Tin Oxide Modified Protective Layer for Photoreceptor Abrasion

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Solution Overview

Problem

Organic photoreceptors in electrophotography face issues with mechanical strength, abrasion, and image quality, particularly under high temperature and high humidity conditions, leading to image blur and image flow problems.

Innovation Solution

A protective layer composed of a reaction product of tin oxide particles with acryloyl or methacryloyl groups and a polymerizable compound having methacryloyl groups, where the methacryloyl function group density (Ac/M) is not less than 0.005, is used to enhance the mechanical strength and durability of the photoreceptor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a protective layer with high mechanical strength is provided on the photoreceptor, then anti-abrasion property is improved, but electric resistivity of the protective layer lowers causing image blur or image flow

Engineering Contradiction:

Improveanti-abrasion propertyVSAvoidimage quality

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters of the protective layer by using silane-modified polyurethane resin with specific functional groups (acryloyl, methacryloyl, or vinyl groups) and controlling the ratio of silane-modified polymer to non-modified polymer. This parameter optimization allows achieving high mechanical strength while maintaining adequate electric resistivity to prevent image blur and image flow.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite protective layer by combining silane-modified polyurethane resin with non-modified polyurethane resin in a specific ratio range (5:95 to 45:55 by weight). This composite approach leverages the high mechanical strength of silane-modified resin while the non-modified resin component helps maintain electric resistivity, thus resolving the contradiction between abrasion resistance and image quality.

Inventive Principle:

Principle #40Composite materials

2Strength

If colloidal silica containing hardenable siloxane resin is used for the protective layer, then mechanical strength is improved, but moisture absorbing characteristics increase causing image blur or image flow

Engineering Contradiction:

Improvemechanical strengthVSAvoidmoisture absorption

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent modifies the chemical structure parameters by using silane-modified polyurethane resin with specific functional groups (acryloyl, methacryloyl, or vinyl groups) instead of conventional siloxane resin. The patent also controls the weight ratio of silane-modified to non-modified polymer within 5:95 to 45:55, which optimizes the balance between mechanical strength and moisture absorption resistance, preventing image blur and image flow.

Inventive Principle:

Principle #35Parameter changes

3Strength

If hardenable resin obtained by reacting metal oxide with polymerizable unsaturated group is used, then anti-abrasion property is improved, but compatibility to hardness and resistance to image blur under high temperature and high humidity is insufficient

Engineering Contradiction:

Improveanti-abrasion propertyVSAvoidresistance to image blur under high temperature and high humidity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent optimizes the chemical composition parameters by using silane-modified polyurethane resin with specific functional groups (acryloyl, methacryloyl, or vinyl groups) and controlling the ratio of silane-modified polymer to non-modified polymer. This parameter optimization enables the protective layer to achieve high mechanical strength while maintaining resistance to image blur and image flow under high temperature and high humidity conditions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite protective layer by combining silane-modified polyurethane resin with non-modified polyurethane resin in a specific ratio range (5:95 to 45:55 by weight). This composite structure provides both high anti-abrasion property and adequate resistance to image blur under adverse environmental conditions, resolving the contradiction between hardness and reliability.

Inventive Principle:

Principle #40Composite materials

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 significantly improves the anti-abrasion properties and reduces image blur and image flow issues at high temperatures and humidity levels, resulting in a high-quality electrophotographic image.

Implementation Method 1

a protective layer is composed of a reaction product of tin oxide particles having an acryloyl or methacryloyl group on their surface with a polymerizable compound having a methacryloyl group

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Implementation Method 2

An organic photoreceptor containing an organic photoconductive material is most widely employed in the electrophotography

Methodology Applied

Scientific EffectPhotoconductivity: Photoconductivity

Data Source

PatentUS8557486B2Organic photoreceptor, manufacturing method of organic photoreceptor, and image forming apparatus

Publication Date: 2013.10.15 KONICA MINOLTA BUSINESS TECH INC

AI summary

An organic photoreceptor having a photosensitive layer, an electric conductive support, and a protective layer is disclosed, in which the protective layer comprises a composition produced by reacting tin oxide particles an acryloyl or methacryloyl group on their surface with a compound having an acryloyl or methacryloyl group. A production method of the same, an image forming apparatus and a process cartridge using the same are also disclosed.