Photoconductor Undercoat Layer Recycling via Solution Stripping

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Solution Overview

Problem

Reclaiming photoreceptor drums is challenging due to the need for a lathing step to remove the charge transport layer, charge generation layer, and undercoat layer, which increases disposal costs and environmental impact.

Innovation Solution

A photoconductor comprising a substrate with an undercoat layer made of a mixture of metal oxide, phenolic resin, and cyclohexanecarboxylate, allowing for the elimination of the lathing step during recycling by facilitating the removal of all coating layers without residues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional undercoat layers are used, then adhesion and performance requirements are met, but lathing step is required for recycling which increases disposal costs and environmental impact

Engineering Contradiction:

Improverecycling processVSAvoidlathing step

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent changes the chemical composition parameters of the undercoat layer by incorporating specific plasticizers (cyclohexanecarboxylate, adipate, or succinate) in controlled amounts (1-20 weight percent) to modify the layer's solubility and adhesion characteristics, enabling complete removal without lathing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite undercoat layer material combining metal oxide particles with phenolic resin and specific plasticizers, where the plasticizer components enable the entire composite structure to be completely removed through solution stripping without requiring mechanical lathing

Inventive Principle:

Principle #40Composite materials

2Loss of substance

If lathing step is performed to remove coating layers, then recycling can proceed, but disposal costs increase and environmental impact worsens

Engineering Contradiction:

Improvematerial recoveryVSAvoiddisposal cost and environmental impact

Core Design Contradiction:

Loss of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potential harm of difficult-to-remove coating layers into a benefit by designing the undercoat layer with specific plasticizer components that enable complete, clean removal through solution stripping, transforming a recycling obstacle into an easy removal feature

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If undercoat layer composition is modified to enable complete removal, then recycling efficiency improves, but adhesion and performance must be maintained

Engineering Contradiction:

Improverecycling efficiencyVSAvoidadhesion and performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent carefully controls the concentration parameters of plasticizers (1-20 weight percent) to achieve the optimal balance where the undercoat layer remains sufficiently adhesive during operation but becomes completely removable through solution stripping during recycling

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different functional properties to different components of the undercoat layer: metal oxide particles provide electrical properties, phenolic resin provides matrix structure and adhesion, and plasticizers provide solubility for complete removal, with each component optimized for its specific function

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8465888B2Photoconductor undercoat layer

Publication Date: 2013.06.18 XEROX CORP

AI summary

A photoconductor comprising a substrate, an undercoat layer, a photogenerating layer and a charge transport layer is described. The undercoat layer is disposed on the substrate and comprises a metal oxide, and a mixture of a phenolic resin and a cyclohexanecarboxylate.