Cut Pipe Photoreceptor Support Surface Control
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Solution Overview
Problem
The use of cut pipes with helical cutting marks as supports for electrophotographic photoreceptors can result in striped density unevenness in images due to periodic variations in the thickness of the photosensitive layer, leading to rough image quality.
Innovation Solution
A cylindrical cut pipe with a cut surface as the outer peripheral surface, having an arithmetic average waviness of 0.15 μm or less and a peak count of 100 to 990 in the axial direction, is used as a support to minimize periodic variations in the photosensitive layer thickness, thereby reducing striped density unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cut pipe with helical cutting marks is used as a support, then productivity is improved, but image quality deteriorates due to striped density unevenness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the surface roughness parameters of the support's outer peripheral surface. Specifically, it sets the arithmetic average waviness Wa to 0.15 μm or less and the peak count PPc to 100 or more and 990 or less, which suppresses the formation of helical cutting marks and resulting striped density unevenness in images, thereby maintaining high image quality while using cost-effective cut pipes
Solution Approach 2:
The patent converts the potentially harmful helical cutting marks into a beneficial outcome by establishing specific quantitative limits on surface roughness parameters. By controlling Wa ≤ 0.15 μm and 100 ≤ PPc ≤ 990, the harmful periodic variations are transformed into acceptable surface characteristics that do not degrade image quality, allowing the use of economical cut pipes
2Manufacturing precision
If the outer peripheral surface is processed to reduce waviness, then image quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent defines specific parameter ranges for arithmetic average waviness (Wa ≤ 0.15 μm) and peak count (100 ≤ PPc ≤ 990) that balance image quality requirements with manufacturing feasibility, avoiding excessive processing complexity while achieving acceptable surface quality
Solution Approach 2:
The patent applies partial action by not requiring complete elimination of all surface irregularities, but rather controlling them within specific quantitative limits. This partial control approach achieves sufficient image quality without implementing overly complex manufacturing processes
3Manufacturing precision
If the peak count is increased to suppress striped density unevenness, then image quality is improved, but surface roughness control becomes more difficult
Solution Approach 1:
The patent establishes a balanced parameter range for peak count (100 ≤ PPc ≤ 990) that is sufficiently high to suppress striped density unevenness but not so high as to make surface roughness control excessively difficult, providing a practical target for manufacturing
Data Source
AI summary
A support for an electrophotographic photoreceptor includes a cylindrical cut pipe having a cut surface as the outer peripheral surface. The outer peripheral surface has an arithmetic average waviness Wa of 0.15 μm or less in the axial direction and a peak count PPc of 100 or more and 990 or less in the axial direction.