Polyarylate Photosensitive Layer Solvent Reaction
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Solution Overview
Problem
Existing electrophotographic photosensitive members face challenges in achieving optimal abrasion resistance and charging characteristics due to the presence of unreacted aromatic dicarboxylic acid dichloride in the photosensitive layer, which affects the performance of polyarylate resin-based binder systems.
Innovation Solution
A method for producing electrophotographic photosensitive members involves using a polyarylate resin with a specific solvent system, including a lower alcohol that reacts with aromatic dicarboxylic acid dichloride to reduce its presence in the photosensitive layer, thereby improving charging characteristics and abrasion resistance. The process includes a standing treatment to ensure sufficient reaction time before application, ensuring the formation of a photosensitive layer with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyarylate resin is used as binder resin in electrophotographic photosensitive member, then charging characteristics are improved, but abrasion resistance deteriorates due to presence of unreacted aromatic dicarboxylic acid dichloride
Solution Approach 1:
The patent applies preliminary action by conducting a standing treatment before application, allowing the lower alcohol to react with aromatic dicarboxylic acid dichloride in advance. This pre-reaction reduces the harmful substance content before the photosensitive layer is formed, thereby improving abrasion resistance while maintaining charging characteristics.
Solution Approach 2:
The patent converts the harmful effect of aromatic dicarboxylic acid dichloride into a beneficial outcome by using lower alcohol to react with it during standing treatment. The previously harmful unreacted dichloride is transformed into a useful reaction that eliminates the abrasion resistance problem while preserving the charging characteristics provided by the polyarylate resin system.
2Strength
If standing treatment is extended to allow complete reaction of lower alcohol with aromatic dicarboxylic acid dichloride, then abrasion resistance improves, but production time increases
Solution Approach 1:
The patent applies partial action by using an excess of lower alcohol in the application liquid. This ensures that sufficient alcohol is available to react with the aromatic dicarboxylic acid dichloride during a relatively short standing treatment period (0.5-24 hours), achieving adequate reduction of harmful substances without requiring excessively long treatment times.
Solution Approach 2:
The patent optimizes the standing treatment time parameter to balance reaction completeness with production efficiency. By establishing that 0.5 to 24 hours of standing treatment is sufficient to achieve the desired reduction in aromatic dicarboxylic acid dichloride content, the patent finds an optimal parameter range that improves abrasion resistance while minimizing production time loss.
3Strength
If aromatic dicarboxylic acid dichloride content is reduced through reaction with lower alcohol, then abrasion resistance improves, but charging characteristics may be affected
Solution Approach 1:
The patent applies local quality by ensuring that the polyarylate resin system maintains its essential charging characteristics while the harmful aromatic dicarboxylic acid dichloride is selectively removed through reaction with lower alcohol. The beneficial properties of the polyarylate resin are preserved locally in the photosensitive layer, while the harmful substance is eliminated, achieving both improved abrasion resistance and maintained charging characteristics.
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 method results in electrophotographic photosensitive members with improved charging characteristics and abrasion resistance, as evidenced by reduced aromatic dicarboxylic acid dichloride content and enhanced performance metrics such as charge potential and sensitivity.
Implementation Method 1
a first solvent and a second solvent, wherein the binder resin includes a polyarylate resin having a repeating unit represented by general formula (1) or general formula (2)
Data Source
Figure 1~3
Figure 4~6
AI summary
A method for producing an electrophotographic photosensitive member (1) includes an electrically conductive substrate (2) and a photosensitive layer (3). The method includes applying an application liquid for photosensitive layer formation containing a solvent, a binder resin, and a hole transport material directly or indirectly onto the electrically conductive substrate (2), and removing a portion of the solvent, to form the photosensitive layer (3). The solvent contains a first solvent that is an alcohol having a carbon number of at least 1 and no greater than 3, and a second solvent other than the first solvent. The binder resin includes a polyarylate resin that is a polymerization product of monomers including a first monomer represented by general formula (1) and a second monomer represented by general formula (2),