Electrophotographic Surface Layer Adhesion via Free-Energy Control
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Solution Overview
Problem
The adhesiveness between a surface layer containing a polysiloxane compound and an underlayer in electrophotographic members is low, leading to peeling issues during use in image forming apparatuses.
Innovation Solution
A surface treatment is applied to set the surface free energy of the underlayer to 30 mJ/m² to 120 mJ/m², followed by forming a surface layer with a polysiloxane compound having a T unit, ensuring an adhesive strength of 0.5 N/mm or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a surface layer containing polysiloxane compound is formed on an underlayer without surface treatment or with surface treatment setting surface free energy to less than 30 mJ/m² or more than 120 mJ/m², then the manufacturing process is simple, but the adhesiveness between surface layer and underlayer is low causing peeling
Solution Approach 1:
The invention changes the surface free energy parameter of the underlayer to a specific range (30-120 mJ/m²) through surface treatment. This parameter optimization ensures proper adhesion between the polysiloxane-containing surface layer and the underlayer, preventing peeling while maintaining manufacturing simplicity
Solution Approach 2:
The surface treatment is performed as a preliminary action before forming the surface layer. By pre-adjusting the surface free energy of the underlayer to the optimal range, the invention ensures that when the polysiloxane compound is subsequently applied, it achieves proper adhesion without requiring complex additional treatments
2Reliability
If surface treatment is performed to set surface free energy to 30 mJ/m² to 120 mJ/m², then adhesiveness and peeling resistance are improved, but manufacturing process complexity increases
Solution Approach 1:
The invention defines a broad optimal range (30-120 mJ/m²) for surface free energy that accommodates various surface treatment methods. This parameter specification allows manufacturers to choose from multiple treatment techniques (plasma, corona, flame, chemical) while ensuring reliable peeling resistance, thus balancing process complexity with performance
3Productivity
If surface free energy is set outside the optimal range (less than 30 mJ/m² or more than 120 mJ/m²), then manufacturing process is simpler, but surface layer peeling occurs during use
Solution Approach 1:
The invention establishes a specific surface free energy range (30-120 mJ/m²) that optimizes the balance between manufacturing efficiency and surface layer stability. Within this range, common surface treatment methods achieve reliable adhesion without excessive complexity, preventing peeling during subsequent use in image forming apparatuses
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method suppresses peeling of the surface layer, improving adhesive strength and reducing waviness, thereby enhancing the functionality and durability of the electrophotographic member.
Implementation Method 1
performing a surface treatment on a surface layer forming surface of an underlayer to set a surface free energy of the surface layer forming surface of the underlayer to 30 mJ/m2 or more and 120 mJ/m2 or less
Data Source
AI summary
A method of manufacturing an electrophotographic member includes performing a surface treatment on a surface layer forming surface of an underlayer to set a surface free energy of the surface layer forming surface of the underlayer to 30 mJ/m2 or more and 120 mJ/m2 or less; and forming a surface layer containing a polysiloxane compound having a T unit represented by Formula: [R1SiO3/2]m (here, in the formula, R1 represents an organic group, m represents an integer of 2 or more, and at least one R1 among a plural R1's present in the T unit is a group including at least one of an alkyl group or an aryl group) on the surface layer forming surface of the underlayer.