Aluminum Grain Orientation in Photosensitive Members for Stable Potential
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Solution Overview
Problem
Existing electrophotographic photosensitive members exhibit significant potential fluctuation due to the random distribution of aluminum crystal grains with different orientations, leading to variations in conductivity and corrosion resistance, which are exacerbated by storage environment changes.
Innovation Solution
The electrophotographic photosensitive member is designed with a controlled surface composition of aluminum crystal grains, limiting the {111} orientation to 10% or less and adjusting the ratio of {001} to {101} orientations within specific ranges to enhance electron flow and reduce potential fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aluminum crystal grains with random orientations are used in the support surface, then the manufacturing process is simple, but the potential fluctuation increases and image quality stability deteriorates
Solution Approach 1:
The invention changes the crystal orientation parameters of aluminum grains in the support surface. Specifically, it controls the ratio of crystal grains with different orientations: the ratio of area occupied by <100> orientation to <110> orientation is set to 0.3 to 2.0, and the ratio of area occupied by <111> orientation to total area is set to 10% or less. This parameter control reduces potential fluctuation while maintaining manufacturing feasibility through controlled rolling and heat treatment processes.
2Reliability
If the crystal grain orientation is controlled to reduce potential fluctuation, then the image quality stability improves, but the manufacturing complexity increases
Solution Approach 1:
The invention specifies precise parameter ranges for crystal orientation control: <100>/<110> ratio between 0.3 and 2.0, and <111> ratio at 10% or less of total area. These parameter specifications enable systematic control of potential fluctuation while providing clear manufacturing guidelines, thus balancing image quality stability with manageable manufacturing complexity.
Solution Approach 2:
The invention applies preliminary heat treatment (annealing at 100-500°C for 1-48 hours) and controlled rolling processes during manufacturing to pre-establish the desired crystal orientation distribution. This preliminary action ensures that the support surface achieves the required crystal grain structure before being assembled into the photosensitive member, thereby reducing potential fluctuation without requiring complex post-manufacturing adjustments.
3Reliability
If aluminum alloy with high conductivity is used, then the electron flow improves, but the corrosion resistance may deteriorate
Solution Approach 1:
The invention applies local quality control by specifying different crystal orientation requirements for different aspects of performance. The <100> and <110> orientation ratio (0.3 to 2.0) is optimized for electrical conductivity and potential stability, while the <111> orientation limit (10% or less) helps maintain corrosion resistance. This localized optimization of crystal grain properties allows simultaneous improvement of conductivity and maintenance of corrosion resistance.
Data Source
AI summary
Provided is an electrophotographic photosensitive member including: a support; and a photosensitive layer, wherein the support has a surface formed of Al and/or an Al alloy, wherein the surface of the support comprises 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 the ratio of an area occupied by the Al crystal grain having the (γ) is 10% or less, and the value of the ratio of an area occupied by the Al crystal grain having the (α) to an area occupied by the Al crystal grain having the (β) is more than 4/6 and less than 6/4.