N-Methoxymethylated Nylon Intermediate Layer for Photoconductor
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Solution Overview
Problem
Electrophotographic photoconductors face issues with durability, particularly in high-speed copiers, where background smear and residual potential rise due to high electric resistance in intermediate layers, leading to productivity losses and image quality degradation.
Innovation Solution
A coating liquid for intermediate layers containing N-methoxymethylated nylon with specific solution viscosity, used to form a multilayer intermediate layer with a charge blocking layer and a moire preventive layer, which includes titanyl phthalocyanine crystals with controlled particle size and dispersion, to enhance adhesion, prevent charge injection, and reduce residual potential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single resin intermediate layer is used, then the manufacturing process is simple, but the electric resistance becomes high causing residual potential and picture density reduction
Solution Approach 1:
The intermediate layer is divided into multiple layers with different functions: a lower layer (charge blocking layer) that prevents charge injection and an upper layer (moire preventive layer) that prevents moire images. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between structural simplicity and electric resistance control.
Solution Approach 2:
The patent uses composite materials in the intermediate layer by combining resin with conductive additives (such as carbon black or metal particles). This composite approach reduces the electric resistance of the intermediate layer while maintaining its structural integrity, thereby preventing residual potential without overly complicating the layer structure.
2Manufacturing precision
If the intermediate layer is made thin to reduce electric resistance, then picture density improves, but electrostatic property becomes insufficient after repeated use
Solution Approach 1:
The intermediate layer is segmented into multiple functional layers. The lower charge blocking layer maintains electrostatic properties and prevents charge injection, while the upper moire preventive layer can be optimized for picture density. This allows the overall structure to maintain electrostatic performance without sacrificing image quality.
Solution Approach 2:
The intermediate layer uses composite materials combining resin with conductive additives. This composite structure provides both the necessary electrostatic properties for repeated use and the appropriate thickness control for maintaining picture density, resolving the contradiction between these two requirements.
3Reliability
If conductive additives are added to the intermediate layer, then electric resistance is controlled, but moire images may be generated
Solution Approach 1:
The intermediate layer is divided into two functional layers: the lower charge blocking layer contains conductive additives for electric resistance control, while the upper moire preventive layer is designed specifically to prevent moire images. This segmentation separates the conflicting functions into different layers, allowing each to be optimized without interfering with the other.
4Object-generated harmful factors
If filler is increased in the intermediate layer to prevent moire image, then moire control improves, but adhesion with support decreases causing peeling
Solution Approach 1:
The intermediate layer is segmented into functional layers where the lower charge blocking layer maintains adhesion to the support through appropriate material selection and composition, while the upper moire preventive layer focuses on moire image prevention with optimized filler content. This segmentation allows each layer to be optimized for its primary function without compromising the other.
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 solution provides stable and uniform film formation, reduces background smear and residual potential, and improves environmental stability, ensuring high-quality images and extended durability of electrophotographic photoconductors.
Implementation Method 1
a coating liquid for an intermediate layer of an electrophotographic photoconductor, which comprises at least one of alcohol solvents and N-methoxymethylated nylon
Implementation Method 2
electrophotographic photoconductors utilizing organic photoconductive materials
Data Source
AI summary
A coating liquid for an intermediate layer of an electrophotographic photoconductor comprises at least one of alcohol solvents; and N-methoxymethylated nylon, in which the N-methoxymethylated nylon has solution viscosity within a range from 43 mPa·s to 50 mPa·s when dissolving into methanol at 30° C. in a concentration of 20% by mass.