Al-Support Photoreceptor Structure for Stable Layer Adhesion
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Solution Overview
Problem
Existing electrophotographic photosensitive members experience peeling of the photosensitive layer from the support when used under low-temperature or high-temperature environments due to minute differences in crystal orientations of the electroconductive support, leading to reduced adhesiveness.
Innovation Solution
The electrophotographic photosensitive member features a support surface with controlled crystal orientations, comprising Al crystal grains with specific planes at −15° to +15° with respect to {001}, {101}, and {111} orientations, where the ratio of {111} oriented grains is more than 10% and {001} oriented grains is less than 10%, enhancing adhesiveness across varying temperature and humidity conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrophotographic photosensitive member is used after storage under low-temperature or high-temperature environment, then the photosensitive layer peels from the support, but the adhesiveness should be maintained
Solution Approach 1:
The patent applies parameter changes by controlling the crystal orientation parameters of the Al alloy support. Specifically, it sets the ratio of Al crystal grains with <100> orientation to 10% or less and <111> orientation to more than 10%, which changes the physical parameters of the support to maintain adhesiveness across different temperature conditions.
Solution Approach 2:
The patent applies local quality by creating non-uniform crystal grain distribution with specific orientations in different regions of the support surface. This localized control of crystal orientation ensures that the support maintains appropriate adhesiveness characteristics under varying temperature environments.
2Reliability
If conventional Al alloy supports are used, then manufacturing is simple, but the photosensitive layer peels under temperature extremes
Solution Approach 1:
The patent transforms a simple manufacturing process into a controlled parameter-based process by specifying crystal orientation ratios. This allows the support to achieve peel resistance through controlled material parameters rather than complex structural designs.
3Reliability
If the crystal grain orientation is not controlled, then manufacturing is easier, but adhesiveness varies under different environmental conditions
Solution Approach 1:
The patent establishes specific parameter ranges for crystal grain orientation (<100> ≤ 10%, <111> > 10%) that ensure adhesiveness stability. By defining these parameters, the patent transforms manufacturing from an imprecise process to one with controlled material properties.
Solution Approach 2:
The patent applies local quality by controlling the distribution and orientation of crystal grains within the Al alloy support. This creates a material with specific local structural characteristics that ensure consistent adhesiveness performance across different environmental conditions.
Data Source
AI summary
An electrophotographic photosensitive member comprises: a support having a cylindrical shape; and a photosensitive layer, wherein the support has a surface formed of Al and/or an Al alloy, and includes Al crystal grains having: (α) a plane at −15° or more and less than +15° with respect to a {001} orientation; (β) a plane at −15° or more and less than +15° with respect to a {101} orientation; and (γ) a plane at −15° or more and less than +15° with respect to a {111} orientation, and wherein a ratio of an area occupied by the Al crystal grain having the (α) to a total area of the surface of the support is 10% or less, and a ratio of an area occupied by the Al crystal grain having the (γ) to the total area of the surface of the support is more than 10%.