Electrophotographic Photoreceptor Base Material Surface Roughness Control
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Solution Overview
Problem
Conventional base materials for electrophotographic photoreceptors often result in vertical streaks in images due to surface unevenness, particularly when the amplitude in the spectrum of surface roughness for a 10 mm portion in the axial direction exceeds 0.22 mm within a specific period range.
Innovation Solution
A base material with a controlled surface roughness, where the amplitude in the spectrum of a 10 mm portion in the axial direction is limited to 0.22 mm or less within a period range of 0.4 mm to 0.7 mm, achieved by adjusting the tool feed speed and cutting process during production, such as using a machining tool with an arc shape and polycrystalline diamond cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional base materials with larger amplitude in surface roughness spectrum are used, then manufacturing is easier and productivity is higher, but vertical streaks occur in images due to surface unevenness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the tool feed speed during cutting operations and adjusting the amplitude characteristics of surface roughness in specific frequency ranges. By modifying the cutting parameters (feed speed, amplitude control in 0.4-0.7mm period range), the invention achieves reduced vertical streaks while maintaining manufacturing feasibility through quantitative parameter optimization.
2Productivity
If surface roughness amplitude in period range of 0.4 mm to 0.7 mm exceeds 0.22 mm, then material removal is faster and production is more efficient, but image quality deteriorates due to vertical streaks
Solution Approach 1:
The invention resolves this contradiction by establishing specific parameter ranges for surface roughness amplitude (0.22 mm or less in the 0.4-0.7 mm period range) and controlling tool feed speed to maintain these parameters. This quantitative parameter control enables the production of high-quality surfaces that prevent vertical streaks while maintaining acceptable manufacturing efficiency.
Data Source
AI summary
A base material for an electrophotographic photoreceptor, in which in a spectrum of a period and an amplitude obtained by performing fast Fourier transform of surface roughness of a 10 mm portion in an axial direction of a surface of the base material for an electrophotographic photoreceptor, an amplitude in a range of a period of 0.4 mm or more and 0.7 mm or less is 0.22 mm or less.