FIELD OF THE INVENTION
[0001] The present invention relates to a method of image formation wherein an organic photoelectroconductive
photoreceptor is used to form an image at high speed.
BACKGROUND OF THE INVENTION
[0002] Traditionally, the Carlson method has been commonly used for electrophotographic
image formation. In the Carlson method, uniformly charging the surface of photoreceptor
is followed by imagewise exposure to form an electrostatic latent image, which is
subjected to toner development to form a toner image, which is transferred and fixed
onto a transferee to form a final image. The photoreceptor after being used for transfer
is subjected to surface discharging using a discharger and residual toner removal
using a cleaning blade, cleaning brush or another cleaning device, whereby it is prepared
for subsequent long-term repeated use.
[0003] Therefore, the electrophotographic photoreceptor is required to be good in physical
properties such as printability, wear resistance and moisture resistance in repeated
use and resistances (environmental endurance) to ozone generated upon corona discharge
and to ultraviolet rays generated upon exposure as well as in charging property and
electrophotographic properties such as high sensitivity and low dark decay.
[0004] Traditionally, inorganic photoreceptors have been widely used as electrophotographic
photoreceptors whose light-sensitive layer is based on an inorganic photoelectroconductive
substance such as selenium, zinc oxide or cadmium sulfide.
[0005] In recent years, there has been a trend toward development of organic electrophotographic
photoreceptors with high sensitivity and high durability in which the carrier generation
and carrier transport functions are allotted to different substances in a light-sensitive
layer which substances are selected from a wide range to exhibit the respective functions
according to the desired characteristics.
[0006] As a binder for such photoreceptors, polycarbonate of the bisphenol A type represented
by the following formula is well known to have good properties in terms of charging
property, sensitivity, residual potential and repeated use property.

[0007] However, investigations by the inventors revealed that the polycarbonate of the bisphenol
A type is faulty in that its solution becomes unusable in some 1 to 2 weeks because
it is liable to gel due to the high crystallinity of the polymer. Also, when a film
is formed by coating, crystalline polycarbonate is likely to separate and cause rises
on the film surface during coating, which can cause film tailing and reduce the yield,
or which allows the uncleaned toner to remain thereon after use of the photoreceptor
and leads easily to an imaging failure due to poor cleaning.
[0008] In addition, the electrophotographic photoreceptor incorporating the polycarbonate
of the bisphenol A as a binder resin, when repeatedly used for image formation for
a long time, has problems of damaging of the light-sensitive layer surface due to
abrasion by magnetic brush or cleaning blade and of gradual wear of the light-sensitive
layer.
[0009] As stated above, the polycarbonate of the bisphenol A type poses problems in the
storage stability of solution during preparation of photoreceptor and the resistance
of the photoreceptor surface to mechanical abrasion. With the aim of solving these
problems, a number of polycarbonates with different structures have been proposed.
[0010] For example, there have been proposed the polycarbonate in which a fluorine atom
has substituted a hydrogen atom of the alkyl group bound to the central carbon atom
between phenylene rings [Japanese Patent Publication Open to Public Inspection (hereinafter
referred to as Japanese Patent O.P.I. Publication) No. 65444/1989], the polycarbonate
in which an alkyl group or halogen atom has substituted the meta-position of the phenylene
ring (Japanese Patent O.P.I. Publication No. 148263/1988), the polycarbonate in which
a phenyl group or cyclohexyl group has substituted the meta-position of the phenylene
ring (Japanese Patent O.P.I. Publication No. 269942/1989 or 269943/1989) and the polycarbonate
in which a cyclohexyl ring having the central carbon atom has been formed between
the phenylene rings (U.S. Patent No. 4,931,372). Having a bulky substituent in their
structure, the polycarbonates described in these patent publications surpass the polycarbonate
of the bisphenol A type in solution stability during preparation of photoreceptor,
stability against ozone during image formation and mechanical wear resistance.
[0011] It should be noted, however, that the recent increase in demands for photocopies
has spurred R & D activities for photocopying machines and relevant articles; for
example, high speed copying machines capable of generating 50 or more copies per minute
with high resolutions of 6 or more lines/mm have been demanded. In forming an image
while rotating the photoreceptor at high speed, the photoreceptor more frequently
undergoes photoelectric shocks from exposure device, charger, transfer device and
other devices and mechanical shocks from the magnetic brush of developing device,
the blade of cleaning apparatus and other devices. Particularly, the developing agent
on the sleeve of developing device is liable to be scattered by centrifugal force,
since the sleeve is usually rotated at a peripheral speed higher than that of the
photoreceptor. To prevent this, it is necessary to increase the magnetic field intensity
to constrain the developing agent on the sleeve. When the magnetic field intensity
on the sleeve is increased, a hard magnetic brush forms on the sleeve, which strongly
abrades the photoreceptor surface and deteriorates the photoreceptor.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide a method of image formation which
makes it possible to form an image with high density and high resolution without being
accompanied by fatigue deterioration or toner scattering by the use of an improved
photoreceptor even in use for repeated image formation at high speed.
[0013] The inventors made by way of trial a very large number of organic photoreceptors
using one or more of the polycarbonates described in the above-mentioned and other
publications as binder resins, and subjected them to repeatedly runs of testing for
a long time with the sample loaded on a high speed testing machine rotating at a peripheral
speed of not less than 300 mm/sec. The inventors thus discovered a photoreceptor suitable
to high speed copying machines and developed a method of image formation which permits
obtainment of high quality images at high speed without being accompanied by developing
agent scattering, and thus developed the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figures 1 through 6 are cross-sectional views showing the structural configuration
of the photoreceptor of the present invention. Figure 7 is a schematic diagram of
an image forming apparatus illustrating the method of image formation of the present
invention.
[0015] The symbols used in these figures denote a support for 1, a carrier generation layer
for 2, a carrier transport layer for 3, a light-sensitive layer for 4, an original
for 10, reflective mirrors for 14a, 14b, 14c and 14d, a charger for 16, a developing
apparatus for 17, a main developing magnetic pole for 17d, a photoreceptor for 20
and a cleaning apparatus for 21, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The object described above can be accomplished by a method of image formation including
a process in which an organic photoelectroconductive photoreceptor being rotated at
high speed is subjected to charging and imagewise exposure to form an electrostatic
latent image and transporting a developing agent from a sleeve rotating around the
periphery of an immobilized magnet having a main developing magnetic pole to develop
the electrostatic latent image, wherein said photoreceptor contains a polycarbonate
based on the repeat unit represented by the following Formula 1 or II is contained
in at least the uppermost layer constituting the light-sensitive layer configuration,
said photoreceptor being rotated at a peripheral speed of at least 300 mm/sec and
the magnetic flux density of the main developing magnetic pole on the sleeve exceeding
950 gauss.

wherein Z represents a group of atoms necessary to form a substituted or unsubstituted
carbon ring or heterocyclic ring group. R₁, R₂, R₃, R₄, R₅, R₆, R₇ and R₈ independently
represent a hydrogen atom, methyl group, chlorine atom or bromine atom, and not all
the substituents are hydrogen atoms at the same time.

wherein R₁ through R₈ are synonymous with those as defined in Formula I, R₉ or R₁₀
represents a hydrogen atom or alkyl group having 1 to 6 carbon atoms.
[0017] In the method of image formation of the present invention, photocopies are generated
at a high speed, for example, 50 copies or more per minute for A4-size landscape position
while rotating an organic photoelectroconductive photoreceptor in a drum or belt form
(hereinafter simply referred to as organic photoreceptor) at a peripheral speed of
not less than 300 mm/sec and the sleeve of the developing device at a peripheral speed
exceeding the peripheral speed of the photoreceptor. It is characterized in that the
magnetic flux density on the sleeve is kept at not less than 950 gauss to prevent
the developing agent being transported on the sleeve from scattering and that a highly
durable polycarbonate enduring such high speed copying has been selected as a binder
resin to constitute the light-sensitive layer of the organic photoreceptor.
[0018] The organic photoreceptor for the method of image formation of the present invention
comprises an electroconductive support and a light-sensitive layer formed thereon
which contains a carrier generation material, a carrier transport material, a binder
resin, and where necessary, an antioxidant, an ultraviolet absorbent and other additives,
between which an interlayer is provided if necessary. The light-sensitive layer may
be of a single layer structure having the above-mentioned compositions in common or
of a laminated structure having a carrier generation layer based on a carrier generation
material and a carrier transport layer based on a carrier transport material.
[0019] Typical structural configurations of the light-sensitive layer for the present invention
are shown in Figures 1 through 6.
[0020] Figure 1 shows a photoreceptor with an laminated layer structure comprising an electroconductive
support 1, a carrier generation layer 2 formed thereon and a carrier transport layer
3 formed thereon. Figure 3 shows a photoreceptor having the same layer structure as
of the photoreceptor of Figure 1 except that an interlayer 5 is present between the
electroconductive support 1 and the carrier generation layer 2.
[0021] Figure 2 shows a photoreceptor with a laminated layer structure wherein comprising
an electroconductive support 1, a carrier transport layer 3 formed thereon, a carrier
generation layer formed thereon and a protective layer 8 formed on the carrier generation
layer to protect it. Figure 4 shows a photoreceptor having the same layer structure
as of the photoreceptor of Figure 2 except that an interlayer 5 is present. Figure
5 shows a photoreceptor with a single layer structure comprising an electroconductive
support 1 and a layer containing a carrier generation material 7 and a carrier transport
material 6. Figure 6 is a photoreceptor having the same layer structure as of the
photoreceptor of Figure 5 except that an interlayer 5 is present. A key to the present
invention is the use of a polycarbonate based on the repeat unit represented by Formula
1 as a binder resin in the light-sensitive layer of the photoreceptor used, whereby
a highly durable photoreceptor is obtained, which ensures stable obtainment of high
quality images over a long period without involving fatigue deterioration of electrophotographic
properties due to severe temperature/humidity conditions, ultraviolet rays, ozone
and mechanical abrasion during repeated image formation at high speed, a feature of
the present invention. The polycarbonate represented by Formula 1 has been selected
as suiting to the present invention from the group comprising conventional polycarbonates
with various structures. The central carbon atom in the polycarbonate structure is
involved in the formation of a ring by Z, which effectively prevents the molecular
chain in the polycarbonate structure from orienting in a particular direction and
hence prevents the crystallization and gelation of the polycarbonate. In the event
of crystallization or gelation upon formation of the light-sensitive layer of photoreceptor,
the resulting crystal or gel separates on, and protrudes from, the light-sensitive
layer surface to cause an imaging failure.
[0022] When using the polycarbonate represented by Formula 1 to form a light-sensitive layer,
it is possible to prepare an electrophotographic photoreceptor which is excellent
in light-sensitive layer physical properties and electrophotographic properties such
as charge retention, sensitivity and residual potential and which shows stable performance
with little fatigue deterioration even in repeated use at high speed.
[0023] When using the photoreceptor of the present invention for copying machines and other
equipment which form images at high speed, the light-sensitive layer surface is not
liable to have flaws even in abrasion with magnetic brush or cleaning blade and high
printability free of characteristic failures such as poor cleaning is obtained.
[0024] The polycarbonate resin of the present invention can easily be synthesized by a conventional
method using, for example, a phenol compound represented by the following formula.

wherein Z represents a group of non-metallic atoms necessary to form a substituted
or unsubstituted carbon ring or heterocyclic ring group; R₁, R₂, R₃, R₄, R₅, R₆, R₇
and R₈ independently represent a hydrogen atom, chlorine atom, bromine atom or methyl
group. Not all the substituents are hydrogen atoms at the same time.

wherein R₁ and R₂ independently represent a hydrogen atom or an alkyl group having
1 to 6 carbon atoms. R₃, R₄, R₅, R₆, R₇, R₈, R₉ and R₁₀ independently represent a
hydrogen atom, methyl group, chlorine atom or bromine atom. Not all the substituents
are hydrogen atoms at the same time.
[0025] An example of the method of producing the polycarbonate resin for the present invention
is such that the phenol compound described above is reacted with an aqueous solution
of alkali, pyridine or another acid recipient in the presence of an inert solvent
such as methylene chloride or 1,2-dichloroethane while introducing phosgene.
[0026] When using an aqueous solution of alkali as an acid recipient, catalytic use of a
tertiary amine such as trimethylamine or triethylamine or a quaternary ammonium compound
such as tetrabutylammonium chloride or benzyltributylammonium bromide increases the
reaction rate.
[0027] A monohydric phenol such as phenol or p-t-butylphenol may be added as a molecular
weight regulator as necessary. The catalyst may be present at initiation of the reaction,
or may be added after preparing the oligomer before increasing the molecular weight.
[0028] In the polycarbonate structure of Formula 1, Z forms a 5- or 6-membered carbon ring
or heterocyclic ring, including a cyclohexyl ring and cyclopentyl ring, wherein a
substituent such as an acetyl group or acetylamino group may have been introduced
locally.
[0030] Of these compounds, (1)-3 and (1)-6 serve as repeat unit structure for excellent
mechanical durability for the polycarbonate.
[0031] The binder resin for the photoreceptor of the present invention may be formulated
with another resin, as long as its effect on the polycarbonate of Formula 1 is not
interfered with, preferably at mixing ratios of not more than 50 wt%.
[0032] The polycarbonate for the present invention may be a homopolymer of a structural
unit (II) represented above but may also be a copolymer with another structural unit
A or B with the following structures. In this case, the mixing ratio of the other
structural unit is preferably not more than 50 wt%.

[0033] Various methods including the following can be used to copolymerize two or more phenol
compounds for the present invention.
(a) Copolymerization is carried out by simultaneously reacting two or more phenol
compounds with phosgene.
(b) Copolymerization is carried out by first reacting one or more phenol compounds
with phosgene and after progress of reaction to some extent, the remaining phenol
compounds are add for further reaction.
(c) Copolymerization is carried out by separately reacting two or more phenol compounds
with phosgene. The degree of polymerization of the homopolymer or copolymer of the
polycarbonate for the present invention is 50 to 5000, preferably 50 to 1000.
[0034] Examples of binder resins which can be used in combination with the homopolymer or
copolymer of the polycarbonate include the following.
(1) Polyester
(2) Methacrylic resin
(3) Acrylic resin
(4) Polyvinyl chloride
(5) Polyvinylidene chloride
(6) Polystyrene
(7) Polyvinyl acetate
(8) Styrene copolymer resins such as styrene-butadiene copolymer and styrene-methyl
methacrylate copolymer
(9) Acrylonitrile copolymer resins such as vinylidene chloride-acrylonitrile copolymer
(10) Vinyl chloride-vinyl acetate copolymer
(11) Vinyl chloride-vinyl acetate-maleic anhydride copolymer
(12) Silicone resin
(13) Silicone-alkyd resin
(14) Phenol resins such as phenol-formaldehyde resin and cresol-formaldehyde resin
(15) Styrene-alkyd resin
(16) Poly-N-vinylcarbazole
(17) Polyvinyl butyral
(18) Polyvinyl formal
(19) Polyhydroxystyrene
[0035] These binders may be used singly or in a mixture of two or more kinds in combination
with the polycarbonate for the present invention at not more than 50 wt%.
[0037] The following organic pigments, for example, are used as carrier generation materials
added to the light-sensitive layer to prepare the photoreceptor of the present invention.
(1) Azo pigments such as monoazo pigments, bisazo pigments, triazo pigments and metal
complex salt azo pigments.
(2) Perillene pigments such as perillic anhydride and perillic imide.
(3) Polycyclic quinone pigments such as anthraquinone derivatives, anthanthrone derivatives,
dibenzopyrenequinone derivatives, pyranthrone derivatives, violanthrone derivatives
and isoviolanthrone derivatives.
(4) Indigoid pigments such as indigo derivatives and thioindigo derivatives.
(5) Phthalocyanine pigments such as metallic phthalocyanines and non-metallic phthalocyanines.
[0038] It is preferable to use an organic pigment such as a fluorenone dis-azo pigment,
fluorenylidene dis-azo pigment, polycyclic quinone pigment, non-metallic phthalocyanine
pigment or oxytitanyl phthalocyanine pigment as a carrier generation material in the
photoreceptor for the present invention, with more preference given to the following
fluorenone diazo pigment, fluorenylidene dis-azo pigment, polycyclic quinone pigment
and X- and τ-type non-metallic phthalocyanines, since they offer remarkable improvements
in sensitivity, durability, image quality and other features.

wherein X₁ and X₂ independently represent a halogen atom, alkyl group, alkoxy group,
nitro group, cyano group, hydroxyl group or substituted or unsubstituted amino group;
p and q independently represent an integer of 0, 1 or 2; when p and q are 2, X₁ and
X₂ may be identical or not; A represents a group represented by the following Formula
2-1.

wherein Ar represents a fluorinated hydrocarbon group or an aromatic carbon ring group
or aromatic heterocyclic ring having a substituent; Z represents a group of non-metallic
atoms necessary to form a substituted or unsubstituted aromatic carbon ring or substituted
or unsubstituted aromatic heterocyclic ring; m and n independently represent an integer
of 0, 1 or 2; m and n are not 0 at the same time.
[0040] The fluorenone dis-azo pigment represented by Formula 2 for the present invention
can easily be synthesized by a known method, for example, the method described in
Japanese Patent Application No. 304862/1987.
[0041] The fluorenylidene dis-azo pigment for the present invention is represented by the
following Formula 3.

wherein A represents

wherein Z represents a group of atoms necessary to form a substituted or unsubstituted
aromatic carbon ring or aromatic heterocyclic ring group; Y represents a hydrogen
atom, hydroxyl group, carboxyl group or its ester, sulfo group, substituted or unsubstituted
carbamoyl group or sulfamoyl group; R₁ represents a hydrogen atom, a substituted or
unsubstituted alkyl group, amino group, carbamoyl group or carboxyl group or its ester
or a cyano group; Ar represents a substituted or unsubstituted aryl group; R₂ represents
a substituted or unsubstituted alkyl group, aralkyl group or aryl group.
[0043] The polycyclic quinone pigments for the present invention are represented by the
following Formulas 4 through 6.

wherein X represents a halogen atom, nitro group, cyano group, acyl group or carboxyl
group; n represents an integer of 0 to 4; m represents an integer of 0 to 6.
[0047] The polycyclic quinones represented by Formulas 4 through 6 for the present invention
can easily be synthesized by known methods.
[0048] Any non-metallic phthalocyanine and its derivative can be used for the present invention,
as long as it is electroconductive. Examples thereof include those of the α-type,
β-type, τ,τ′-type, η,η′-type, X-type and crystal configuration described in Japanese
Patent O.P.I. Publication No. 103651/1987 and derivatives thereof. It is desirable
to use the τ-, X- or K/R-X type. Non-metallic phthalocyanines of the X-type are described
in U.S. Patent No. 3,357,989. Non-metallic phthalocyanines of the τ-type are described
in Japanese Patent O.P.I. Publication No. 182639/1983. The phthalocyanines of the
K/R-X type are characterized in that major peaks appear at 7.7, 9.2, 16.8, 17.5, 22.4
and 28.8° as of Brag angle (2ϑ ±0.2°) with respect to the X-ray from CuK₂ of 1.541
Å with the ratio of the 16.8° peak intensity to the 9.2° peak intensity ranging from
0.8 to 1.0 and the ratio of the 28.8° peak intensity to the 22.4° peak intensity exceeding
0.4, as described in Japanese Patent O.P.I. Publication No. 103651/1987.
[0049] There is no limitation on the choice of carrier transport materials for the present
invention. Examples of usable carrier transport materials include oxazole derivatives,
oxadiazole derivatives, thiazole derivatives, thiadiazole derivatives, triazole derivatives,
imidazole derivatives, imidazolone derivatives, imidazolidine derivatives, bisimidazolidine
derivatives, styryl compounds, hydrazone compounds, pyrazoline derivatives, amine
derivatives, oxazolone derivatives, benzothiazole derivatives, benzimidazole derivatives,
quinazoline derivatives, benzofuran derivatives, acridine derivatives, phenazine derivatives,
aminostylbene derivatives, poly-N-vinylcarbazole, poly-1-vinylpyrene and poly-9-vinylanthracene.
[0050] The carrier transport material for the present invention is preferably a carrier
transport material which is highly capable of transporting the holes which result
in upon light irradiation to the support side and which is suitable for combined use
with the organic pigment for the present invention. Such carrier transport materials
are exemplified by the styryl compounds represented by the following Formulas 7 and
8.

wherein R₁₁ and R₁₂ independently represent a substituted or unsubstituted alkyl group
or aryl group, the substituent being exemplified by an alkyl group, alkoxy group,
substituted amino group, hydroxyl group, halogen atom and aryl group. Ar₅ and Ar₆
independently represent a substituted or unsubstituted aryl group, the substituent
being exemplified by an alkyl group, alkoxy group, substituted amino group, hydroxyl
group, halogen atom and aryl group. R₁₃ and R₁₄ independently represent a substituted
or unsubstituted aryl group or hydrogen atom, the substituent being exemplified by
an alkyl group, alkoxy group, substituted amino group, hydroxyl group, halogen atom
and aryl group.
[0051] Compounds represented by Formula 7 are described in Japanese Patent O.P.I. Publication
Nos. 65440/1983, 198425/1983, 198043/1983, 93445/1985 and 98437/1985 and other publications.

wherein R₁₅ represents a substituted or unsubstituted aryl group; R₁₆ represents a
hydrogen atom, halogen atom, substituted or unsubstituted alkyl group, alkoxy group,
amino group, substituted amino group or hydroxyl group; R₁₇ represents a substituted
or unsubstituted aryl group or heterocyclic group.
[0052] Compounds represented by Formula 8 are described in Japanese Patent O.P.I. Publication
No. 148750/1982 and other publications.
[0053] The hydrazone compounds of the following Formulas 9 through 11 can also be used as
carrier transport materials.

wherein R₁₈ and R₁₉ independently represent a hydrogen atom or halogen atom; R₂₀ and
R₂₁ independently represent a substituted or unsubstituted aryl group; Ar⁷ represents
a substituted or unsubstituted arylene group. Compounds represented by Formula 9 are
described in Japanese Patent O.P.I. Publication No. 72148/1982 and other publications.

wherein R₂₂ represents a substituted or unsubstituted aryl group or heterocyclic group;
R₂₃ represents a hydrogen atom or a substituted or unsubstituted aralkyl group or
aryl group; Q represents a hydrogen atom, halogen atom, alkyl group, substituted amino
group, alkoxy group or cyano group; S represents an integer of 0 or 1.
[0054] Compounds represented by Formulas 10 and 11 are described in Japanese Patent O.P.I.
Publication Nos. 134642/1983 and 166354/1983 and other publications.
[0055] The tetraphenylbenzidine compound of Formula 12 can also be used as a carrier transport
material.

wherein R₂₄ and R₂₅ independently represent a hydrogen atom or methyl group; R₂₆ represents
a hydrogen atom, methyl group, ethyl group or chlorine atom.
[0056] Examples of other useful carrier transport materials include those described in Japanese
Patent O.P.I. Publication Nos. 64244/1982, 15252/1984, 67940/1982, 2285/1980, 195254/1982
and 4148/1981.
[0058] Examples of the dispersant or solvent used to disperse the carrier generation material
or dissolve the carrier transport material and binder resin in the formation of the
light-sensitive layer of the photoreceptor of the present invention include hydrocarbons
such as hexane, benzene, toluene and xylene, halogenated hydrocarbons such as methylene
chloride, methylene bromide, 1,2-dichloroethane, syn-tetrachloroethane, cis-1,2-dichloroethylene,
1,1,2-trichloroethane, 1,1,1-trichloroethane, 1,2-dichloropropane, chloroform, bromoform
and chlorobenzene, ketones such as acetone, methyl ethyl ketone and cyclohexanone,
esters such as ethyl acetate and butyl acetate, alcohols such as methanol, ethanol,
propanol, butanol, cyclohexanol, heptanol, ethylene glycol, methyl cellosolve, ethyl
cellosolve, acetyl cellosolve and derivatives thereof, ethers or acetals such as tetrahydrofuran,
1,4-dioxane, furan and furfural, nitrogen compounds such as pyridine, butylamine,
diethylamine, ethylenediamine, isopropanolamine and other amines and N,N-dimethylformamide
and other amides, fatty acids, phenols and sulfur or phosphorus compounds such as
carbon disulfide and triethyl phosphate.
[0059] In the present invention, for improving the sensitivity, reducing the residual potential
and the fatigue during repeated use and other purposes, the light-sensitive layer
may contain one or more electron recipient substances.
[0060] Examples of electron recipients which can be used for these purposes include succinic
anhydride, maleic anhydride, dibromomaleic anhydride, phthalic anhydride, tetrachlorophthalic
anhydride, tetrabromophthalic anhydride, 3-nitrophthalic anhydride, 4-nitrophthalic
anhydride, pyromellitic anhydride, mellitic anhydride, tetracyanoethylene, tetracyanoquinodimethane,
o-dinitrobenzene, m-dinitrobenzene, 1,3,5-trinitrolbenzene, p-nitrobenzonitrile, picryl
chloride, quinone chlorimide, chloranil, bromanil, dichlorodicyanoparabenzoquinone,
anthraquinone, dinitroanthraquinone, 2,7-dinitrofluorenone, 2,4,7-trinitrofluorenone,
2,4,5,7-tetranitrofluorenone, 9-fluorenylidene [dicyanomethylenemalonodinitrile],
polynitro-9-fluorenylidene [dicyanomethylenemalonodinitrile], picric acid, o-nitrobenzoic
acid, p-nitrobenzoic acid, 3,5-dinitrobenzoic acid, pentafluorobenzoic acid, 5-nitrosalicylic
acid, 3,5-dinitrosalicylic acid, phthalic acid, mellitic acid and other highly electrophilic
compounds. The ratio of electron recipient added is 0.01 to 200 parts by weight, preferably
0.1 to 100 parts by weight to 100 parts by weight of the organic pigment used as a
carrier generation material for the invention.
[0061] The light-sensitive layer for the present invention may contain an organic amine
to improve the charge generation function of the carrier generation material, with
preference given to a secondary amine. Such compounds are described in Japanese Patent
O.P.I. Publication Nos. 218447/1984 and 8160/1987.
[0062] The photoreceptor for the present invention may contain as necessary an ultraviolet
absorbent and other additives to protect the light-sensitive layer and also a color
sensitivity correcting dye.
[0063] The protective layer 8 shown in Figure 2 or 4 may contain as necessary a thermoplastic
resin at concentrations below 50 for the purpose of improving the processability and
physical properties, for example, to prevent cracking and providing flexibility.
[0064] The interlayer 5 shown in Figure 3, 4 or 6 functions as an adhesive layer, blocking
layer or another layer, which may comprise polyvinyl alcohol, ethyl cellulose, carboxymethyl
cellulose, vinyl chloride-vinyl acetate copolymer, vinyl chloride-vinyl acetate-maleic
anhydride copolymer, casein, N-alkoxymethylated nylon, starch and other substances
as well as ordinary binder resins.
[0065] The electroconductive support 1 which constitutes the photoreceptor for the present
invention is prepared mainly from the following substances, but these are not to be
construed as limitative.
1) Metal plates such as aluminum and stainless steel plates.
2) Paper or plastic film supports on which a thin layer of a metal such as aluminum,
palladium or gold has been formed by lamination or evaporative deposition.
3) Paper or plastic film supports on which a layer of an electroconductive compound
such as electroconductive polymer, indium oxide or tin oxide has been formed by coating
or evaporative deposition.
[0066] The light-sensitive layer 4 of the photoreceptor may be of a double layer structure
as illustrated in Figures 1 through 4 or of a single layer structure as illustrated
in Figures 5 and 6. In the case of double layer structure, it depends on the charging
polarity, positive or negative, which of the carrier generation layer 2 or carrier
transport layer 3 is located on the counterpart layer. To obtain a negatively charged
photoreceptor, it is advantageous to locate the carrier transport layer 3 on the carrier
generation layer 2. To obtain a positively charged photoreceptor, it is advantageous
to locate the carrier generation layer 2 on the carrier transport layer 3. This is
because the carrier transport material in the carrier transport layer 3 is highly
capable of transporting positive holes. A photoreceptor having a light-sensitive layer
4 of a double layer structure described above is prepared by the following methods.
(1) Vacuum deposition.
(2) Coating a solution of carrier transport material in an appropriate solvent.
(3) Coating a dispersion prepared by finely pulverizing a carrier transport material
using a ball mill, sand grinder or another means in a dispersant and if necessary
mixing and dispersing with a binder.
[0067] Specifically, there can be used vapor phase deposition methods such as vacuum deposition,
sputtering and CVD and coating methods such as dip coating, spray coating, blade coating
and roll coating.
[0068] The thickness of the carrier generation layer 2 thus formed is preferably 0.01 to
5 µm, more preferably 0.05 to 3 µm. The carrier generation layer 2 is a layer wherein
fine particles of carrier generation material typically having a diameter of not more
than 1 µm as a main component is dispersed in a binder resin in a ratio of 0.1 to
3 parts by weight of the binder resin to 1 part by weight of the carrier generation
material.
[0069] The carrier generation layer 2 may contain as necessary a carrier transport material
at 0 to 1 part by weight.
[0070] The carrier transport layer 3 is a layer wherein a carrier transport material as
a main component is compatibly dissolved in a binder resin in a ratio of 0.1 to 5
parts by weight of the binder resin to 1 part by weight of the carrier transport material.
The light-sensitive layer 4 of the photoreceptor for the present invention may be
of a single layer structure. In this case, the thickness of the light-sensitive layer
is 10 to 50 µm, preferably 15 to 40 µm, wherein 0.5 to 5 parts by weight of the carrier
transport material and 0.5 to 10 parts by weight of the binder resin are contained
per 1 part by weight of the carrier generation material.
[0071] With the structure described above, the photoreceptor for the present invention offers
excellent electrophotographic performance with high durability and little fatigue
deterioration when used for high speed repetitive transfer electrophotography.
[0072] Developers suitable for the present invention are described below. The developer
used for the present invention is a two-component developer which is excellent in
fluidity and frictional chargeability and hence in developability. The two-component
developer preferably comprises a fine grains of non-magnetic toner and magnetic carrier
grains.
[0073] To obtain such fine grains of non-magnetic toner, a colorant such as carbon black
in a ratio of not more than 20 wt% and, where necessary, a charge control agent in
a ratio of not more than 5 wt%, are added to the thermoplastic or thermosetting resin
described below, followed by melting, kneading, cooling, pulverization and classification,
and if necessary heat treatment to yield insulating grains having a volume resistivity
of not less than 10¹⁴ Ω-cm and a weight average grain size of 2 to 20 µm. A binder
resin monomer containing the colorant and other additives may be polymerized while
stirring to yield a spherical toner.
[0074] Examples of the binder resin to prepare the toner include addition polymerization
resins such as styrene resin, styrene-acrylic resin, styrene-butadiene resin and acrylic
resin, condensation polymerization resins such as polyester resin, polycarbonate resin,
polyamide resin, polysulfonate resin and polyurethane resin, and epoxy resin.
[0075] Examples of the monomer used to form an addition polymerization resin include styrenes
such as styrene, o-methylstyrene, m-methylstyrene, p-methylstyrene and 3,4-dichlorostyrene,
ethylenic unsaturated monoolefins such as ethylene, propylene, butylene and isobutylene,
halogenated vinyls such as vinyl chloride, vinylidene chloride, vinyl bromide and
vinyl fluoride, vinyl esters such as vinyl acetate, vinyl propionate, vinyl benzoate
and vinyl acetate, α-methylene aliphatic monocarboxylates such as methyl acrylate,
ethyl acrylate, butyl acrylate, isobutyl acrylate, propyl acrylate, octyl acrylate,
dodecyl acrylate, lauryl acrylate, 2-ethylhexyl acrylate, octyl methacrylate, dodecyl
methacrylate, lauryl methacrylate, 2-ethylhexyl methacrylate, stearyl methacrylate,
phenyl methacrylate, dimethylaminoethyl methacrylate and diethylaminoethyl methacrylate,
acrylic acid or methacrylic acid derivatives such as acrylonitrile, methacrylonitrile
and acrylamide, vinyl ethers such as vinylmethyl ether, vinylethyl ether and vinylisobutyl
ether, vinyl ketones such as vinyl methyl ketone, vinyl hexyl ketone and methyl isopropenyl
ketone, N-vinyl compounds such as N-vinylpyrrole, N-vinylcarbazole, N-vinylindole
and N-vinylpyrrolidone, monoolefinic monomers such as vinylnaphthalenes, and diolefinic
monomers such as propadiene, butadiene, isoprene, chloroprene, pentadiene and hexadiene.
These monomers may be used singly or in combination. Examples of the monomer used
to form a condensation polymerization resin include ethylene glycol, triethylene glycol
and 1,3-propylene glycol.
[0076] As for charge control agents, all of the negative charge control agents described
in Japanese Patent O.P.I. Publication Nos. 88743/1984, 88745/1984, 79256/1984, 78362/1984,
228259/1984 and 124344/1984 and all of the positive charge control agents described
in Japanese Patent O.P.I. Publication Nos. 9456/1976, 204851/1984, 204850/1984 and
177571/1984 can be used.
[0077] For the purpose of preventing the offset phenomenon due to toner adherence to fixation
roller, a low molecular polyolefin such as polypropylene, polyethylene or wax may
be added to binder resin at 0 to 5 wt%.
[0078] For the purpose of providing fluidity and other charge control properties (negative)
for the developer, hydrophobic silica may be externally added to the toner at 0 to
3 wt%.
[0079] The carrier for the two-component developer for the present invention is capable
of providing the desired charge for the toner. A magnetic material may be used as
such, used after being coated with resin etc. or used as fine powder in mixture with
resin, with preference given to a coated carrier prepared by coating a resin on the
magnetic grain surface. Examples of the magnetic material include substances which
magnetize very strongly in the direction of magnetic field, such as iron, cobalt,
nickel and other metals, ferrite, magnetite, hematite and other alloys or compounds
containing a ferromagnetic element such as iron, cobalt or nickel, and alloys which
contain no ferromagnetic substance but which show ferromagnetism upon appropriate
heat treatment such as Heusler's alloys containing manganese and copper (manganese-copper-aluminum
alloy and manganese-copper-tin alloy) and chromium dioxide.
[0080] The weight average grain diameter d of the carrier is normally 40 to 120 µm. The
carrier resistivity is not less than 10³ Ω-cm, preferably not less than 10¹³ Ω-cm,
and still more preferably not less than 10¹⁴ Ω-cm for preventing charge injection
into the carrier by bias voltage and subsequent adherence of the carrier on the image
formation surface and leakage of bias voltage leading to elimination of the latent
image charge.
[0081] The specific resistivity of carrier or toner is determined by tapping the subject
grains in a container having a cross sectional area of 0.5 cm², then exerting a load
of 1 kg/cm³ on the tapped grains, applying a voltage such that a 10² to 10⁵ V/cm electric
field appears between the loaded grains and the bottom electrode, reading the value
for current and making a given calculation. The thickness of the carrier or toner
grain layer is about 1 mm.
[0082] The carrier for the present invention is preferably made spherical to improve the
frictional chargeability between the carrier and the toner as well as to improve the
developer fluidity and to make blocking among the carrier grains or between the carrier
and the toner unlikely to occur. To obtain such a spherical carrier, a thermoplastic
or thermosetting resin, for example, is coated to a thickness of 0.1 to 2 µm (0.5
to 5 wt% relative to the carrier weight) on magnetic grains previously made spherical
for a resin-coated carrier, or dispersed grains prepared by dispersing a fine ferromagnetic
power in resin at 30 to 70 wt% may be heated to make them spherical or subjected to
spray drying to directly prepare spherical grains.
[0083] The two-component developer contains the carrier and toner in weight ratios of 98:2
to 85:15 and may contain as necessary a fluidizing agent such as hydrophobic silica,
colloidal silica or silicon varnish and a cleaning aid such as a metal salt of fatty
acid or fluorine surfactant in a ratio of 0.1 to 3 wt% of the toner.
[0084] The developer for the present invention has been described above. The method of image
formation using the photoreceptor and developer described above is explained below
with reference to the image forming apparatus illustrated in Figure 7. The numerical
symbols in Figure 7 denote an original placed an original table 11 for 10, exposure
lamps for 12 and 13, reflective mirrors for 14a, 14b, 14c and 14d and an image forming
lens for 15, a charger for 16, a developing apparatus for 17, a sleeve rotating in
the direction of arrow for 17a, an immobilized magnet having a main developing magnetic
pole 17d for 17b, a hopper for supplying the toner T for 17c, a stirrer for developer
D for 18, a highly durable organic photoreceptor drum for 20, a cleaning apparatus
for 21, a blade housed in the cleaning apparatus 21 for 21a, a power source to apply
a DC bias voltage to the developing sleeve 17a for 22, a paper feed cassette for 23,
a paper feed roller for 24, a resist roller for 25, a transfer pole for 28, a separation
pole for 29, a transfer paper transport apparatus for 26, a fixation roller for 27,
a discharge roller for 28 and a paper receiving tray for 29, respectively.
[0085] First, the original 10 on the original table 11 is scanned at a speed of X in the
direction of arrow by the exposure system comprising the exposure lamps 12 and 13
and the reflective mirror 14a, which scanning light is reflected by the V mirrors
14b and 14c being running at a speed of X/2 and reaches the photoreceptor drum 20,
pre-charged to 400 to 800 V by the charger 16 and rotating at a peripheral speed of
not less than 300 mm/sec in the direction of arrow, via the image forming lens 15
and the reflective mirror 14d, on which photoreceptor drum imagewise exposure occurs
and an electrostatic latent image forms. The resulting electrostatic latent image
is sled and developed by a magnetic brush developing device 17 containing a single-component
developer based on a magnetic toner, or a two-component developer preferably comprising
a magnetic carrier and a non-magnetic toner to form a toner image. Then, the developer
D in the developing device 17 is thoroughly stirred, mixed and slid and hence charged
with the toner T supplied via a toner supplying mechanism such as the hopper 17c by
the stirrer 18, after which it is magnetically adsorbed to the sleeve 17a and then
transported to the developing zone for developing the electrostatic latent image.
[0086] Rotating the sleeve 17a at too high a peripheral speed even in a high speed copying
machine results in an excess torque, which is undesirable from the viewpoint of mechanism.
To obtain high image quality, the peripheral speed of the sleeve 17a is set at 1 to
5 times the peripheral speed of the photoreceptor drum 20 (peripheral speed ratio
K); therefore, as the copying speed increases, the peripheral speed of the sleeve
17a increases and carrier scattering becomes more likely to occur. In the method of
image formation of the present invention, the magnetic flux density on the sleeve
is at least 950 gauss, preferably not more than 1200 gauss to ensure development free
of carrier scattering. If the magnetic flux density exceeds 1200 gauss, the iron powder
grains mingled in the developer stand up as if they are magnetically attracted and
cause abrasive deterioration of the surface of the photoreceptor during repeated image
formation even when the photoreceptor has been improved according to the present invention.
[0087] Accordingly, inorder to prevent the carrier scattering under the magnetic flux density
less than 1200 gauss, the peripheral speed of the photoreceptor preferably be under
600 mm/sec.
[0088] In the method of image formation of the present invention, the peripheral speed ratio
K is set at lower level to avoid excess of the peripheral speed of the sleeve 17a
and the magnetic flux density on the sleeve as the copying speed increases. However,
the peripheral speed ratio K should be not less than 1 to maintain imaging performance,
and the magnetic flux density ont the sleeve must be not less than 950 gauss to prevent
carrier scattering.
[0089] The toner image obtained by development as above is transferred by the transfer pole
28 onto transfer paper transported from the paper feed cassette 23 to the developing
zone via the paper feed roller 24 and resist roller 25 in synchronization with image
formation and then transferred by the action of the separating pole 29. The transfer
paper carrying the toner image is transported by the transport means 26 to the fixing
device 27, wherein it is fixed, after which it is discharged to the paper receiving
tray 29 via the paper discharge roller 28.
[0090] The method of image formation described above makes it possible to stably forming
a high quality image at high speed.
EXAMPLES
[0091] The present invention is hereinafter described in more detail by means of the following
examples, but the mode of embodiment of the invention is not limited by these examples.
[0092] In the examples given below, a carrier generation material, carrier transport material,
carrier generation layer and carrier transport layer are abbreviated CGM, CTM, CGL
and CTL, respectively.
Example 1
Preparation of inventive photoreceptor 1
[0093] 30 g of a copolymer polyamide having a 1:1:1 monomer composition comprising -amino-caproic
acid, adipic acid and N-(β-aminoethyl)piperazine was added to, and dissolved in, 800
mℓ of 50°C-heated methanol (produced by Kanto Chemical Co., Ltd., EL grade) while
stirring the methanol. After cooling to room temperature, 200 mℓ of 1-butanol ((produced
by Kanto Chemical Co., Ltd., special grade) was added, Then, the solution was dip-coated
on an aluminum drum of 100 mm in diameter to form a 0.5 µm thick interlayer.
[0094] Next, 20 g of a fluorenone dis-azo pigment (Exemplified Compound 2-23) as CGM and
10 g of a polyvinyl butyral resin S-LEC BX-1 (produced by Sekisui Chemical Co., Ltd.)
as a binder were dissolved in 1000 mℓ of methyl ethyl ketone (produced by Kanto Chemical
Co., Ltd., EL grade), followed by 24 hours of milling using a sand mill to yield a
CGL coating solution, which was dip-coated on the interlayer to form a 0.3 µm thick
CGL. Then, 120 g of a styryl compound (Exemplified Compound 7-1) and 165 g of a polycarbonate
(molecular weight 22000) comprising a homopolymer of the repeat unit of Exemplified
Compound 1-1 were dissolved in 1000 mℓ of 1,2-dichloroethane (produced by Kanto Chemical
Co., Ltd., special grade) to yield a CTL coating solution, which was dip-coated on
the CGL, followed by drying at 100°C for 1 hour to yield a 20 µm thick CTL. A photoreceptor
1 comprising sequentially laminated interlayer, CGL and CTL was thus prepared.
Preparation of inventive photoreceptor 2
[0095] A photoreceptor 2 was prepared in the same manner as in Example 1 except that the
polycarbonate was replaced with a polymer comprising a homopolymer of the repeat unit
of Exemplified Compound 1-2 and the CTM was Exemplified Compound 7-3.
Preparation of inventive photoreceptor 3
[0096] An interlayer was formed in the same manner as in Example 1. 20 g of a polycyclic
quinone pigment (Exemplified Compound 4-3) as CGM and 10 g of a polycarbonate resin
L-1250 (produced by Teijin Chemicals Ltd.) as a binder were dissolved in 1,2-dichloroethane
(produced by Kanto Chemical Co., Ltd., special grade), followed by 24 hours of milling
in a ball mill to yield a CGL coating solution, which was dip-coated on the interlayer
to yield a 0.3 µm thick CGL.
[0097] Then, a photoreceptor 3 was prepared by CTL lamination in the same manner as in Example
1 except that the CTM was Exemplified Compound 7-5 and the binder resin was replaced
with a polycarbonate (molecular weight 20000) comprising a homopolymer of the repeat
unit of Exemplified Compound 1-3.
Preparation of inventive photoreceptor 4
[0098] 12 g of a polyvinyl butyral resin (S-LEC BX-1, produced by Sekisui Chemical Co.,
Ltd.) was dissolved in 1000 mℓ of methyl ethyl ketone. To this solution were added
5.7 g of Exemplified Compound 4-3 and 0.3 g of Exemplified Compound 2-23 as CGM, followed
by dispersion using a sand grinder for 10 hours.
[0099] The resulting dispersion was dip-coated on the interlayer described in Example 1
to yield a CGL, followed by CTL formation in the same manner as in Example 2 to yield
a photoreceptor 4.
Preparation of inventive photoreceptor 5
[0100] A photoreceptor (5) was prepared in the same manner as in Example 1 except that CTL
binder was replaced with simple polycarbonate instead of examplified compound (1)-4
unit repeated polymer.
Preparation of comparative photoreceptor 1
[0101] A comparative photoreceptor 1 was prepared in the same manner as in Example 1 except
that a bisphenol A polycarbonate (Panlite K-1300, produced by Teijin Chemicals Ltd.)
was used as a CTL binder.
[0102] The sensitizing solution was found unstable, poor in retention stability and easily
gelable during preparation of the photoreceptor.
Preparation of comparative photoreceptor 2
[0103] A comparative photoreceptor 2 was prepared in the same manner as in Example 1 except
that a bisphenol Z polycarbonate (produced by Mitsubishi Gas Chemical Company, Inc.)
was used as a CTL binder.
Preparation of developer
(i) Preparation of toner
[0104] 72 parts by weight of styrene, 10 parts by weight of methyl methacrylate, 14 parts
by weight of butyl acrylate, 4 parts by weight of monoacryloyloxyethyl succinate and
0.5 part by weight of zinc oxide were treated to yield a metal-crosslinked styrene-acrylic
copolymer resin having a double peak molecular weight distribution, a weight average
molecular weight of 170000 and a number average molecular weight of 9000.
[0105] Resin obtained above 100 parts by weight
[0106] Carbon black Mogal L (produced by Cabot) 10 parts by weight
[0107] These substances were mixed, kneaded in a molten state and cooled, after which they
were coarsely pulverized and then finely pulverized and classified to yield a toner
having an average grain size of 10 µm.
(ii) Preparation of inorganic grains
[0108] A polysiloxane having an ammonium salt functional group represented by the following
formula was dissolved in xylene to yield a treating solution.

X represents an integer.
[0109] Next, fine grains of silica Aerosil 200 (produced by Nihon Aerosil Co., Ltd.) were
placed in a mixer and sprayed with the polysiloxane in a ratio such that the ratio
of the polysiloxane was 5 wt%, after which they were transferred to a flask, followed
by removing the solvent xylene while stirring at 200°C for 5 hours to yield inorganic
fine grains surface treated with the polysiloxane having an ammonium salt functional
group.
[0110] The inorganic fine grains had a primary grain size of 12 mµ and a specific area of
115 m²/g as determined by the BET method.
(iii) Preparation of carrier
[0111] Using a fluidized bed system, the surface of ferrite grains F-150 (produced by Nippon
Teppun Kogyo) was coated with a fluorine resin with the following structure to a film
thickness of about 1.5 µm to yield a resin-coated carrier, which had a grain size
of 80 µm.

[0112] First, 0.5 part by weight of the inorganic grains was added to 100 parts by weight
of the toner, followed by mixing using a Henshel mixer to adhere the inorganic grains
onto the toner grain surface, followed by mixing with the carrier using a V mixer
to yield a developer having a toner concentration of 5 wt%.
[0113] The inventive photoreceptors 1 through 4 and comparative photoreceptors 1 and 2 were
loaded on a version of U-BIX 5000 (produced by Konica Corporation), and the two-component
developer was filled in the developing device of the copying machine, and the tests
of Table 2 were conducted under the mechanical conditions shown in Table 1. Each test
was repeated in 100000 cycles, and the surface potential of the photoreceptor was
measured before and after actual imaging.
[0114] The black paper potential Vb in Table 2 is the surface potential of the photoreceptor
to an original with a reflective density of 1.3. The white paper potential V
W is the surface potential of the photoreceptor to an original with a reflex density
of 0. The residual potential V
R is the surface potential of the photoreceptor after discharging. All these values
were measured using a voltameter probe placed at the developing device before and
after actual imaging.
[0115] Film wear due to friction on the photoreceptor surface was determined by measuring
the film thickness of the photoreceptor after 100000 copies were taken and compared
with the initial value.
[0116] As for image quality, the image sample was sequentially checked by counting the copies
with visible streaks or cleaning failures associated with flaws in the direction of
the drum periphery.
[0117] As an additional data, the photoreceptor (1) was carried the above tests under the
condition of setting the peripheral speed of the photoreceptor drum as 616 mm/sec,
the peripheral speed of the sleeve as 1078 mm/sec (peripheral speed ratio K = 1.75)
and the magnetic flux density on the sleeve as 1050 gauss. (test No. 11)
[0119] Form Table 2, it is evident that the test samples according to the present invention
showed little wear deterioration and electrophotographic performance degradation during
repeated high speed copying, while the comparative samples showed significant wear
deterioration in the photoreceptor.
[0120] When the magnetic flux density of the main developing magnetic pole was 900 gauss,
developer scattering occurred from the initial stage, the photoreceptor lacking practical
applicability (the relevant data are not given in Table 2).
[0121] As is evident from the description above, the method of image formation of the present
invention is effective in stably obtaining high quality images without being accompanied
by photoreceptor wear, imaging failure or electrophotographic performance degradation
during repeated image formation at high speed.