N-Alkoxymethylated Nylon Intermediate Layer for Photoreceptor Residual Potential Control
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Solution Overview
Problem
Electrophotographic photoreceptors using organic photoconductive materials face issues with residual potential increase and abnormal images like background fouling and black spots, especially when repeatedly used in varying environmental conditions, due to limitations in intermediate layer materials which affect durability and image quality.
Innovation Solution
An electrophotographic photoreceptor with an intermediate layer comprising N-alkoxymethylated nylon having a molecular weight not greater than 5,000 in a specific weight percentage, along with a titanylphthalocyanine crystal with controlled particle size, to prevent charge injection and maintain stable image quality across different humidity and temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional intermediate layers (cellulose resin, nylon resin, maleic acid resin, polyvinylalcohol resin) are used, then the photoreceptor structure is formed, but the residual potential increases due to high electric resistivity, causing deterioration of image density and image gradation
Solution Approach 1:
The patent applies parameter changes by carefully controlling the molecular weight of nylon resin (5,000-50,000) and the degree of N-alkoxymethylation (10-60%) to achieve optimal electric resistivity and ion conductivity balance, preventing residual potential increase while maintaining image quality
Solution Approach 2:
The patent uses composite materials by combining nylon resin with N-alkoxymethylated components to create an intermediate layer with balanced electrical properties, achieving both sufficient charge blocking and controlled ion conductivity to prevent background fouling and residual potential issues
2Manufacturing precision
If the intermediate layer is made thinner to reduce residual potential, then image density and gradation improve, but chargeability deteriorates after repeated use
Solution Approach 1:
The patent optimizes the thickness of the intermediate layer within specific ranges (0.1-5.0 μm depending on composition) and adjusts the molecular weight and alkoxymethylation degree to achieve the right balance between charge blocking capability and ion conductivity, ensuring both low residual potential and sustained chargeability
3Manufacturing precision
If electroconductive additives are dispersed in the intermediate layer to control electric resistivity, then residual potential decreases, but moiré images occur due to light interference
Solution Approach 1:
The patent changes the chemical composition parameters by using N-alkoxymethylated nylon resin with specific molecular weight and alkoxymethylation degree to inherently control electric resistivity without adding electroconductive fillers, thus avoiding moiré images while maintaining proper charge blocking
4Productivity
If photoreceptors are used in ultrahigh-speed image forming apparatus, then printing speed increases, but durability decreases due to repeated use and environmental variations
Solution Approach 1:
The patent optimizes the intermediate layer composition parameters including nylon resin molecular weight (5,000-50,000), N-alkoxymethylation degree (10-60%), and thickness (0.1-5.0 μm) to enhance durability against repeated use and environmental variations while maintaining ultrahigh-speed printing performance
Solution Approach 2:
The patent employs composite materials with N-alkoxymethylated nylon resin that provides both charge blocking and environmental stability, enabling the photoreceptor to maintain durability and image quality in ultrahigh-speed applications with varying temperature and humidity conditions
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 effectively reduces residual potential and prevents abnormal images, ensuring high-quality image production even after repeated use and in diverse environmental conditions, enhancing the photoreceptor's durability and performance.
Implementation Method 1
these intermediate layers including a resin alone have high electric resistivities, and therefore the residual potential increases
Implementation Method 2
a charge generation layer (CGL) and a charge transport layer (CTL) overlying the CGL
Data Source
AI summary
An electrophotographic photoreceptor, including an electroconductive substrate; an intermediate layer, located overlying the electroconductive substrate; and a photosensitive layer, located overlying the intermediate layer, wherein the intermediate layer includes a N-alkoxymethylated nylon including a component having a molecular weight not greater than 5,000 in an amount of from 3 to 10% by weight.