Electrophotographic Photoreceptor Surface Layer for Abrasion Resistance

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Solution Overview

Problem

Electrophotographic photoreceptors in image forming devices face issues with surface deterioration due to discharge products adherence, leading to image blur and abrasion, necessitating improved abrasion resistance for longer device lifespan.

Innovation Solution

A photoreceptor with a photosensitive layer and a surface layer containing group 13 elements and nitrogen, formed using remote plasma at a low temperature to maintain the organic layer's integrity, achieving a center line average roughness of 0.1 μm or less, enhancing mechanical strength and resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a noncontact electrification method is used, then discharge products are adhered to the photoreceptor, but image blur occurs and the photoreceptor surface deteriorates due to abrasion from cleaning particles

Engineering Contradiction:

Improvephotoreceptor lifespanVSAvoidsurface deterioration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the physical and chemical parameters of the photoreceptor surface by forming a surface layer with specific composition (group 13 element and nitrogen) and controlled roughness (Ra ≤ 0.1 μm), which fundamentally alters the surface properties to resist discharge product adhesion and abrasion without changing the electrification method itself

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite structure by laminating a surface layer containing group 13 element and nitrogen onto the photosensitive layer. This composite material structure combines the electrophotographic functionality of the organic photosensitive layer with the enhanced mechanical strength and abrasion resistance of the inorganic-containing surface layer

Inventive Principle:

Principle #40Composite materials

2Strength

If the hardness of the photoreceptor surface is increased to improve abrasion resistance, then the surface becomes more resistant to wear, but the organic photosensitive layer may be damaged by high temperature processing

Engineering Contradiction:

Improveabrasion resistanceVSAvoidorganic layer damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The surface layer acts as an intermediary protective layer between the external environment (abrasion, discharge products) and the organic photosensitive layer. It provides the necessary hardness and protection while being formed at low temperatures that do not damage the underlying organic layer

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the processing temperature parameter by using low-temperature plasma processing to form the surface layer, avoiding the high-temperature damage to the organic photosensitive layer while still achieving the desired surface hardness and composition

Inventive Principle:

Principle #35Parameter changes

3Strength

If a surface layer is formed to improve abrasion resistance, then mechanical strength increases, but surface roughness may increase leading to image quality degradation

Engineering Contradiction:

Improvemechanical strengthVSAvoidsurface smoothness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention precisely controls the formation parameters of the surface layer, including thickness (0.01-1 μm), composition ratio, and processing conditions, to achieve the optimal balance between mechanical strength and surface smoothness, with the surface roughness controlled to Ra ≤ 0.1 μm

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The surface layer provides localized protection with different properties at different depths: the top surface maintains high smoothness (Ra ≤ 0.1 μm) for image quality, while the layer as a whole provides enhanced mechanical strength and abrasion resistance

Inventive Principle:

Principle #3Local quality

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 prevents surface damage, maintains image quality, and extends the photoreceptor's lifespan by ensuring smooth surface cleaning and reducing mechanical stress, while maintaining sensitivity and residual potential levels.

Implementation Method 1

the surface layer containing a group 13 element and nitrogen, the thickness of the surface layer being from about 0.01 μm to less than about 1 μm, and a center line average roughness (Ra) of a surface of the surface layer being about 0.1 μm or less

Methodology Applied

Scientific EffectPlasma: Plasma

Data Source

PatentUS7727688B2Electrophotographic photoreceptor and manufacturing method thereof, process cartridge, and image forming device

Publication Date: 2010.06.01 FUJIFILM BUSINESS INNOVATION CORP

AI summary

There is provided: an electrophotographic photoreceptor including a photosensitive layer and a surface layer laminated on a conductive substrate in this order, the photosensitive layer including an organic substance, the surface layer including a group 13 element and nitrogen, a thickness of the surface layer being from about 0.01 μm to less than about 1 μm, and a center line average roughness (Ra) of a surface of the surface layer being about 0.01 μm or less; a manufacturing method thereof; a process cartridge; and an image forming device.