Organic Photoreceptor Intermediate Layer Pe Number Control
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Solution Overview
Problem
Existing organic photoreceptors in electrophotographic systems face issues with uneven density and image defects such as spots and fogging due to insufficient electron transport properties in the intermediate layer, particularly when using sensitive charge generating materials.
Innovation Solution
A production process for an organic photoreceptor involving a conductive support, an intermediate layer with first and second metal oxide fine particles dispersed in a binder resin, where the Pe number of the first metal oxide fine particles is two or more times larger than that of the second, enhancing electron transport while preventing irregular electron injection, thereby suppressing image defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electron transport property of the intermediate layer is improved by using a particularly-sensitive charge generating material, then uneven density is improved, but injection of irregular electrons occurs causing image defects such as spots and fogging
Solution Approach 1:
The patent applies local quality by using two types of metal oxide fine particles with different Pe numbers in the intermediate layer. The first metal oxide fine particles (with higher Pe number) provide electron transport capability to reduce uneven density, while the second metal oxide fine particles (with lower Pe number) provide hole blocking capability to prevent irregular electron injection. This localized differentiation of particle functions resolves the contradiction between improving electron transport and preventing harmful effects.
Solution Approach 2:
The patent employs composite materials by combining two different metal oxide fine particles with distinct Pe numbers in the intermediate layer formulation. This composite approach allows the intermediate layer to simultaneously exhibit both electron transport properties (from the first metal oxide particles) and hole blocking properties (from the second metal oxide particles), thereby resolving the technical contradiction without sacrificing either function.
2Manufacturing precision
If the electron transport property of the intermediate layer is improved, then uneven density is reduced, but carrier leakage increases causing spots and fogging
Solution Approach 1:
The patent applies local quality by assigning different functional roles to different metal oxide particles within the intermediate layer. The first metal oxide fine particles (higher Pe number) are optimized for electron transport to address uneven density, while the second metal oxide fine particles (lower Pe number) are optimized for hole blocking to prevent carrier leakage. This functional differentiation allows simultaneous improvement of electron transport and prevention of carrier leakage.
Solution Approach 2:
The patent uses composite materials comprising two types of metal oxide fine particles with different Pe numbers to create an intermediate layer that exhibits both electron transport and hole blocking properties. This composite structure enables the material to simultaneously improve electron transport (reducing uneven density) and prevent carrier leakage (reducing spots and fogging), thereby resolving the contradiction between these two requirements.
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 process effectively reduces uneven density and image defects like spots and fogging, maintaining high electron transport properties and preventing carrier leakage, even with sensitive charge generating materials.
Implementation Method 1
the intermediate layer has been required to have an electron transport property (to readily transfer electrons generated in the charge generating layer by the exposure to the conductive support)
Implementation Method 2
a positive hole-blocking property (to prevent injection of positive holes to the photosensitive layer from the conductive support)
Implementation Method 3
the coating liquid being obtained by dissolving a binder resin in a solvent
Implementation Method 4
applying a coating liquid for forming the intermediate layer to the conductive support to form a coating film
Implementation Method 5
drying the coating film
Data Source
AI summary
Disclosed is a production process of an organic photoreceptor which can suppress occurrence of uneven density and image defects. The production process of an organic photoreceptor, the organic photoreceptor including an intermediate layer and an organic photosensitive layer on the intermediate layer, includes: applying a coating liquid for forming the intermediate layer to a conductive support to form a coating film, the coating liquid being obtained by dissolving a binder resin in a solvent and dispersing first and second metal oxide fine particles therein; and drying the coating film. The Pe number of the first metal oxide fine particles is two or more times larger than that of the second metal oxide fine particles.Pe number=(6πμEHR)/kT Equation (1):