Electrophotographic Photoreceptor Surface Flatness Control
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Solution Overview
Problem
Electrophotographic photoreceptors with recesses on their outer peripheral surfaces can lead to point defects in images due to the reflection of these recesses by the photosensitive layer, especially when the aspect ratio of the recesses is high, causing image quality issues.
Innovation Solution
A conductive support with a maximum surface roughness height of 4.0 μm or less and a single-layer photosensitive layer with a thickness of 20 μm or more and a modulus of elasticity of 4.5 GPa or more is used, minimizing the reflection of recesses and reducing point defects by ensuring a flat outer peripheral surface of the photosensitive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional conductive support with recesses is used, then the photoreceptor can be manufactured with standard processes, but the recesses are reflected by the photosensitive layer causing point defects in images
Solution Approach 1:
The conductive support is pre-treated by ironing to flatten its outer peripheral surface before the photosensitive layer is applied. This preliminary action removes recesses that would otherwise be reflected by the photosensitive layer, preventing point defects in the final image.
Solution Approach 2:
The surface roughness parameter of the conductive support is controlled to have a maximum surface roughness height (Rmax) of 4.0 μm or less. This parameter change ensures that the photosensitive layer produces a flat outer peripheral surface, eliminating the reflection of recesses and preventing point defects.
2Manufacturing precision
If the outer peripheral surface of the conductive support is made flat, then point defects are reduced, but the surface roughness must be controlled to 4.0 μm or less
Solution Approach 1:
The conductive support undergoes ironing as a preliminary processing step to flatten its surface. This pre-treatment ensures that the outer peripheral surface achieves the required flatness (Rmax ≤ 4.0 μm) before the photosensitive layer is applied, making the overall manufacturing process more controllable.
Solution Approach 2:
The surface roughness parameter is specifically controlled to achieve Rmax ≤ 4.0 μm through the ironing process. This parameter control is essential to prevent recess reflection while remaining compatible with standard manufacturing capabilities.
3Manufacturing precision
If a single-layer photosensitive layer with high modulus of elasticity is used, then the outer peripheral surface remains flat, but the layer thickness must be 20 μm or more
Solution Approach 1:
The modulus of elasticity parameter of the photosensitive layer is controlled to be 4.5 GPa or more. This parameter change, combined with a thickness of 20 μm or more, ensures that the photosensitive layer maintains a flat outer peripheral surface without requiring complex multi-layer structures.
Solution Approach 2:
The photosensitive layer is designed as a single-layer structure with specific material properties (modulus of elasticity ≥ 4.5 GPa) that provide sufficient rigidity to maintain surface flatness, eliminating the need for multiple layers while meeting thickness requirements.
Data Source
AI summary
An electrophotographic photoreceptor includes a conductive support and a single-layer photosensitive layer. The conductive support has an outer peripheral surface with a maximum surface roughness height (Rmax) of about 4.0 μm or less, and the outer peripheral surface has a recess with a depth-to-aperture size ratio (depth/aperture size) of about 0.03 or more and about 0.12 or less. The single-layer photosensitive layer is disposed on the conductive support and has a thickness of about 20 μm or more and a modulus of elasticity of about 4.5 GPa or more.