the folds formed on the outer surface of the electrophotographic photosensitive drum are periodically and uniformly distributed in any direction within the surface of the electrophotographic photosensitive drum.

[0058] Furthermore, the difference Δ between the average value hm and the average height of the folds in the observation area is preferably in the range of 0.5 μm to 2.0 μm, where the average value hm is obtained by arbitrarily selecting five points at the vertices of the convex parts of the folds in the observation area and averaging the heights of the vertices of the convex parts of the folds at the selected five points. Here, the arbitrarily selected five points do not refer to specific five points. That is, this means that even when arbitrarily selecting five points, the same result as described above is obtained.

[0059] Furthermore, the frequency rp where the radial distribution function p(r) has a maximum value is preferably at 0.05 μm. -1 ~1.00μm -1 Within the range.

[0060] When a square observation area with each side of 50.0 μm is positioned at an arbitrary location on the surface of an electrophotographic photosensitive element, and the angle formed by the tangents of the ridges of the protrusions forming the wrinkles and a line parallel to the circumferential direction of the electrophotographic photosensitive element is denoted by θ, the observation area preferably includes one or more ridge portions of the wrinkles where θ falls within the range of 45° to 135°. This θ reference... Figure 1A The example shown is used to illustrate this. In this case, θ is, for example, the angle formed by the tangent TL at point 1c on the ridge line of the protrusion forming the wrinkle and the line CL parallel to the circumferential direction of the electrophotographic photosensitive element.

[0061] Furthermore, when observation points are set at 5.0 μm intervals on the ridge line of the convex portion forming the wrinkles in the observation area, observation points whose θ falls within the range of 45° and 135° more preferably occupy more than half of the observation points present in the observation area.

[0062] In this disclosure, when obtaining a cross-sectional profile of the electrophotographic photosensitive element in the circumferential direction for a fold, the cross-sectional profile is preferably gentle. As used herein, the term "gentle" means that the radius of curvature of the curve representing the cross-sectional profile of the fold is 5 μm or more.

[0063] In addition, in this disclosure, the uneven shape present on the surface of the electrophotographic photosensitive component preferably satisfies the following conditions.

[0064] When the angle formed by the tangent of each ridge of the protrusion forming the fold and the line parallel to the circumferential direction of the electrophotographic photosensitive element is represented by θ, the average distance between the ridges of adjacent protrusions, Lave, is 1.0 to 20.0 μm, each of the protrusions having a ridge portion where θ falls within the range of 45° to 135°, and the average height of the protrusion having this ridge portion is 0.5 to 3.0 μm.

[0065] In this paper, the average value of this distance, Lave, can be determined as follows.

[0066] Square observation areas, each 50.0 μm on each side, were set at each of 76 specific locations on the surface of the electrophotographic photosensitive component, and the following measurements were performed for each observation area.

[0067] First, five locations are arbitrarily selected from the ridges of folds present in the observation area, with the tangent angle of the folds ranging from 45° to 135°.

[0068] Next, measure the shortest distance from each of the five selected sites to the ridge line of the fold component (the closer of the two fold components on either side of the site) within a range of 45° to 135°.

[0069] For the measurements taken at 5 locations in each of the 76 observation areas, totaling 76 × 5 = 380 values, the arithmetic mean is determined, and the determined value is defined as Lave.

[0070] When a "fold component that does not have a chamfer angle between 45° and 135°" exists between two "fold components that each have a chamfer angle between 45° and 135°", the two "fold components that each have a chamfer angle between 45° and 135°" are considered not adjacent to each other and are therefore excluded from the distance measurement. The selection is repeated when points on such fold components are included in any of the five selected locations.

[0071] Additionally, the average height *have* can be determined by measuring the height at the same location selected as the average height *Lave* used to determine the distance; and by determining the arithmetic mean of the resulting measurements. In height measurement, the height of the valley floor (two valley floors existing on either side of the ridge line) closest to the point on the ridge line to be determined is measured, and the two values ​​obtained from the valley floors on either side of the reference ridge line are averaged.

[0072] <Composition of Toners>

[0073] The characteristic of toners is that they satisfy the following relationship (1).

[0074] 320(mJ)≤E (1)

[0075] In equation (1), E represents the sum of the rotational torque and vertical load obtained when: in a powder flowability analyzer, a propeller blade rotates vertically at a circumferential speed of 10 mm / s at its outermost edge while entering a toner powder layer with a load of 3 kPa applied inside the container. The measurement begins at a position 80 mm from the bottom surface of the powder layer and continues until the blade reaches a position 20 mm from the bottom surface. In other words, an increase in the E value indicates a decrease in toner flowability.

[0076] [Methods for measuring E(mJ)]

[0077] E(mJ) in this disclosure is measured using a Powder Flowability Analyzer FT4 (manufactured by Freeman Technology Ltd., sometimes abbreviated as "FT4" below).

[0078] Specifically, the measurement is performed through the following steps.

[0079] Throughout the entire operation, Figure 3 The 23.5 mm diameter blade 31 (material: SUS, sometimes abbreviated as "blade" below), specifically designed for FT4, shown in the diagram, is used as a propeller blade. The cylindrical separation container (model: C4031, material: glass, diameter: 25 mm, sometimes abbreviated as "container" below), specifically designed for FT4, is used as a measuring container.

[0080] (1) Compression operation

[0081] A pressure of 3 kPa was applied to the toner powder layer to compress it.

[0082] Specifically, the FT4 is equipped with a piston (24 mm in diameter and with a mesh-like lower section) for compression testing instead of the propeller blades 31. 7.0 g of toner is loaded into the container, and the piston descends at 0.1 mm / s to compress the toner. When the load on the piston reaches 3 kPa, the piston stops descending and remains in place for 60 seconds to form a compressed powder layer. This operation is repeated three times to form a compressed powder layer. Finally, the compressed powder layer is leveled using the separation section of the container specifically designed for the FT4, allowing the toner on top of the compressed powder layer to be removed.

[0083] (2) Measurement operation

[0084] The propeller-type blade 31 rotates counterclockwise relative to the surface of the powder layer (the rotation of the blade 31 compresses the powder layer), such that the circumferential speed of the outermost part of the blade 31 can be 10 mm / sec. The blade 31 enters the powder layer vertically from the surface at an angle of 5°, reaching a position 80 mm from the bottom surface of the toner powder layer. Then, the blade 31 rotates counterclockwise relative to the surface of the powder layer, such that the circumferential speed of the outermost part can be 10 mm / s, and the blade enters the powder layer vertically at an angle of 5°, reaching a position 20 mm from the bottom surface of the powder layer. Further, the blade 31 is moved to a position 100 mm from the bottom surface of the powder layer at a speed of 2° and then pulled out.

[0085] In this article, the angle formed in relation to the entry velocity refers to the angle formed by the spiral trajectory of the outermost edge of the propeller and the toner powder layer as observed from one side when the blade is rotating and moving vertically.

[0086] When the pulling is complete, the toner adhering to the blade 31 is shaken off by rotating the blade 31 alternately clockwise and counterclockwise with small amplitudes. The sum of the integral value of the rotational torque over the moving distance of the blade and the integral value of the vertical load over the moving distance, Et, is defined as E. This rotational torque is obtained when the blade 31 moves from a position 80 mm away from the bottom surface of the toner powder layer to a position 20 mm away from the bottom surface of the toner powder layer.

[0087] <Mechanism of the effect>

[0088] The inventors of this disclosure envision the following mechanism by which the processing box having the above-described configuration is effective in reducing the torque of the electrophotographic photosensitive component and suppressing poor cleaning.

[0089] It is speculated that the presence of mountain-like folds reduces the contact area between the electrophotographic photosensitive component and the cleaning squeegee when they come into contact, thereby reducing the friction between them. The ridges of the mountain-like folds point in various directions, thus preventing image damage effects such as streaks caused by toner pooling at one point and escaping from the squeegee during groove-shaped processing. However, when using a low-flow toner, the toner receives various forces from the slopes of the mountain-like folds, causing the toner to move and circulate before the deposition layer. Consequently, fine toner or its external additives leak from the openings in the squeegee. As a result, although no image damage occurs, the charging component becomes contaminated. In view of the foregoing, when the toner is combined with a high-flow toner, the flow of toner before the barrier layer can be suppressed, thus suppressing toner escape and preventing damage to the barrier layer. Therefore, poor cleaning does not occur. Although the use of low-flow toners typically increases the torque on electrophotographic photosensitive components, this increase in torque during the cleaning step can be mitigated by the wrinkle shape on the surface of the electrophotographic photosensitive component. Therefore, both torque reduction and suppression of poor cleaning can be achieved at a high level.

[0090] As described in the foregoing mechanism, the effects according to the present disclosure can be achieved when the various components of the photosensitive element and the toner in the processing box according to one aspect of the present disclosure interact synergistically with each other.

[0091] The configuration of the electrophotographic photosensitive element according to one aspect of this disclosure is described in detail below.

[0092] [Electronic photographic sensor]

[0093] An electrophotographic photosensitive component includes a support, a photosensitive layer disposed on the support, and a surface layer comprising a curable resin. A method for manufacturing an electrophotographic photosensitive component includes, for example, a method involving: preparing a coating liquid for each of the layers described later; applying the liquid in a desired layer sequence; and drying the liquid. Examples of coating liquid application methods in this case include dip coating, spray coating, inkjet coating, roller coating, die coating, doctor blade coating, curtain coating, wire rod coating, and ring coating. From the viewpoint of efficiency and productivity, dip coating is preferred.

[0094] The support structure and each layer are described below.

[0095] <Support Body>

[0096] In this disclosure, the electrophotographic photosensitive component includes a support and a surface layer. In this disclosure, the support is preferably a conductive support with electrical conductivity. Examples of the support's shape include cylindrical, strip-shaped, and sheet-shaped. Among these shapes, a cylindrical support is preferred. Furthermore, the surface of the support can be subjected to, for example, electrochemical treatments such as anodizing, sandblasting, or cutting.

[0097] Materials such as metal, resin, or glass are preferred as supports.

[0098] Examples of metals include aluminum, iron, nickel, copper, gold, stainless steel, and their alloys. Among these metals, aluminum supports are preferred.

[0099] In addition, conductivity can be imparted to resins or glass through processes involving, for example, mixing or coating the resin or glass with a conductive material.

[0100] <Conductive Layer>

[0101] In this disclosure, a conductive layer can be disposed on a support. The placement of the conductive layer can conceal imperfections and irregularities on the surface of the support and can control the reflection of light on the surface of the support.

[0102] The conductive layer preferably comprises conductive particles and resin.

[0103] The conductive particles are made of materials such as metal oxides, metals, or carbon black.

[0104] Examples of metal oxides include zinc oxide, aluminum oxide, indium oxide, silicon oxide, zirconium oxide, tin oxide, titanium oxide, magnesium oxide, antimony oxide, and bismuth oxide. Examples of metals include aluminum, nickel, iron, nichrome, copper, zinc, and silver.

[0105] The metal oxide is preferably used as the conductive particle. In particular, titanium oxide, tin oxide, or zinc oxide is more preferably used.

[0106] When metal oxides are used as conductive particles, the surface of the metal oxides can be treated with silane coupling agents, or the metal oxides can be doped with elements such as phosphorus or aluminum or their oxides.

[0107] Alternatively, the conductive particles can each be composed of a stack of core particles and a capping layer covering the core particles. The core particles can be made of materials such as titanium oxide, barium sulfate, or zinc oxide. The capping layer can be made of materials such as metal oxides, such as tin oxide.

[0108] In addition, when metal oxides are used as conductive particles, the volume average particle size is preferably 1 to 500 nm, more preferably 3 to 400 nm.

[0109] Examples of resins include polyester resins, polycarbonate resins, polyvinyl acetal resins, acrylic resins, silicone resins, epoxy resins, melamine resins, polyurethane resins, phenolic resins, and alkyd resins.

[0110] In addition, the conductive layer may further include, for example, a concealing agent, such as silicone oil, resin particles, or titanium dioxide.

[0111] The average thickness of the conductive layer is preferably 1 to 50 μm, and particularly preferably 3 to 40 μm.

[0112] The conductive layer can be formed by: preparing a coating liquid for the conductive layer comprising the above-mentioned materials and solvents; forming a coating film of the coating liquid; and drying the coating film. Examples of solvents used for the coating liquid include alcohol-based solvents, sulfoxide-based solvents, ketone-based solvents, ether-based solvents, ester-based solvents, and aromatic hydrocarbon-based solvents. Dispersion methods for dispersing conductive particles in the coating liquid for the conductive layer include, for example, methods using a paint mixer, a sand mill, a ball mill, or a liquid impact type high-speed disperser.

[0113] <Undercoat>

[0114] In this disclosure, the primer layer can be disposed on a support or a conductive layer. The placement of the primer layer can improve interlayer adhesion to impart charge injection barrier functionality.

[0115] The primer layer preferably comprises a resin. Alternatively, the primer layer can be formed into a cured film by polymerizing a composition comprising monomers having polymerizable functional groups.

[0116] Examples of resins include polyester resins, polycarbonate resins, polyvinyl alcohol acetal resins, acrylic resins, epoxy resins, melamine resins, polyurethane resins, phenolic resins, polyvinylphenol resins, alkyd resins, polyvinyl alcohol resins, polyethylene oxide resins, polypropylene oxide resins, polyamide resins, polyamic acid resins, polyimide resins, polyamide-imide resins, and cellulose resins.

[0117] Examples of polymerizable functional groups in monomers include isocyanate groups, terminal isocyanate groups, hydroxymethyl groups, alkylated hydroxymethyl groups, epoxy groups, metal alkoxide groups, hydroxyl groups, amino groups, carboxyl groups, thiol groups, carboxylic anhydride groups, and carbon-carbon double bond groups.

[0118] Furthermore, for the purpose of improving electrical properties, the base coating may further include electron transport materials, metal oxides, metals, and conductive polymers. Among these, electron transport materials and metal oxides are preferred.

[0119] Examples of electron transport materials include quinone compounds, imide compounds, benzimidazole compounds, cyclopentadienyl compounds, fluorenone compounds, xanthonesone compounds, benzophenone compounds, cyanovinyl compounds, halogenated aryl compounds, thiophene compounds, and boron-containing compounds. Electron transport materials with polymerizable functional groups can be used as electron transport materials and copolymerized with the aforementioned monomers having polymerizable functional groups to form a base coating as a cured film.

[0120] Examples of metal oxides include indium tin oxide, tin oxide, indium oxide, titanium oxide, zinc oxide, aluminum oxide, and silicon dioxide. Examples of metals include gold, silver, and aluminum.

[0121] In addition, the base coat may contain additives.

[0122] The average thickness of the base coating is preferably 0.1 to 50 μm, more preferably 0.2 to 40 μm, and particularly preferably 0.3 to 30 μm.

[0123] The primer layer can be formed by: preparing a primer coating liquid comprising the above-described materials and solvents; forming a coating film of the coating liquid; and drying and / or curing the coating film. Examples of solvents used in the coating liquid include alcohol solvents, ketone solvents, ether solvents, ester solvents, and aromatic hydrocarbon solvents.

[0124] <Photosensitive layer>

[0125] The photosensitive layers of electrophotographic photosensitive components are mainly classified into (1) stacked photosensitive layers and (2) single-layer photosensitive layers. (1) Stacked photosensitive layers include: a charge-generating layer containing charge-generating material and a charge-transporting layer containing charge-transporting material. (2) Single-layer photosensitive layers include photosensitive layers that simultaneously contain charge-generating material and charge-transporting material.

[0126] (1) Layered photosensitive layer

[0127] A stacked photosensitive layer includes a charge generation layer and a charge transport layer.

[0128] (1-1) Charge generation layer

[0129] The charge-generating layer preferably comprises a charge-generating substance and a resin.

[0130] Examples of charge-generating substances include azo pigments, perylene pigments, polycyclic quinone pigments, indigo pigments, and phthalocyanine pigments. Among these, azo pigments and phthalocyanine pigments are preferred. Of the phthalocyanine pigments, titanium dioxide phthalocyanine pigments, gallium chloride phthalocyanine pigments, and hydroxy gallium phthalocyanine pigments are preferred.

[0131] The content of charge-generating material in the charge-generating layer is preferably 40-85% by mass, more preferably 60-80% by mass, relative to the total mass of the charge-generating layer.

[0132] Examples of resins include polyester resins, polycarbonate resins, polyvinyl acetal resins, polyvinyl butyral resins, acrylic resins, silicone resins, epoxy resins, melamine resins, polyurethane resins, phenolic resins, polyvinyl alcohol resins, cellulose resins, polystyrene resins, polyvinyl acetate resins, and polyvinyl chloride resins. Among these, polyvinyl butyral resins are more preferred.

[0133] In addition, the charge-generating layer may further contain additives, such as antioxidants or UV absorbers. Specific examples include hindered phenolic compounds, hindered amine compounds, sulfur compounds, phosphorus compounds, and benzophenone compounds.

[0134] The average thickness of the charge generation layer is preferably 0.1 to 1 μm, more preferably 0.15 to 0.4 μm.

[0135] The charge-generating layer can be formed by: preparing a coating solution containing the above-described materials and solvents; forming a coating film of the coating solution; and drying the coating film. Examples of solvents used in the coating solution include alcohol solvents, sulfoxide solvents, ketone solvents, ether solvents, ester solvents, and aromatic hydrocarbon solvents.

[0136] (1-2) Charge transport layer

[0137] The charge transport layer preferably comprises a charge transport material and a resin.

[0138] Examples of charge-transporting substances include polycyclic aromatic compounds, heterocyclic compounds, hydrazone compounds, styryl compounds, enamine compounds, benzidine compounds, triarylamine compounds, and resins having groups derived from any of these substances. Among these, triarylamine compounds and benzidine compounds are preferred, and compounds having the following structures are suitably used.

[0139]

[0140] In equation (1), R 1 ~R 10 Each can be used independently to represent a hydrogen atom or a methyl group.

[0141] Examples of structures represented by equation (1) are shown in equations (1-1) to (1-10). Among them, the structures represented by equations (1-1) to (1-6) are more preferred.

[0142]

[0143]

[0144]

[0145] Thermoplastic resins are used as resins, and examples include polyester resins, polycarbonate resins, acrylic resins, and polystyrene resins. Polycarbonate resins and polyester resins are preferred. Polyarylate resins are particularly preferred as polyester resins.

[0146] The charge transport material content in the charge transport layer is preferably 25-70% by mass, more preferably 30-55% by mass, relative to the total mass of the charge transport layer.

[0147] The content ratio (mass ratio) between the charge transport material and the resin is preferably 4:10 to 20:10, and more preferably 5:10 to 12:10.

[0148] In addition, the charge transport layer may contain additives such as antioxidants, UV absorbers, plasticizers, leveling agents, slip-improving agents, or abrasion resistance modifiers. Specific examples include hindered phenolic compounds, hindered amine compounds, sulfur compounds, phosphorus compounds, benzophenone compounds, siloxane-modified resins, silicone oils, fluoropolymer particles, polystyrene resin particles, polyethylene resin particles, silica particles, alumina particles, and boron nitride particles.

[0149] The average thickness of the charge transport layer is preferably 5 to 50 μm, more preferably 8 to 40 μm, and particularly preferably 10 to 30 μm.

[0150] The charge transport layer can be formed by: preparing a coating solution containing the aforementioned materials and solvents; forming a coating film of the coating solution; and drying the coating film. Examples of solvents used for the coating solution include alcohol-based solvents, ketone-based solvents, ether-based solvents, ester-based solvents, and aromatic hydrocarbon-based solvents. Among these solvents, ether-based solvents or aromatic hydrocarbon-based solvents are preferred.

[0151] (2) Single-layer photosensitive layer

[0152] A single-layer photosensitive layer can be formed by: preparing a coating solution for the photosensitive layer containing a charge-generating substance, a charge-transporting substance, a resin, and a solvent; forming a coating film of the coating solution; and drying the coating film. The examples of the charge-generating substance, the charge-transporting substance, and the resin are the same as those in the above section "(1) Layered Photosensitive Layer".

[0153] <Protective Layer>

[0154] In this disclosure, a protective layer may be disposed on the photosensitive layer. The placement of the protective layer can improve the durability of the electrophotographic photosensitive component.

[0155] The protective layer preferably comprises conductive particles and / or charge-transporting substances as well as resin.

[0156] Examples of conductive particles include particles of metal oxides such as titanium oxide, zinc oxide, tin oxide, and indium oxide.

[0157] Examples of charge-transporting substances include polycyclic aromatic compounds, heterocyclic compounds, hydrazone compounds, styryl compounds, enamine compounds, benzidine compounds, triarylamine compounds, and resins having groups derived from any of these substances. Among these, triarylamine compounds and benzidine compounds are preferred.

[0158] Examples of resins include polyester resins, acrylic resins, phenoxy resins, polycarbonate resins, polystyrene resins, phenolic resins, melamine resins, and epoxy resins. Polycarbonate resins, polyester resins, and acrylic resins are preferred. Furthermore, the protective layer can be formed into a cured film by polymerizing a composition containing monomers with polymerizable functional groups. The reaction in this case is, for example, thermal polymerization, photopolymerization, or radiation polymerization. Examples of polymerizable functional groups in monomers include acrylic groups and methacrylic groups. Materials with charge-transporting capabilities can be used as monomers with polymerizable functional groups.

[0159] Compounds with polymerizable functional groups can possess both charge-transporting structures and chain-polymerizable functional groups. For charge transport purposes, the charge-transporting structure is preferably a triarylamine structure. The chain-polymerizable functional group is preferably acryloyl or methacryloyl. The number of functional groups can be one or more. It is particularly preferred that the cured film is formed by introducing compounds with multiple functional groups and compounds with one functional group into such compounds, because this readily eliminates distortion caused by the polymerization of multiple functional groups.

[0160] Examples of compounds having a functional group are shown in (2-1) to (2-6).

[0161]

[0162]

[0163] Examples of compounds having multiple functional groups are shown in (3-1) to (3-7).

[0164]

[0165]

[0166] The protective layer may contain additives such as antioxidants, UV absorbers, plasticizers, leveling agents, slip-improving agents, or abrasion resistance modifiers. Specific examples include hindered phenolic compounds, hindered amine compounds, sulfur compounds, phosphorus compounds, benzophenone compounds, siloxane-modified resins, silicone oils, fluoropolymer particles, polystyrene resin particles, polyethylene resin particles, silica particles, alumina particles, and boron nitride particles.

[0167] The protective layer can be formed by: preparing a coating liquid containing the above-described materials and solvents; forming a coating film of the coating liquid; and drying and / or curing the coating film. Examples of solvents used in the coating liquid include alcohol solvents, ketone solvents, ether solvents, sulfoxide solvents, ester solvents, and aromatic hydrocarbon solvents.

[0168] <Methods for forming uneven surfaces on the surface of electrophotographic photosensitive components>

[0169] Methods for forming irregularities on the surface of an electrophotographic photosensitive component are classified into (1) methods for forming wrinkled shapes and (2) methods for forming embossed shapes. The wrinkled shape in (1) is obtained by stacking films with different thermal expansion behaviors, and by heating and cooling the stack, thus forming... Figure 1A Such patterns are shown in the example. As disclosed in Japanese Patent Application Publication No. 2015-161786, (2) the method of forming the embossed shape includes pressing a mold made of metal or the like against the surface of an electrophotographic photosensitive member to form a pattern, and is widely known as a technique for giving a surface shape to an electrophotographic photosensitive member.

[0170] (1) Shape of folds

[0171] The method for forming a wrinkled shape includes: forming a protective layer as a cross-linked curable film on a charge transport layer containing a thermoplastic resin as the main component; and then subjecting the laminate to heat treatment to produce a wrinkled shape. It is speculated that at this time, compressive stress is applied in the surface direction of the electrophotographic photosensitive component through the difference in the amount of deformation between the protective layer and the charge transport layer, causing the surface protective layer to buckle, thus forming a wrinkled shape.

[0172] (2) Embossed shape

[0173] The method for forming an embossed shape includes a step of pressing a mold member having an embossed shape into an electrophotographic photosensitive member to transfer the embossed shape of the mold member onto the surface of the electrophotographic photosensitive member. Although the embossed shape can be uniformly formed on the photosensitive member without any protective layer, for durability reasons, the photosensitive member preferably includes a protective layer.

[0174] Figure 4An example of a pressure pattern transfer apparatus for forming recesses on the surface of an electrophotographic photosensitive component is shown.

[0175] according to Figure 4 The pressure pattern transfer apparatus shown in the figure applies pressure to the surface (outer peripheral surface) of the electrophotographic photosensitive component 2-1, which is used as the workpiece, while the component rotates. Consequently, a recess can be formed on the surface of the electrophotographic photosensitive component 2-1.

[0176] The material of the pressure member 2-3 is, for example, metal, metal oxide, plastic, or glass. Stainless steel (SUS) is preferred from the viewpoints of mechanical strength, dimensional accuracy, and durability. The mold member is disposed on the upper surface of the pressure member 2-3. Furthermore, the mold member 2-2 can contact the surface of the electrophotographic photosensitive member 2-1 supported by the support member 2-4 under a predetermined pressure via a support member (not shown) disposed on the lower surface side of the pressure member and the pressure member (not shown). Additionally, the support member 2-4 can press against the pressure member 2-3 under a predetermined pressure, or the support member 2-4 and the pressure member 2-3 can press against each other.

[0177] Figure 4 The example shown is one in which the pressure member 2-3 moves in a direction perpendicular to the axial direction of the electrophotographic photosensitive member 2-1 to continuously process the surface of the electrophotographic photosensitive member 2-1, while simultaneously causing the electrophotographic photosensitive member to rotate passively or drivenly. Further, the surface of the electrophotographic photosensitive member 2-1 can be continuously processed by moving the support member 2-4 in a direction perpendicular to the axial direction of the electrophotographic photosensitive member 2-1 while fixing the pressure member 2-3; or by moving both the support member 2-4 and the pressure member 2-3.

[0178] From the viewpoint of effectively transferring the shape of the mold components, it is preferable to heat the mold component 2-2 and the electrophotographic photosensitive component 2-1.

[0179] Examples of mold components 2-2 include: metal or resin films with micro-surface processing; products obtained by patterning the surface of silicon wafers, etc., with a photoresist; resin films in which fine particles are dispersed; and products obtained by coating a resin film with a micro-surface shape with metal.

[0180] Furthermore, from the viewpoint of uniformizing the pressure that causes the mold component to press against the electrophotographic photosensitive component 2-1, the elastomer is preferably disposed between the mold component 2-2 and the pressure member 2-3.

[0181] The composition of the toner according to one aspect of this disclosure is described in detail below.

[0182] [Toner]

[0183] The method for producing the toner particles disclosed herein is not particularly limited, as long as the aforementioned flowability torque can be achieved, and known production methods can be used.

[0184] The toner particles disclosed herein are preferably toners obtained by suspension polymerization, wherein the toner particles are prepared by means of a known production method, namely: dispersing free radical polymerizable monomers and colorants; then, dispersing droplets of the dispersion in an aqueous medium or the like to obtain a desired toner particle size; and then subjecting the result to suspension polymerization. This is because particles with a narrow particle size distribution, high sphericity, and a surface with a substantially uniform material can be formed, thus easily obtaining stable flowability and excellent charge properties.

[0185] The method for producing toner particles for use in this disclosure is described below by employing suspension polymerization, as an example, which is most suitable for obtaining toner particles.

[0186] Polymerizable monomer compositions are prepared by uniformly dissolving or dispersing polymerizable monomers, colorants, polar resins, release agents, and any other additives as needed using a dispersant such as a homogenizer, ball mill, colloid mill, or ultrasonic disperser, and by dissolving a polymerization initiator in the result.

[0187] Next, the polymerizable monomer composition is dispersed in an aqueous medium containing a dispersion stabilizer and granulated to form particles, and the polymerizable monomers in the particles are polymerized to produce toner particles.

[0188] The polymerization initiator can be added simultaneously with other additives to the polymerizable monomer, or it can be mixed immediately before the polymerizable monomer composition is dispersed in an aqueous medium.

[0189] In addition, polymerizable monomers or polymerization initiators dissolved in the solvent can be added immediately after granulation or before the polymerization reaction begins.

[0190] In this disclosure, a suitable acid is preferably added during dispersion, during granulation, or before the start of the polymerization reaction to adjust the pH.

[0191] Commonly used acids such as hydrochloric acid, sulfuric acid, or nitric acid can be used as acids in the toners disclosed herein.

[0192] When the pH of the aqueous solution during polymerization is adjusted to an appropriate pH, a toner with more uniform charge properties can be obtained.

[0193] When a polar resin is added during a polymerization reaction that begins with a dispersion of the polymerizable monomer composition and ends with a polymerization step, the state of the polar resin can be controlled according to the balance between the polarity exhibited by the polymerizable monomer composition as toner particles and the polarity exhibited by the aqueous dispersion medium.

[0194] That is, the addition of polar resin ensures separation according to the function of the resin layer. In addition, toner particles obtained by suspension polymerization are preferred because each particle has a core-shell structure in which the mold release agent component is encapsulated.

[0195] Examples of polar resins include polyester resins, epoxy resins, styrene-acrylic acid copolymers, styrene-methacrylic acid copolymers, and styrene-maleic acid copolymers.

[0196] Examples of polymerizable monomers forming binder resins for use in the toners of this disclosure include commonly used styrene-acrylic copolymers, styrene-methacrylic copolymers, epoxy resins, and styrene-butadiene copolymers.

[0197] Free radical polymerizable vinyl monomers can be used as polymerizable monomers to form adhesive resins. Monofunctional or polyfunctional polymerizable monomers can be used as vinyl polymerizable monomers.

[0198] Examples of polymerizable monomers that form adhesive resins include: styrene; styrene-based monomers, such as o-(m-, p-)methylstyrene and m-(p-)ethylstyrene; acrylate or methacrylate-based monomers, such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, butyl acrylate, butyl methacrylate, octyl acrylate, octyl methacrylate, dodecyl acrylate, dodecyl methacrylate, stearyl acrylate, stearyl methacrylate, behenyl acrylate, behenyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl acrylate and diethylaminoethyl methacrylate; and olefinic monomers, such as butadiene, isoprene, cyclohexene, acrylonitrile, methacrylonitrile, acrylamide, and methacrylamide.

[0199] In this disclosure, a crosslinking agent can be used during the synthesis of the binder resin to improve the mechanical strength of each toner particle and control the molecular weight of the THF-soluble component of the toner.

[0200] Examples of difunctional crosslinking agents include divinylbenzene, bis(4-acryloyloxypolyethoxyphenyl)propane, ethylene glycol diacrylate, 1,3-butanediol diacrylate, 1,4-butanediol diacrylate, 1,5-pentanediol diacrylate, 1,6-hexanediol diacrylate, neopentanediol diacrylate, diethylene glycol diacrylate, triethylene glycol diacrylate, tetraethylene glycol diacrylate, diacrylates of polyethylene glycol #200, #400 and #600, dipropylene glycol diacrylate, polypropylene glycol diacrylate, polyester diacrylates (MANDA Nippon Kayaku Co., Ltd.), and products obtained by changing the above diacrylates to dimethacrylates.

[0201] Examples of multifunctional crosslinking agents include pentaerythritol triacrylate, trimethylolethane triacrylate, trimethylolpropane triacrylate, tetramethylolmethane tetraacrylate, low-polyester acrylate and low-polyester methacrylate, 2,2-bis(4-methacryloyloxypolyethoxyphenyl)propane, diallyl phthalate, triallyl cyanurate, triallyl isocyanurate and triallyl trimellitate.

[0202] Examples of release agents used in this disclosure include: petroleum-based waxes and their derivatives, such as paraffin wax, microcrystalline wax, and petrolatum; montan waxes and their derivatives; hydrocarbon waxes and their derivatives obtained by the Fischer-Tropsch process; polyolefin waxes and their derivatives, such as polyethylene wax and polypropylene wax; natural waxes and their derivatives, such as carnauba wax and candelilla wax; higher fatty alcohols; fatty acids, such as stearic acid and palmitic acid; amide waxes; ester waxes; hydrogenated castor oil and its derivatives; vegetable waxes; and animal waxes. Among these, paraffin wax, ester waxes, and hydrocarbon waxes are particularly preferred from the viewpoint of excellent release properties.

[0203] Examples of polymerization initiators used in the toners of this disclosure include: azo or diazo polymerization initiators, such as 2,2′-azobis-(2,4-dimethylpentanonitrile), 2,2′-azobisisobutyronitrile, 1,1′-azobis(cyclohexane-1-carboxynitrile), 2,2′-azobis-4-methoxy-2,4-dimethylpentanonitrile, and azobisisobutyronitrile; and peroxide polymerization initiators, such as benzoyl peroxide, methyl ethyl ketone peroxide, diisopropyl percarbonate, cumene hydroperoxide, 2,4-dichlorobenzoyl peroxide, lauroyl peroxide, and tert-butyl peroxypentanoate. These polymerization initiators can be used alone or as mixtures thereof with reference to a 10-hour half-life temperature, although the type of polymerization initiator varies slightly depending on the polymerization method.

[0204] The colorants disclosed herein contain colorants as essential components for imparting tinting strength. Examples of preferred colorants for use in this disclosure include organic pigments, organic dyes, and inorganic pigments.

[0205] Examples of organic pigments or dyes that serve as cyan colorants include copper phthalocyanine compounds and their derivatives, anthraquinone compounds, and alkali dye lake compounds.

[0206] Specific examples include CI Pigment Blue 1, CI Pigment Blue 7, CI Pigment Blue 15, CI Pigment Blue 15:1, CI Pigment Blue 15:2, CI Pigment Blue 15:3, CI Pigment Blue 15:4, CI Pigment Blue 60, CI Pigment Blue 62 and CI Pigment Blue 66.

[0207] Examples of organic pigments or dyes that serve as magenta colorants include condensed azo compounds, diketopyrrolopyrrole compounds, anthraquinones, quinacridones, alkali lake compounds, naphthol compounds, benzimidazolone compounds, thioindole compounds, and perylene compounds.

[0208] Specific examples include CI Pigment Red 2, CI Pigment Red 3, CI Pigment Red 5, CI Pigment Red 6, CI Pigment Red 7, CI Pigment Violet 19, CI Pigment Red 23, CI Pigment Red 48:2, CI Pigment Red 48:3, CI Pigment Red 48:4, CI Pigment Red 57:1, CI Pigment Red 81:1, CI Pigment Red 122, CI Pigment Red 144, CI Pigment Red 146, CI Pigment Red 150, CI Pigment Red 166, CI Pigment Red 169, CI Pigment Red 177, CI Pigment Red 184, CI Pigment Red 185, CI Pigment Red 202, CI Pigment Red 206, CI Pigment Red 220, CI Pigment Red 221, and CI Pigment Red 254.

[0209] Examples of organic pigments or dyes that serve as yellow colorants include compounds represented by: condensed azo compounds, isoindolone compounds, anthraquinone compounds, azo metal complexes, methine compounds, and allylamide compounds.

[0210] Specific examples include CI Pigment Yellow 12, CI Pigment Yellow 13, CI Pigment Yellow 14, CI Pigment Yellow 15, CI Pigment Yellow 17, CI Pigment Yellow 62, CI Pigment Yellow 74, CI Pigment Yellow 83, CI Pigment Yellow 93, CI Pigment Yellow 94, CI Pigment Yellow 95, CI Pigment Yellow 97, CI Pigment Yellow 109, CI Pigment Yellow 110, CI Pigment Yellow 111, CI Pigment Yellow 120, CI Pigment Yellow 127, CI Pigment Yellow 128, CI Pigment Yellow 129, CI Pigment Yellow 147, CI Pigment Yellow 151, CI Pigment Yellow 154, CI Pigment Yellow 155, CI Pigment Yellow 168, CI Pigment Yellow 174, CI Pigment Yellow 175, CI Pigment Yellow 176, CI Pigment Yellow 180, CI Pigment Yellow 181, CI Pigment Yellow 191, and CI Pigment Yellow 194.

[0211] Black colorants, for example, are colorants that are tinted to black using carbon black, yellow colorants, magenta colorants, or cyan colorants.

[0212] These colorants can be used alone or as mixtures thereof, and can each be used in a solid solution state. The colorants used in the toners of this disclosure are selected in consideration of hue angle, chroma, brightness, lightfastness, OHP transparency and dispersibility in the toner.

[0213] In this disclosure, when colorant particles are obtained by using a polymerization method, attention needs to be paid to the polymerization inhibition and water phase migration of the colorant. Therefore, the colorant is preferably hydrophobically treated with a substance that does not hinder any polymerization.

[0214] Known inorganic and organic dispersion stabilizers can each be used as dispersion stabilizers in the preparation of aqueous media.

[0215] Specific examples of inorganic dispersing stabilizers include tricalcium phosphate, magnesium phosphate, aluminum phosphate, zinc phosphate, magnesium carbonate, calcium carbonate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, calcium metasilicate, calcium sulfate, barium sulfate, bentonite, silica, and alumina.

[0216] In addition, examples of organic dispersants include polyvinyl alcohol, gelatin, methylcellulose, methyl hydroxypropyl cellulose, ethyl cellulose, sodium salts of carboxymethyl cellulose, and starch.

[0217] Alternatively, commercially available nonionic, anionic, or cationic surfactants can be used. Examples of such surfactants include sodium dodecyl sulfate, sodium tetradecyl sulfate, sodium pentadecyl sulfate, sodium octyl sulfate, sodium oleate, sodium laurate, potassium stearate, and calcium oleate.

[0218] Inorganic and poorly water-soluble dispersion stabilizers are preferably used as dispersion stabilizers in the preparation of aqueous media for the toners of this disclosure, and more preferably, poorly water-soluble inorganic dispersion stabilizers soluble in acids are used.

[0219] In this disclosure, when preparing an aqueous medium in which the dispersion stabilizer described above is dispersed, a commercially available dispersion stabilizer can be used and dispersed as is.

[0220] In addition, in order to obtain dispersion stabilizer particles with fine and uniform particle size, aqueous media can be prepared by producing dispersion stabilizers in liquid media such as water under high-speed stirring.

[0221] For example, when tricalcium phosphate is used as a dispersion stabilizer, a preferred dispersion stabilizer can be obtained by mixing an aqueous solution of sodium phosphate and an aqueous solution of calcium chloride under high-speed stirring to form fine particles of tricalcium phosphate.

[0222] In the toners disclosed herein, charge control agents can be used as needed by mixing with toner particles. The blending of charge control agents can improve and stabilize the charge characteristics of the toner particles and control their optimal triboelectric charge according to the developing system.

[0223] Known charge control agents can be used as charge control agents, and charge control agents with fast charging speed and the ability to stably maintain a constant charge are particularly preferred.

[0224] Furthermore, when toner particles are produced by direct polymerization, charge control agents with low polymerization inhibition and containing a small amount of substances soluble in aqueous media are particularly preferred.

[0225] Examples of agents that control toners to make them negatively charged charge control agents include the following reagents. Organometallic compounds and chelating compounds are effective, and examples include: monoazo metal compounds; acetylacetone metal compounds; and aromatic hydroxycarboxylic acid, aromatic dicarboxylic acid, oxycarboxylic acid, and dicarboxylic acid metal compounds. Additionally, examples of such reagents include aromatic hydroxycarboxylic acids, aromatic monocarboxylic acids, and polycarboxylic acids, as well as their metal salts, anhydrides, and esters, and phenolic derivatives such as bisphenol. Further examples include urea derivatives, metal-containing salicylic acid compounds, metal-containing naphtholic acid compounds, boron compounds, quaternary ammonium salts, calixarenes, and resin-based charge control agents.

[0226] Among them, the polymer with sulfonic acid functional groups that serves as a charge control agent is preferably a polymer or copolymer having sulfonic acid groups, sulfonate groups, or sulfonate groups.

[0227] The method for controlling the E value in this disclosure is, for example, a method of controlling the value by changing the type, amount, and addition conditions of the inorganic fine particles added to the toner particles.

[0228] [Processing box and electrophotographic equipment]

[0229] The processing box according to this disclosure is characterized in that the processing box integrally supports the aforementioned electrophotographic photosensitive component and at least one unit selected from the group consisting of a charging unit, a developing unit, a transfer unit and a cleaning unit, and is detachably mounted to the main body of the electrophotographic device.

[0230] Furthermore, the electrophotographic apparatus according to this disclosure is characterized by including the aforementioned electrophotographic photosensitive component, charging unit, exposure unit, developing unit, and transfer unit.

[0231] An example of an illustrative configuration of an electrophotographic device including a processing box (which contains an electrophotographic photosensitive element) is shown in Figure 2 As shown in the image.

[0232] An electrophotographic photosensitive element 1, having a cylindrical shape, is driven to rotate about an axis 2 at a predetermined circumferential speed in the direction of the arrow. The surface of the electrophotographic photosensitive element 1 is charged to a predetermined positive or negative potential via a charging unit 3. Although the roller charging system based on a roller-type charging element... Figure 2 The charging system is shown, but can employ, for example, a corona charging system, a proximity charging system, or an injection charging system. The charged surface of the electrophotographic photosensitive element 1 is irradiated with exposure light 4 from an exposure unit (not shown), thus forming an electrostatic latent image corresponding to the target image information. The electrostatic latent image formed on the surface of the electrophotographic photosensitive element 1 is developed using toner stored in a developing unit 5, and a toner image is formed on the surface of the electrophotographic photosensitive element 1. The toner image formed on the surface of the electrophotographic photosensitive element 1 is transferred to a transfer material 7 via a transfer unit 6. The transfer material 7, on which the toner image has been transferred, is conveyed to a fixing unit 8 for fixing the toner image, and then printed out to the outside of the electrophotographic apparatus. The electrophotographic apparatus may include a cleaning unit 9 for removing, for example, deposits such as toner remaining on the surface of the electrophotographic photosensitive element 1 after transfer. Alternatively, a so-called cleanerless system can be used, where deposits are removed by a developing unit 5 or similar device without a separate cleaning unit 9. The electrophotographic apparatus may include a de-energizing mechanism for de-energizing the surface of the electrophotographic photosensitive element 1 with pre-exposure light 10 from a pre-exposure unit (not shown). Additionally, a guide unit 12, such as a track, may be configured for detachably mounting the processing cartridge 11 according to this disclosure to the main body of the electrophotographic apparatus.

[0233] Electrophotographic photosensitive components can be used in, for example, laser beam printers, LED printers, and copiers.

[0234] According to this disclosure, a treatment box that simultaneously achieves torque reduction and cleanliness can be provided.

[0235] Example

[0236] This disclosure is described in more detail below with reference to embodiments and comparative examples. This disclosure is by no means limited to the following embodiments, and various modifications can be made without departing from the spirit of this disclosure. In the following description of the embodiments, "parts" are based on mass unless otherwise stated.

[0237] Production of Drum-Shaped Electrophotographic Photosensitive Components (Photosensitive Drums)

[0238] [Manufacturing method of photosensitive drum 1]

[0239] An aluminum cylinder (JIS-A3003, aluminum alloy) with a diameter of 24 mm and a length of 257.5 mm is used as the support (conductive support).

[0240] [Conductive layer]

[0241] Next, prepare the following materials.

[0242] • Titanium oxide (TiO2) particles coated with oxygen-deficient tin oxide (SnO2) as metal oxide particles (average primary particle size: 230 nm) 214 parts

[0243] • Phenolic resin (monomers / oligomers of phenolic resin) as a binder (Product name: PLYOPHEN J-325, manufactured by DIC Corporation, resin solids content: 60% by mass) 132 parts

[0244] • 98 parts of 1-methoxy-2-propanol as a solvent

[0245] The materials were loaded into a sand mill using 450 parts each of glass beads with a diameter of 0.8 mm, and dispersed at 2,000 rpm for 4.5 hours and with cooling water at a set temperature of 18°C ​​to provide a dispersion. The glass beads were removed from the dispersion using a mesh screen (pore size: 150 μm). Silicone resin particles (product name: TOSPEARL 120, manufactured by Momentive Performance Materials Inc., average particle size: 2 μm) as a surface roughening material were added to the resulting dispersion. The amount of silicone resin particles added was set to 10% by mass relative to the total mass of metal oxide particles and binder material in the dispersion after removing the glass beads. In addition, silicone oil (product name: SH28PA, manufactured by Dow Corning Toray Co., Ltd.) as a leveling agent was added to the dispersion such that its addition amount became 0.01% by mass relative to the total mass of metal oxide particles and binder material in the dispersion. Next, a mixed solvent of methanol and 1-methoxy-2-propanol (mass ratio: 1:1) was added to the dispersion so that the total mass (i.e., the mass of the solid component) of the metal oxide particles, binder, and surface roughening agent in the dispersion became 67% by mass relative to the mass of the dispersion. The mixture was then stirred to prepare a coating solution for the conductive layer. The coating solution was applied to the support by dip coating and heated at 140°C for 1 hour to form a conductive layer with a thickness of 30 μm.

[0246] [Base Coating]

[0247] Next, prepare the following materials.

[0248]

[0249] The materials were dissolved in a mixed solvent of 50 parts tetrahydrofuran and 50 parts 1-methoxy-2-propanol to prepare a primer coating solution. The primer coating solution was applied to the conductive layer by dip coating and heated at 170°C for 30 minutes to form a primer coating with a thickness of 0.7 μm.

[0250]

[0251] [charge generation layer]

[0252] Next, 10 parts of hydroxy gallium phthalocyanine in crystalline form, exhibiting peaks at 7.5° and 28.4° as shown in the CuKα characteristic X-ray diffraction pattern, and 5 parts of polyvinyl butyral resin (product name: S-LEC BX-1, manufactured by Sekisui Chemical Co., Ltd.) were prepared. These materials were added to 200 parts of cyclohexanone and dispersed therein for 6 hours using a sand mill with glass beads of 0.9 mm diameter. 150 parts of cyclohexanone and 350 parts of ethyl acetate were further added to the dispersion to dilute it. Thus, a coating solution for the charge-generating layer was obtained. The resulting coating solution was applied to the primer layer by dip coating and dried at 95°C for 10 minutes to form a charge-generating layer with a thickness of 0.20 μm.

[0253] X-ray diffraction measurements were performed under the following conditions.

[0254] [Powder X-ray Diffraction Measurement]

[0255] Measurement equipment used: RINT-TTRII X-ray diffraction equipment, manufactured by Rigaku Corporation.

[0256] X-ray tube bulb: Cu

[0257] Tube voltage: 50KV

[0258] Tube current: 300mA

[0259] Scanning method: 2θ / θ scan

[0260] Scanning speed: 4.0° / min

[0261] Sampling interval: 0.02°

[0262] Starting angle (2θ): 5.0°

[0263] Angle of stop (2θ): 40.0°

[0264] Attachment: Standard Sample Rack

[0265] Filter: Not used

[0266] Incident monochromatic: using

[0267] Counter monochromator: Not used

[0268] Diverging slit: Open

[0269] Longitudinal diverging slit: 10.00mm

[0270] Scattering slit: Open

[0271] Light receiving slit: Open

[0272] Flat panel monochromator: using

[0273] Counter: Blink Counter

[0274] [charge transport layer]

[0275] Next, prepare the following materials.

[0276]

[0277] The materials were dissolved in a mixed solvent of 60 parts toluene, 2.3 parts methyl benzoate, and 12.8 parts tetrahydrofuran to prepare a coating solution for the charge transport layer. The coating solution for the charge transport layer was applied to the charge generation layer by dip coating to form a coating film, and the coating film was dried at 100°C for 20 minutes to form a charge transport layer with a thickness of 16 μm.

[0278]

[0279] [Protective Layer]

[0280] Next, prepare the following materials.

[0281] • 8 parts of the compound represented by structural formula (2-1)

[0282] • 16 parts of the compound represented by structural formula (3-1)

[0283] • 0.1 part of siloxane-modified acrylic compound (SYMAC US270, manufactured by Toagosei Co., Ltd.)

[0284] The materials were mixed into 58 parts cyclohexane and 25 parts 1-propanol, and the mixture was stirred. Thus, a coating solution for the protective layer was prepared.

[0285] The protective layer was applied to the charge transport layer by dip coating to form a film, and the resulting film was dried at 40°C for 5 minutes. Then, under a nitrogen atmosphere, the film was irradiated with an electron beam at an accelerating voltage of 70 kV and a beam current of 5.0 mA for 1.6 seconds, while the support (the irradiated target) rotated at 300 rpm. The electron beam dose at the outermost surface layer of the support was 15 kGy. Next, under a nitrogen atmosphere, the film was first heated by increasing the temperature from 25°C to 100°C over 20 seconds. This resulted in a protective layer with a thickness of 1.5 μm. The oxygen concentration during the period from electron beam irradiation to the subsequent heat treatment was below 10 ppm. Next, the film was allowed to cool naturally in air until its temperature reached 25°C, and a second heat treatment was performed at a temperature of 220°C for 15 minutes, thereby forming a wrinkled shape. Therefore, the photosensitive drum 1 of Example 1, which is an electrophotographic photosensitive component including a protective layer and having a drum shape (cylindrical shape), was produced.

[0286] [Manufacturing method of photosensitive drum 2]

[0287] Except that the thickness of the protective layer is set to 0.5 μm, the photosensitive drum 2 is manufactured in the same manner as the photosensitive drum 1.

[0288] [Manufacturing method of photosensitive drum 3]

[0289] Except that the thickness of the protective layer is set to 0.3 μm, the photosensitive drum 3 is manufactured in the same manner as the photosensitive drum 1.

[0290] [Manufacturing method of photosensitive drum 4]

[0291] Except that after drying the charge transport layer, the layer is rubbed with nonwoven fabric in its circumferential direction and then coated with a protective layer, the photosensitive drum 4 is produced in the same manner as in the photosensitive drum 1.

[0292] For the friction treatment method, TORAYSEE MK SHEET (manufactured by Toray Industries, Inc.) is used as the nonwoven fabric for friction. The nonwoven fabric is kept taut without twisting and comes into contact with the surface of the support that has undergone this process until the formation of the charge transport layer. The fabric is squeezed 3 mm into the surface from the point of maximum contact, and the support rotates at 60 rpm for 1 second to rub the layer in the circumferential direction.

[0293] [Manufacturing method of photosensitive drum 5]

[0294] Except that the thickness of the protective layer is set to 0.5μm, the photosensitive drum 5 is produced in the same manner as the photosensitive drum 4.

[0295] [Manufacturing method of photosensitive drum 6]

[0296] Except that the thickness of the protective layer is set to 0.3μm, the photosensitive drum 6 is produced in the same manner as the photosensitive drum 4.

[0297] [Manufacturing method of photosensitive drum 7]

[0298] Except that after drying the charge transport layer, the layer is rubbed with nonwoven fabric along its length and then coated with a protective layer, the photosensitive drum 7 is produced in the same manner as in the photosensitive drum 1.

[0299] For the friction treatment method, TORAYSEE MK SHEET (manufactured by Toray Industries, Inc.) is used as a nonwoven fabric for friction. The nonwoven fabric is kept taut without twisting and comes into contact with the surface of the support that has undergone this process until the formation of the charge transport layer. The fabric is extruded 3 mm into the surface from the point of maximum contact and rubbed against the layer in the length direction.

[0300] [Manufacturing method of photosensitive drum 8]

[0301] Except that the thickness of the protective layer is set to 0.5μm, the photosensitive drum 8 is manufactured in the same manner as the photosensitive drum 7.

[0302] [Manufacturing method of photosensitive drum 9]

[0303] Except that the thickness of the protective layer is set to 0.3μm, the photosensitive drum 9 is manufactured in the same manner as the photosensitive drum 7.

[0304] [Manufacturing method of photosensitive drum 10]

[0305] Except that no second heating is performed during the drying step after applying the protective layer, so that the drum is produced without forming a wrinkled shape, the photosensitive drum 10 is produced in the same manner as the photosensitive drum 1.

[0306] [Manufacturing method of photosensitive drum 11]

[0307] A photosensitive drum was prepared without performing a second heating of the photosensitive drum of Example 1.

[0308] The surface of the photosensitive drum is subjected to the following conditions. Figure 4 The grinding machine shown in the image is used for grinding.

[0309]

[0310] The grinding method is as follows. While a grinding disc, obtained by dispersing abrasive particles in a binder resin on a sheet substrate, is supplied in the direction of the arrow, a photosensitive drum (an electrophotographic photosensitive component having a drum shape) is subjected to surface roughening treatment by rotating in the direction of the arrow and applying pressure for 20 seconds.

[0311] <Evaluation of Photosensitive Drum>

[0312] The following evaluations were made for photosensitive drums 1 to 5.

[0313] [Surface Shape Observation and Analysis 1]

[0314] Using the method described above, for the surface of each photosensitive drum, the average distance Lave between the ridges of adjacent protrusions, each protrusion having a ridge portion in which θ falls within the range of 45° to 135°, and the average height have of the protrusions having ridge portions are determined. The evaluation results are shown in Table 1.

[0315] [Surface Shape Observation and Analysis 2]

[0316] The surface shape of each photosensitive drum was observed magnified using a laser microscope (VK-X200, manufactured by Keyence Corporation) to identify whether the photosensitive drum had wrinkles covering the entire surface. Furthermore, the method described above was used to identify whether the observation area included more than one ridge portion of wrinkles within the range of θ falling between 45° and 135°, and whether observation points within the range of θ falling between 45° and 135° occupied more than half of the observation points existing in the observation area.

[0317] For the following conditions 1, 2, and 3, the case where all observation areas are detected and all conditions are met is judged as A; the case where conditions 1 and 2 are met is judged as B; the case where only condition 1 is met is judged as C; and the case where no conditions are met is judged as D.

[0318] Condition 1: The photosensitive drum has mountain-like folds.

[0319] Condition 2: There exists at least one tangent that satisfies 45°≤θ≤135°.

[0320] Condition 3: The number of tangents that achieve 45°≤θ≤135° is greater than the number of tangents that achieve θ<45° and the number of tangents that achieve 135°<θ.

[0321] The evaluation results are shown in Table 1.

[0322] Table 1

[0323]

[0324] <Example of Toner Production>

[0325] Examples of the production of the toners used in the embodiments and comparative examples of this disclosure are described below.

[0326] First, a production example of the toner used in the embodiments and comparative examples of this disclosure is described.

[0327] Although toner particles produced by suspension polymerization are used as toners in the embodiments and comparative examples of this disclosure, the toner particles in this disclosure are not necessarily limited thereto, and toner particles obtained by pulverization, emulsion polymerization aggregation or dissolution suspension can also be used.

[0328] [Example of colorant granule production]

[0329] The colorant particles 1 are produced by suspension polymerization as described below.

[0330] The following materials are mixed and stirred for 2 hours until the polar resin dissolves. Thus, a monomer composition containing the polar resin is obtained.

[0331]

[0332] In addition, the following materials are mixed and stirred with zirconia beads (3 / 16 inch) at 200 rpm for 3 hours using a mill (manufactured by Mitsui Mining Co., Ltd.), followed by separation of the beads. Thus, a colorant dispersion is obtained.

[0333]

[0334] Next, mix the above materials. Then, heat the mixture to 60°C and add 10.0 parts by weight of wax (HNP-51: manufactured by Nippon Seiro Co., Ltd.). Next, add 5.0 parts by weight of polymerization initiator PERBUTYL O (manufactured by NOF Corporation) to the mixture and stir the mixture for 5 minutes.

[0335] Simultaneously, 875 parts by mass of a 0.1 mol / L aqueous solution of Na3PO4 and 8.0 parts by mass of 10% hydrochloric acid were added to a container equipped with a CLEARMIX high-speed stirring device (manufactured by M Technique Co., Ltd.). The speed of the device was adjusted to 15,000 rpm, and the mixture was heated to 60°C. 70 parts by mass of a 1.0 mol / L aqueous solution of CaCl2 were added to the mixture to prepare an aqueous medium containing the fine and poorly water-soluble dispersant Ca3(PO4)2. Five minutes after the polymerization initiator was added to the polymerizable monomer composition, the polymerizable monomer composition at 60°C was added to the aqueous medium heated to 60°C, and the mixture was granulated for 15 minutes while the CLEARMIX was rotating at 15,000 rpm. Afterward, the high-speed stirring device was changed to a stirrer with propeller blades, and the granulated product was reacted at 60°C for 5 hours while being refluxed. The temperature of the resulting liquid was then set to 80°C, and the liquid was further reacted for 5 hours. After polymerization, the liquid temperature was lowered to approximately 20°C, and dilute hydrochloric acid was added to set the pH of the aqueous medium below 3.0, thereby dissolving the poorly water-soluble dispersant. The solution was further washed and dried to provide toner particles with a weight-average particle size (D4) of 5.96 μm.

[0336] [Production example of silica fine particles 1]

[0337] The specific surface area of ​​BET is 300m² 2 / g of dry silica (average primary particle size = 8nm) was loaded into an autoclave equipped with a stirrer, and under a nitrogen atmosphere, 20 parts of dimethyl silicone oil (kinematic viscosity: 50cSt) were added to 100 parts of dry silica. The mixture was then maintained at 250°C for 30 minutes. Afterward, the mixture was removed from the autoclave and then pulverized to provide fine silica particles.

[0338] [Example of production of fine silica particles 2]

[0339] 687.9 g of methanol, 42.0 g of pure water, and 47.1 g of 28% ammonia solution were placed in a 3-liter glass reactor equipped with a stirrer, dropping funnel, and thermometer, and mixed. The temperature of the resulting solution was adjusted to 35°C, and while stirring the solution, 1,100.0 g (7.23 mol) of tetramethoxysilane and 395.2 g of 5.4% ammonia solution were added dropwise over 5 hours, followed by the addition of ammonia solution over 4 hours.

[0340] Even after the addition is complete, stirring is continued for another 0.2 hours to allow for hydrolysis. This results in a suspension of hydrophilic and spherical sol-gel silica particles.

[0341] The pH of the resulting suspension was then adjusted to approximately 3.5. After adjustment, the reactor was heated to 75°C, and a solution obtained by dissolving 8.8 g of octyltriethoxysilane in 220 ml of isopropanol was added dropwise while the suspension in the reactor was stirred. After the addition, the mixture was stirred continuously for 5 hours.

[0342] After stirring, the mixture was cooled to room temperature and filtered. The filtrate was washed with deionized water and then dried overnight at 120°C. The dried product was then pulverized using a pulverizer (manufactured by Hosokawa Micron Corporation) to provide the target fine silica particles.

[0343] <Production Example of Toner 1>

[0344] 0.15 parts by weight of fine silica particles 1 were added to 100.0 parts by weight of toner particles, and the materials were mixed at 4,000 rpm for 10 minutes using a Henschel mixer (manufactured by Mitsui Mining Co., Ltd.) to provide toner 1.

[0345] The flow torque E of toner 1 is 346 mJ.

[0346] <Production Examples of Toners 2 to 4>

[0347] Except that the type and amount of silica fine particles added are changed to those shown in Table 2 in the production example of toner 1, toners 2 to 4 are obtained in the same manner as in the production example of toner 1. The values ​​of the flow torque E of the produced toners are also shown in Table 2.

[0348] Table 2

[0349] Types of additives Added amount E / mJ Toner 1 2. Fine silica particles 0.15 copies 346 Toner 2 2. Fine silica particles 0.30 copies 431 Toner 3 2. Fine silica particles 0.10 copies 318 Toner 4 Fine silica particles 1 0.30 copies 256

[0350] [Example 1]

[0351] The laser beam printer, available from Hewlett-Packard Company under the product name "HP Color LaserJet CP4525nd," has been modified for use as an electrophotographic device. The printer is modified to allow measurement of the drive current of its photosensitive drum's rotary motor. Additionally, the printer is modified to allow adjustment and measurement of the voltage applied to its charging roller, and to allow adjustment and measurement of the image exposure.

[0352] In addition, the cyan cartridge (hereinafter referred to as "CRG") of the device was modified by replacing the photosensitive drum with photosensitive drum 1, and the toner in the cartridge was replaced with toner 1. Furthermore, the pressure of the CRG's cleaning blade against the photosensitive drum was changed to 40% of the product conditions.

[0353] [Examples 2-11 and Comparative Examples 1-4]

[0354] Except for the changes to the photosensitive drum and toner shown in Table 4 in Example 1, the processing boxes of Examples 2-11 and Comparative Examples 1-4 were prepared in the same manner as in Example 1.

[0355] [evaluate]

[0356] The processing boxes produced in Examples 1-11 and Comparative Examples 1-4 were evaluated under the following conditions.

[0357] [Evaluation of the relative value of torque]

[0358] Print 5% of the test image onto 100 sheets of A4-sized plain paper. As a charging condition, the dark area potential was adjusted to -500V, and as an exposure condition, the image exposure intensity was adjusted to 0.25μJ / cm². 2 Read the drive current value (current value A) at the 100th output. A higher current value indicates greater friction between the photosensitive drum and the cleaning blade.

[0359] The measured value of the processing box using a photosensitive drum 10 with no wrinkles on its surface and toner 3 is defined as the current value B and used as a reference for relative values.

[0360] Calculate the ratio of the drive current value (current value A) to the drive current value (current value B) of the rotary motor of the photosensitive drum obtained as described above. The resulting value of "(current value A) / (current value B)" is used as a relative value of torque for comparison. The smaller the relative value, the greater the reduction in friction between the photosensitive drum and the cleaning blade. The evaluation results are shown in Table 3.

[0361] [Evaluation of image stripes]

[0362] Furthermore, immediately after the horizontal lines in the image, drawn at 10 spatial intervals, were output on 1,000 sheets of paper, an evaluation was performed using halftone images. Specifically, a visual count was used to determine the number of streaks (stripes) occurring in the poorly clean output images, and a rating was given. The evaluation results are shown in Table 3.

[0363] Rating of image stripes

[0364] A: There are no stripes in the image quality, therefore the image quality is satisfactory.

[0365] B: Slight stripes appear.

[0366] C: Stripes appear in part of the image.

[0367] D: Stripes appear throughout the image.

[0368] [Evaluation of contamination of the charging roller]

[0369] A strip of toner is applied to a charging roller deposited on the strip used to evaluate image stripes, and the concentration of the toner attached to the strip is measured using an X-Rite 504 spectrophotometer (manufactured by X-Rite Inc.). The grading is then performed based on the reflectance concentration value.

[0370] A higher value means a greater amount of toner adhering to the charging roller.

[0371] Evaluation of the contamination level of the charging roller

[0372] A: Less than 0.1

[0373] B: 0.1 or higher and less than 0.2

[0374] C: 0.2 or higher and less than 0.3

[0375] D: 0.3 or higher

[0376] The evaluation results are shown in Table 3.

[0377] Table 3

[0378] Photosensitive component No. Toner No. relative torque Image stripe level Contamination level of charging roller Example 1 1 1 0.66 B C Example 2 2 1 0.68 A B Example 3 3 1 0.68 A A Example 4 4 1 0.65 B C Example 5 5 1 0.67 B B Example 6 6 1 0.68 A B Example 7 7 1 0.68 A B Example 8 8 1 0.69 A A Example 9 9 1 0.70 A A Example 10 3 2 0.70 A B Example 11 6 2 0.70 A B Example 12 9 2 0.71 A A Comparative Example 1 10 1 1.0 A A Comparative Example 2 11 1 0.68 D B Comparative Example 3 9 3 0.64 A D Comparative Example 4 9 4 0.63 A D

[0379] While this disclosure has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the appended claims should be accorded the broadest interpretation to cover all such modifications and equivalent structures and functions.

Claims

1. A process cartridge, comprising: an electrophotographic photosensitive member having a drum shape; a developing unit for developing an electrostatic latent image on a surface of the electrophotographic photosensitive member with a toner; and a cleaning blade for removing the toner on the surface of the electrophotographic photosensitive member, the cleaning blade being in contact with the electrophotographic photosensitive member, characterized in that the electrophotographic photosensitive member includes a wrinkle on the surface of the electrophotographic photosensitive member, and wherein a flowability torque E of the toner is 320 mJ or more, wherein when a square observation area of 50.0 μm per side is set on an optional position on the surface of the electrophotographic photosensitive member, and an angle formed by a tangent line of each ridge line of a convex portion forming the wrinkle and a line parallel to a circumferential direction of the electrophotographic photosensitive member is represented by θ, the observation area includes one or more ridge line portions of the wrinkle for which the θ falls within a range between 45° and 135°.

2. The process cartridge according to claim 1, wherein when observation points are set on the ridge line of the convex portion forming the wrinkle in the observation area at intervals of 5.0 μm, observation points for which the θ falls within a range between 45° and 135° account for more than half of the observation points existing in the observation area.

3. The process cartridge according to claim 1 or 2, wherein when a cross-sectional profile in a circumferential direction of the electrophotographic photosensitive member is obtained for the wrinkle, the cross-sectional profile is gentle.

4. The process cartridge according to claim 1 or 2, wherein when an angle formed by a tangent line of each ridge line of a convex portion forming the wrinkle and a line parallel to a circumferential direction of the electrophotographic photosensitive member is represented by θ, an average value Lave of a distance between ridge lines of the convex portions adjacent to each other, each of which has a ridge line portion for which the θ falls within a range between 45° and 135°, is 1.0 to 20.0 μm, and an average value have of a height of the convex portions having the ridge line portion is 0.5 to 3.0 μm.

5. The process cartridge according to claim 1 or 2, wherein the electrophotographic photosensitive member includes a wrinkle on the entire surface of the electrophotographic photosensitive member.

6. The process cartridge according to claim 1 or 2, wherein the electrophotographic photosensitive member includes a wrinkle on the entire area where the cleaning blade is in contact with the electrophotographic photosensitive member.

Images