Electrophotographic image forming apparatus and process cartridge, and electrophotographic photoreceptor therefor

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to an electrophotographic image forming apparatus and a process cartridge as well as an electrophotographic photoreceptor used for copiers and printers using coherent light as the light sources.

[0003] 2. Discussion of the Background

[0004] Recently, a printer having a laser diode as the light source is widely used because of its compactness, high reliability, high-speed printing and high image quality. However, a photoreceptor which is sensitive to infrared light is desired because the laser diode has a wavelength of from 780 to 830 nm. As such photoreceptors, inorganic photoreceptors formed from cadmium sulfide doped with copper, indium, etc. and from selenium including increased tellurium have been used. However, organic photoreceptors are prevailing recently in view of the low pollution high productivity, stable quality and low cost. Among the organic photoreceptors, particularly a functionally-separated multilayer photoreceptor having a charge generation layer and a charge transport layer attracts attention in view of the high sensitivity and high durability because the materials can be flexibly selected.

[0005] The charge generation layer of the multilayer photoreceptor generates a charge by absorbing light, and the thickness of the layer is typically 0.01 to 5 μm for shortening the carrying range of the photo-carrier to prevent the recombination and the trap thereof.

[0006] In addition, a charge transport layer which scarcely absorbs imagewise light is typically used in view of the sensitivity.

[0007] Generally, the light volume which is absorbed in the photosensitive layer has a limit. The imagewise light coming in the photosensitive layer is not all absorbed therein, and some of the light reach the substrate and reflect on the surface thereof. The reflected light comes in the photosensitive layer again, and interferes with the imagewise light and the light reflecting on the surface of the photosensitive layer. Such a phenomenon remarkably occurs when the imagewise light is a coherent laser beam, causing image-density irregularity when a solid image and a half tone image are produced.

[0008] In order to prevent such a light interference, there is a method, in which an intermediate layer, including a resin containing a dispersed pigment having a large refraction index and an average particle diameter of from about 0.2 μm to 5 μm, is formed between the substrate and the photosensitive layer to scatter the light and prevent the mirror reflection. However, such an intermediate layer cannot completely prevent the light interference when the imagewise light volume and the developing condition change, and when a minimization of the diameter of the imagewise light and a high-density writing are desired for a higher image quality

[0009] On the other hand, a non-cut aluminium tube is considered instead of a conventional cut aluminium tube recently in view of the manufacturing cost and the adherence to the photosensitive layer. However, the non-cut aluminium tube has a surface having a high smoothness and a high reflectance, and has the opposite effect to the light interference.

SUMMARY OF THE INVENTION

[0010] Accordingly, an object of the present invention is to provide an electrophotographic image forming apparatus preventing the image-density irregularity due to the light interference.

[0011] Briefly this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by an image forming apparatus including at least an image irradiator configured to irradiate a photoreceptor with a coherent light beam while scanning to form pixel light spots thereon for forming an electrostatic latent image thereon, wherein the light spots overlap with adjacent light spots; and an image developer configured to develop the electrostatic latent image with a developer, wherein the photoreceptor comprises an intermediate layer located overlying an electroconductive substrate, a charge generation layer located overlying the intermediate layer and a charge transport layer located overlying the charge generation layer, wherein the charge generation layer satisfies the following relationship:

T1≦3.5%

[0012] wherein T1 represents a relative mirror reflectance of the charge generation layer against the coherent light beam when the coherent light beam irradiates the charge generation layer formed on the intermediate layer at an incident angle of 5°.

[0013] These and other objects, features and advantages of the present invention will become apparent upon consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the detailed description when considered in connection with the accompanying drawings in which like reference characters designate like corresponding parts throughout and wherein:

[0015]
FIG. 1 is a schematic view illustrating a relationship between the coherent light spots;

[0016]
FIG. 2 is a graph showing a relationship between a coherent light beam and an adjacent coherent light beam;

[0017]
FIG. 3 is a measuring principle of the relative mirror reflectance;

[0018]
FIG. 4 is a schematic view of an embodiment of the electrophotographic process of the present invention;

[0019]
FIG. 5 is a schematic view of another embodiment of the electrophotographic process of the present invention; and

[0020]
FIG. 6 is a schematic view of an embodiment of the process cartridge of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] Generally, the present invention provides an electrophotographic image forming apparatus preventing the image-density irregularity due to the light interference.

[0022] In an electrophotographic device, an image irradiation is performed by irradiating coherent light, in which an interval between a coherent light spot and an adjacent coherent light spot is smaller than the diameter of the coherent light, namely there is an overlapped portion between the coherent light spot and the adjacent coherent light spot. The present inventors found that the overlapped portion is a cause of the image-density irregularity in case of the above-mentioned irradiation. Particularly, when the overlapped area becomes large in proportion to high image resolution, the inventors found that the light interference affects the image-density irregularity far more than considered. As a result of the inventors' investigation, it was found that the image-density irregularity due to the light interference in the photoreceptor including an intermediate layer between the substrate and the photosensitive layer occurs when the relative mirror reflectance of the charge generation layer against the coherent light when the coherent light irradiates the charge generation layer formed on the intermediate layer at an incident angle of 50 is greater than 3.5%, and that the image-density irregularity can be prevented when the relative mirror reflectance is not greater than 3.5%.

[0023] In addition, as a result of the inventors' further investigation, it was found that when a photoreceptor including at least an intermediate layer, a charge generation layer and charge transport layer has the intermediate layer and the charge generation layer satisfying the following relationship, the image-density irregularity can be more effectively prevented.

T1≦T2≦3.5%

[0024] wherein T1 represents a relative mirror reflectance of the charge generation layer; and T2 represents a relative mirror reflectance against the coherent light when the coherent light irradiates the intermediate layer at an incident angle of 5°.

[0025] A photoreceptor having the relative mirror reflectance of the present invention is particularly effective for an electrophotographic device in which the diameter of the pixel light spots is not greater than 40 μm and the overlapped area is not less than 50% of the area of each of the light spot. The diameter of the pixel light spots is preferably not greater than 25 μm.

[0026] Intervals and Diameter of the Coherent Light Spots

[0027]
FIG. 1 is a schematic view illustrating a relationship between the coherent light spots, and FIG. 2 is a graph showing a relationship between a coherent light beam and an adjacent coherent light beam.

[0028] The intervals (a and a′) between the coherent light spots is determined depending on the density (writing resolution) of a latent image formed by the coherent light. The coherent light diameter (d and d′) is defined as an area in which the light energy is α/e2 or more when α is a peak energy of the coherent light having a Gauss distribution.

[0029] Relative Mirror Reflectance

[0030] The relative mirror reflectance against the coherent light having an incident angle of 5° can be typically measured by a measuring device based on the measuring principle as shown in FIG. 3. An aluminium-deposited mirror having a stable spectral reflectance is preferably used as a reflection standard.

[0031] In principle, from about 5 to 60° can be selected as the incident angle. However, when the incident angle becomes large, scattered light increases and a precise judgement cannot be made for the object of the present invention.

[0032] In the present invention, T1 is preferably not greater than 3.0%, and more preferably not greater than 2.5%. T2 is preferably not greater than 3.5%, and more preferably not greater than 3.0%.

[0033] Intermediate Layer

[0034] The intermediate layer of the present invention preferably includes a resin containing a dispersed pigment having a large refractive index. Known pigment powders can be used for the dispersed pigment particulate powder. However, white powders or others which are similar thereto are preferable in consideration of the high sensitivity of the resultant photoreceptor. Specific examples of such powders include metal oxides such as titanium oxide, zinc oxide, tin oxide, indium oxide, zirconium oxide, alumina and silica. These are preferably used because they are not hygroscopic and do not change much in quality due to change of the environment. Particularly, the titanium oxide having a good refractive index and electrical properties is preferably used.

[0035] In addition, as a binder resin for the intermediate layer of the present invention, appropriate resins can be used. However, a resin having a high solvent resistance against general organic solvents is preferably used because a photosensitive layer is coated on the intermediate layer.

[0036] Specific examples of such resins include water-soluble resins such as polyvinylalcohol, casein and sodium polyacrylate; alcohol-soluble resins such as nylon copolymers and methoxymethylated nylon; and curing resins forming a 3-dimensional network structure such as polyurethane resins, melamine resins and epoxy resins.

[0037] The intermediate layer preferably has a thickness of from 0.5 to 50 μm, and more preferably from 1.0 to 20 μm.

[0038] The volume ratio of the powder (P) and the binder resin (R), i.e., P/R of the intermediate layer is preferably from 1/1 to 3/1. When the P/R is less than 1/1, the properties of the intermediate layer tend to depend on the properties of the resin. When the P/R is greater than 3/1, the intermediate layer has many empty spaces therein and air bubbles tend to generate in the photosensitive layer formed thereon.

[0039] The relative mirror reflectance T2 of the present invention changes in accordance with the pigment. However, T2 can be also controlled by the dispersed condition of the pigment, and the affinity and mixing ratio of the pigment and the binder resin.

[0040] Charge Generation Layer

[0041] As a charge generation material which can be used for the photoreceptor of the present invention, a pigment which is sensitive to a long wavelength can be used. For example, phthalocyanine pigments such as metallic phthalocyanine and metal-free phthalocyanine, azulenium salt pigments, Squarilium salt pigments and azo pigments can be used. The relative mirror reflectance T1 can be preferably obtained by using a disazo pigment having the following formula (I). Particularly, a coupler residual group having the formula (II) can be preferably used in respect of sensitivity of the resultant photoreceptor.

[0042] The reason is still unapparent, however, a shape of the crystal particle and an agglomerating condition in forming a layer of the disazo pigment having the following formula (I) are considered to have some optical good effects. In addition, even if the disazo pigment is mixed with other heterogeneous pigments according to the wavelength to be absorbed, a sufficient effect can be expected.

[0043] wherein A and B independently represent a coupler residual

[0044] group having one of the following formulae (II) to (VIII).

[0045] wherein X1 represents —OH, —NHCOCH3 or —NHSO2CH3; Y1 represents —CON(R2)(R3), —CONHN═C (R6)(R7), —CONHN (R8)(R9), —CONHCONH(R12), a hydrogen atom, —COOH, —COOCH3, COOC6H5 or a benzimidazolyl group,

[0046] wherein R2 and R3 independently represent a hydrogen atom, a substituted or unsubstituted alkyl group, a substituted or unsubstituted aryl group and a substituted or unsubstituted hetero ring group; R2 and R3 optionally form a ring together with a nitrogen atom ; R6 and R7 independently represent a hydrogen atom, a substituted or unsubstituted alkyl group, a substituted or unsubstituted aralkyl group, a substituted or unsubstituted aryl group, a substituted or unsubstituted styryl group and a substituted or unsubstituted hetero ring group; R6 and R7 optionally form a ring together with a carbon atom; R8 and R9 independently represent a hydrogen atom, a substituted or unsubstituted alkyl group, a substituted or unsubstituted aralkyl group, a substituted or unsubstituted aryl group, a substituted or unsubstituted styryl group and a substituted or unsubstituted hetero ring group; R8 and R9 optionally form a 5 or 6 membered ring, which optionally includes a condensed aromatic group; and R12 represents a substituted or unsubstituted alkyl group, a substituted or unsubstituted aryl group and a substituted or unsubstituted hetero ring group; and Z represents a residual group selected from the group consisting of groups which are combined with the adjacent benzene ring to form a naphthalene ring, an anthracene ring, a carbazole ring, a benzocarbazole ring, a dibenzocarbazole ring, a dibenzofuran ring, a benzonaphthofuran ring and a dibenzothiophene ring; or a residual ring needed to form a hetero ring, which optionally have a substituted group;

[0047] wherein R4 represents a hydrogen atom, a substituted or unsubstituted alkyl group, or a substituted or unsubstituted aryl group;

[0048] wherein R5 represents a hydrogen atom, a substituted or unsubstituted alkyl group, or a substituted or unsubstituted aryl group;

[0049] wherein Y represents a divalent aromatic hydrocarbon group or a divalent hetero ring including a nitrogen atom in the ring;

[0050] wherein Y represents a divalent aromatic hydrocarbon group or a divalent hetero ring including a nitrogen atom in the ring;

[0051] wherein R10 represents a hydrogen atom, a lower alkyl group having 1 to 6 carbon atoms, a carboxyl group or an ester of a carboxyl group; and Ar1 represents a substituted or unsubstituted aromatic hydrocarbon ring group; and

[0052] wherein R10 represents a hydrogen atom, a lower alkyl group having 1 to 6 carbon atoms, a carboxyl group or an ester of a carboxyl group; and Ar1 represents a substituted or unsubstituted aromatic hydrocarbon ring group.

[0053] Within the context of the present invention, the term “alkyl group” means a saturated hydrocarbyl group having from 1 to 16 carbons, preferably from 1 to 11 carbons. Preferred alkyl groups include, but are not limited to methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and undecyl groups, either linear or branched. More preferred are methyl, ethyl, propyl, butyl, hexyl and undecyl.

[0054] Within the context of the present invention, the term “aryl group” means mono to hexavalent aromatic hydrocarbon groups made of aromatic hydrocarbon rings, preferably including but not limited to, phenyl, naphthyl, anthracenyl and pyrenyl, which may be unsubstited or substituted.

[0055] Within the context of the present invention, the term “aralkyl group” means a combination of one of the above mentioned aryl groups and one of the above mentioned alkyl groups, wherein the group is preferably attached to the molecule core through the alkyl portion of the group.

[0056] Within the context of the present invention, the term “hetero ring group” means mono-to-hexavalent aromatic heterocyclic groups having one or more aromatic heterocyclic rings. The aromatic heterocyclic rings include, but are not limited to, pyridinyl, quinolinyl, thiophenyl, furyl, oxazolyl, oxadiazolyl and carbazolyl, wherein the heterocyclic ring may be substituted or unsubtituted.

[0057] When any of the above noted aromatic (either aryl or heteroaryl) groups is substituted, the substituents can be selected from any substituent that does not interfere with the charge generation properties of the compound. Preferably the substituent includes, but is not limited to, one or more groups independently selected from alkyl having 1 to 16 carbons, alkoxy groups having 1 to 16 carbons, halogen groups and aryl groups as defined above. More preferably, the substituent(s) include one or more groups independently selected from methyl, ethyl, propyl, butyl, hexyl, undecyl, methoxy, ethoxy, propoxy, butoxy, fluoro, chloro, bromo, iodo and the above noted aryl groups.

[0058] Specific examples of the couplers forming a coupler residual group of the disazo pigments having the formula (I) are shown in Tables 1 to 16.

1TABLE 1-1

Melting PointCoupler No.R1(R2)n(° C.)1HH243 to 2442H2-NO2194 to 1963H3-NO2246 to 2474H4-NO2 266 to 267.55H2-CF3178 to 1796H3-CF3237.5 to 238.57H4-CF3279 to 2818H2-CN 221 to 222.59H3-CN256.5 to 258.510H4-CN274.5 to 277 11H2-I 199 to 199.512H3-I258.5 to 259.513H4-I261.5 to 262 14H2-Br217 to 21815H3-Br254 to 25516H4-Br265 to 26817H2-Cl228 to 23018H3-Cl256.5 to 257

[0059]

2

TABLE 1-2

Melting Point

Coupler No.
R1
(R2)n
(° C.)

19
H
4-Cl
264 to 266

20
H
2-F
223.0 to 224.0

21
H
3-F
250.0 to 251.0

22
H
4-F
265.0 to 267.0

23
H
2-CH3
195.5 to 198.0

24
H
3-CH3
214.5 to 216.5

25
H
4-CH3
227.0 to 229.0

26
H
2-C2H5
168.5 to 169.5

27
H
4-C2H5
203.0 to 204.5

28
H
2-OCH3
167 to 168

29
H
3-OCH3
195.5 to 198.0

30
H
4-OCH3
229 to 230

31
H
2-OC2H5
157 to 158

32
H
3-OC2H5
188.5 to 189.0

33
H
4-OC2H5
225.0 to 225.5

34
H
4-N(CH3)2
232.0 to 233.5

35
—CH3
H
189.5 to 190.5

36

H
182.0 to 183.0

37
H
2-OCH3, 5-OCH3
186.0 to 188.0

38
H
2-OC2H5,
173.0 to 173.5

5-OC2H5

39
H
2-CH3, 5-CH3
207.0 to 208.5

40
H
2-Cl, 5-Cl
253.5 to 254.5

[0060]

3

TABLE 1-3

Melting Point

Coupler No.
R1
(R2)n
(° C.)

41
H
2-CH3, 5-Cl
245 to 247

42
H
2-OCH3, 4-OCH3
151.0 to 152.0

43
H
2-CH3, 4-CH3
226 to 228

44
H
2-CH3, 4-Cl
244 to 245

45
H
2-NO2, 4-OCH3
179.5 to 181.0

46
H
3-OCH3, 5-OCH3
180.5 to 182.0

47
H
2-OCH3, 5-Cl
219.0 to 220.0

48
H
2-OCH3, 5-OCH3, 4-Cl
193.5 to 195.5

49
H
2-OCH3, 4-OCH3, 5-Cl
193 to 194

50
H
3-Cl, 4-Cl
272.5 to 273.5

51
H
2-Cl, 4-Cl, 5-Cl
257.5 to 258.5

52
H
2-CH3, 3-Cl
227.5 to 228.5

53
H
3-Cl, 4-CH3
259.5 to 260.5

54
H
2-F, 4-F
246.0 to 246.5

55
H
2-F, 5-F
259.0 to 260.0

56
H
2-Cl, 4-No2
283.0 to 284.0

57
H
2-No2, 4-Cl
226.5 to 227.5

58
H
2-Cl, 3-Cl, 4-Cl, 5-Cl
280.0 to 281.5

59
H
4-OH
268

[0061]

4

TABLE 2-1

Melting Point

Coupler No.
R1
(R2)n
(° C.)

60
H
H
>300

61
H
2-NO2
283 to 284

62
H
3-NO2
>300

63
H
4-NO2
>300

64
H
2-Cl
>300

65
H
3-Cl
>300

66
H
4-Cl
>300

67
H
2-CH3
>300

68
H
3-CH3
>300

69
H
4-CH3
>300

70
H
2-C2H5
271 to 273

71
H
4-C2H5
>300

72
H
2-OCH3
276 to 278

73
H
3-OCH3
>300

74
H
4-OCH3
>300

75
H
2-OC2H5
273.5 to 275.0

76
H
4-OC2H5
>300

77
H
2-CH3, 4-OCH3
296

[0062]

5

TABLE 2-2

Melting Point

Coupler No.
R1
(R2)n
(° C.)

78
H
2-CH3, 4-CH3
>300

79
H
2-CH3, 5-CH3

80
H
2-CH3, 6-CH3

81
H
2-OCH3, 4-OCH3

82
H
2-OCH3, 5-OCH3

83
H
3-OCH3, 5-OCH3

84
H
2-CH3, 3-Cl

85
H
2-CH3, 4-Cl

86
H
2-CH3, 5-Cl

87
H

88
H
2-CH(CH3)2

[0063]

6

TABLE 3-1

Melting Point

Coupler No.
R1
(R2)n
(° C.)

89
H
H
228.0 to 230.0

90
H
4-N(CH3)2
238.5 to 240.0

91
H
2-OCH3
218.0 to 222.0

92
H
3-OCH3
186.5 to 188.5

93
H
4-OCH3
224.5 to 225.0

94
H
4-OC2H5
236.0 to 237.5

95
H
2-CH3
227.0 to 228.0

96
H
3-CH3
212.5 to 214.0

97
H
4-CH3
233.0 to 236.0

98
H
2-F
233.0 to 233.5

99
H
3-F
248.5

100
H
4-F
239.5 to 240.0

101
H
2-Cl
254.0 to 255.0

102
H
3-Cl
226.5 to 230.0

103
H
4-Cl
265.5 to 269.0

104
H
2-Br
243.0

105
H
3-Br
231.0 to 231.50

106
H
4-Br
259.0

[0064]

7

TABLE 3-2

Melting

Coupler

Point

No.
R1
(R2)n
(° C.)

107
H
2-Cl, 4-Cl
251.5 to

252.0

108
H
3-Cl, 4-Cl
260.0 to

261.0

109
H
2-CN
175.0 to

176.5

110
H
4-CN
267.5 to

268.0

111
H
2-NO2
240.0

112
H
3-NO2
255.5 to

257.0

113
H
4-NO2
260.0 to

261.0

114
H
2-CH3, 4-CH3
234.5 to

236.5

115
H
2-OCH3, 5-OCH3
221.5 to

222.0

116
H
2-OCH3, 3-OCH3
191.0 to

4-OCH3
192.0

117
—CH3
H
248.5 to

250.0

118

H
182.5 to 185.0

119

H
213.0 to 214.5

120
H

237.0 to 237.5

[0065]

8

TABLE 4

Coupler

Melting Point

No.
R1
R2
(° C.)

121
—CH3
—CH3
232.5 to 233.0

122
H

208.5 to 209.0

123
H

224.0 to 224.5

124
H

197.5 to 199.0

125
H

188.0 to 188.5

126
H

227.0 to 228.0

127
—CH3

225.5 to 226.0

128
H

212.5 to 214.0

129
H

257

130
H

250

131
H

32.5 to 236.0

132
H

240.5 to 241.5

[0066]

9

TABLE 5

Coupler No.
(R)n
Melting Point (° C.)

133
H
>300

134
2-OCH3
268

135
3-OCH3
281.0 to 283.0

136
4-OCH3
293

137
2-CH3
297

138
3-CH3
296

139
4-CH3
>300

140
4-Cl
>300

141
2-NO2
>300

142
4-NO2
>300

143
2-OH
>300

144
2-OH, 3-NO2
>300

145
2-OH, 5-NO2
>300

146
2-OH, 3-OCH3
>300

[0067]

10

TABLE 6

Coupler No.
(R)n
Melting Point (° C.)

147
4-Cl
>300

148
2-NO2
268

149
3-NO2
>300

150
4-NO2
>300

151

296

152
H
300 to 307

153
2-OCH3
242 to 248

154
3-OCH3
269 to 275

155
4-OCH3
312

156
2-CH3
265 to 270

157
3-CH3
270 to 278

158
4-CH3
304

159
2-Cl
283 to 288

160
3-Cl
281 to 287

[0068]

11

TABLE 7

Melting Point

Coupler No.
R1
(R2)n
(° C.)

161
H
2-OCH3, 4-Cl,
208.0 to 208.5

5-CH3

162
—OCH3
H
230.5 to 231.5

163
—OCH3
2-CH3
205.5 to 206.0

164
—OCH3
2-OCH3, 5-OCH3, 4-Cl
245.5 to 246.0

[0069]

12

TABLE 8

Coupler No.
X
Melting Point (° C.)

165

207.0 to 209.0

166

257.0 to 259.0

167

290

[0070]

13

TABLE 9

Coupler No.
R1
Melting Point (° C.)

168

>300

169

>300

170

>300

171

298

[0071]

14

TABLE 10

Coupler

Melting Point

No.
X
R
(° C.)

172

180 to 183

173

228.5 to 229.5

174

>262

175

226.5 to 227.0

176

308 to 310

177

222 to 223

[0072]

15

TABLE 11

Melting

Coupler

Point

No.
R1
R2
(° C.)

178
H
H
220.5 to

221.5

179
—CH3
H
190.5 to

192.5

180
—CH3
—CH3
196.0 to

198.0

181
H

222.0 to 223.0

[0073]

16

TABLE 12-1

Coupler

Melting Point

No.
Structure
(° C.)

182

>300

183

>300

184

>300

185

>300

186

>300

187

>300

188

122.0 to 122.5

[0074]

17

TABLE 12-2

Coupler

Melting Point

No.
Structure
(° C.)

189

222.5 to 224.0

190

74.5 to 75.5

191

275.5 to 276.5

192

130.5 to 131.5

193

>300

194

>300

195

>300

196

172.5 to 173.5

[0075]

18

TABLE 12-3

Coupler

Melting Point

No.
Structure
(° C.)

197

262.5 to 265.5

198

>300

199

>300

200

128.0 to 129.0

[0076]

19

TABLE 13-1

Melting Point

Coupler No.
R1
(R2)n
(° C.)

201
Cl
H
>300

202
Cl
2-OCH3
>300

203
Cl
3-OCH3
>300

204
Cl
4-OCH3
>300

205
Cl
2-CH3
>300

206
Cl
3-CH3
>300

207
Cl
4-CH3
>300

208
Cl
2-Cl
>300

209
Cl
3-Cl
>300

210
Cl
4-Cl
>300

211
Cl
2-NO2
>300

212
Cl
3-NO2
>300

213
Cl
4-NO2
>300

214
Cl
2-CH3, 4-Cl
>300

215
Cl
2-CH3, 4-CH3
>300

216
Cl
2-C2H5
299.0 to

301.0

217
CH3
H
>300

[0077]

20

TABLE 13-2

Melting Point

Coupler No.
R1
(R2)n
(° C.)

218
CH3
2-OCH3
297

219
CH3
3-OCH3
>300

220
CH3
4-OCH3
>300

221
CH3
2-CH3
>300

222
CH3
3-OH3
>300

223
CH3
4-CH3
>300

224
CH3
2-Cl
>300

225
CH3
3-Cl
>300

226
CH3
4-Cl
>300

227
CH3
2-NO2
>300

228
CH3
3-NO2
>300

229
CH3
4-NO2
>300

230
CH3
2-CH3, 4-Cl
>300

231
CH3
2-CH3, 4-CH3
>300

232
CH3
2-C2H5
268.5 to 270.0

233
OCH3
H
289.0

234
OCH3
2-OCH3
268.0 to 270.0

235
OCH3
3-OCH3
>300

236
OCH3
4-OCH3
>300

237
OCH3
2-CH3
284.5 to 285.5

238
OCH3
3-CH3
>300

239
OCH3
4-CH3
>300

[0078]

21

TABLE 13-3

Melting Point

Coupler No.
R1
(R2)n
(° C.)

240
OCH3
2-Cl
>300

241
OCH3
3-Cl
>300

242
OCH3
4-Cl
>300

243
OCH3
2-NO2
>300

244
OCH3
3-NO2
>300

245
OCH3
4-NO2
>300

246
OCH3
2-C2H5
264.5 to

266.5

[0079]

22

TABLE 14-1

Coupler No.
Structure

247

248

249

250

251

252

253

[0080]

23

TABLE 14-2

Coupler No.
Structure

254

255

256

257

258

[0081]

24

TABLE 15

Coupler No.
(R2)n

259
2-Cl, 3-Cl

260
2-Cl, 4-Cl

261
3-Cl, 5-Cl

[0082]

25

TABLE 16

Coupler No.
(R2)n

262
4-CH3

263
3-NO2

264
2-Cl

265
3-Cl

266
4-Cl

267
2-Cl, 3-Cl

268
2-Cl, 4-Cl

269
3-Cl, 5-Cl

270
2-Cl, 5-Cl

271
3-Cl, 4-Cl

[0083] The charge generation layer can be formed by the following method:

[0084] (1) the above-mentioned charge generation materials are dispersed in a liquid solution of a binder resin such as polyester resins, polycarbonate resins, polyvinylbutyral resins and acrylic resins by a ball mill, an attritor, a sand mill, etc; and

[0085] (2) the dispersed liquid is properly diluted and coated on a substrate by a dip coating, a spray coating, a bead coating method, etc.

[0086] The relative mirror reflectance T1 of the present invention changes in accordance with the charge generation material. However, T1 can be also controlled by the dispersed condition of the charge generation material, and the affinity and mixing ratio of the pigment and the binder resin as well as the composition of the above-mentioned intermediate layer.

[0087] The charge generation layer preferably has a thickness of from 0.01 to 5 μm, and more preferably from 0.1 to 2 μm.

[0088] Charge Transport Layer

[0089] The charge transport layer is formed from a charge transport material and a binder resin which is optionally used. The material is dissolved or dispersed in a proper solvent, and the liquid solution is coated on a substrate and dried to form the charge transport layer.

[0090] As the charge transport materials, there are a hole transport material and an electron transport material.

[0091] Specific examples of the hole transport materials include electron imparting materials such as poly-N-vinylcarbazole and its derivatives, poly-γ-carbazolylethylgultamate and its derivatives, pyrene-formaldehyde condensates and their derivatives, polyvinylpyrene, polyvinylphenanthrene, oxazole derivatives, oxadiazole derivatives, imidazole derivatives, triphenylamine derivatives, 9-(P-diethylaminostyryl)anthracene, 1,1-bis-(4-dibenzylaminophenyl)propane, styrylanthracene, styrylpyrazoline, phenylhydrazone compounds and α-phenylstilbene derivatives.

[0092] Specific examples of the electron transport materials include electron accepting materials such as chloranil, bromoanil, tetracyanoethylene, tetracyanoquinodimethane, 2,4,7-trinitro-9-fluorenone, 2,4,5,7-tetranitro-9-40 fluorenone, 2,4,5,7-tetranitroxanthone, 2,4,8-trinitrothioxanthone, 2,6,8-trinitro-indeno [1,2-b] thiophene-4-one and 1,3,7-trinitrodibenzothiophene-5,5-dioxide. These charge transport materials can be used alone or in combination.

[0093] Specific examples of the binder resins for optional use in the present invention include thermoplastic or thermosetting resins such as polystyrene resins, styrene-acrylonitrile copolymers, styrene-butadiene copolymers, styrene-maleic anhydride copolymers, polyester resins, polyvinyl chloride resins, vinyl chloride-vinyl acetate copolymers, polyvinyl acetate resins, polyvinylidene chloride resins, polyarylate resins, polycarbonate resins, cellulose acetate resins, ethyl cellulose resins, polyvinyl butyral resins, polyvinyl formal resins, polyvinyl toluene resins, poly-N-vinylcarbazole resins, acrylic resins, silicone resins, epoxy resins, melamine resins, urethane resins, phenol resins and alkyd resins.

[0094] Specific examples of the solvents include tetrahydrofuran, dioxane, toluene, monochlorobenzene, dichloroethane, methylene chloride, etc.

[0095] The charge transport layer preferably has a thickness of from 5 to 100 μ/m.

[0096] In addition, a plasticizer and a leveling agent can be included in the charge transport layer of the present invention. As the plasticizer, conventional plasticizers for resins, such as dibutylphthalate and dioctylphthalate can be used. The content of the plasticizer is preferably from 0 to 30% by weight per 100% by weight of the binder resin. As the leveling agent, silicone oils such as dimethyl silicone oils and methyl phenyl silicone oils can be used. The content of the leveling agent is preferably from 0 to 1% by weight per 100% by weight of the binder resin.

[0097] In addition, an insulating layer and a protective layer can be formed on the photosensitive layer in the present invention.

[0098] Electroconductive Substrate

[0099] The substrate used for the photoreceptor of the present invention is formed as follows. Metals such as aluminium and nickel are deposited or laminated on metallic drums and sheets such as aluminium, brass, stainless and nickel; polyethyleneterephthalate; polypropylene; nylon; paper, etc. Among the substrates, a cylindrical drum formed of aluminium or its alloyed metals is widely used at present. Particularly, non-cut aluminium tube without a cutting process is preferably used because the manufacturing cost is lower and the adherence to the photosensitive layer is higher than that of a conventional cut aluminium tube.

[0100] In addition, the photoreceptor having the relative mirror reflectance of the present invention can prevent image-density irregularity of the resultant image even if the non-cut aluminium tube is used for the substrate.

[0101] Such aluminium alloys are formed by the method disclosed in JIS3003, 5000, 6000, etc. and the non-cut aluminium tube is formed by a conventional method such as EI, ED, DI and II methods.

[0102] In addition, neither a surface cut process and grind with a diamond turning tool, etc. nor a surface treatment such as anodizing is performed on the aluminium tube.

[0103] Electrophotographic Device and Method

[0104] Next, the electrophotographic process and device of the present invention will be explained in detail, referring to the drawings.

[0105]
FIG. 4 is a schematic view for explaining the electrophotographic process and device of the present invention, and the following modified example also belongs to the present invention. In FIG. 4, a photoreceptor 1 includes a drum substrate on which a photosensitive layer is formed. For a charger 3, a pre-transfer charger 7, a transfer charger 10, a separation charger 11 and a pre-cleaning charger 13, known chargers such as corotrons, scorotrons, solid state chargers and charging rollers are used. For the transfer means, the above-mentioned chargers can be used, however, a combination of a transfer charger 10 and a separation charger 11 as shown in FIG. 4 is effectively used. For an image irradiator 5, coherent light such as light emitting diodes (LEDS), laser diode (LDs) and electroluminescence (EL) lamps is used. As a light source for a discharging lamp 2, etc., any known illuminators such as fluorescent lamps, tungsten lamps, halogen lamps, mercury lamps, sodium lamps, light emitting diodes (LEDs), laser diodes (LDs) and electroluminescense (EL) lamps can be used. In order to irradiate only the light having a desired wavelength, various filters such as sharp cut filters, band pass filters, near infrared cutting filters, dichroic filters, interference filters and conversion filters can be also used. Such light sources can be also used for irradiating the photoreceptor in processes such as a transfer process combined with light irradiation, a charge eliminating process, a cleaning process, a pre-exposure process, etc. as well as the processes mentioned above.

[0106] Toner images formed on the photoreceptor 1 by developing unit 6 are transferred on a transfer paper 9. However, all of the toner particles of the toner images are not transferred on the transfer paper 9 and there also remain toner particles on the photoreceptor 1. Such toner particles are removed from photoreceptors by a fur brush 14 and a blade 15. Cleaning may be made only by a known cleaning brush such as fur brushes and mag-fur brushes.

[0107] When a photoreceptor is charge positively (negatively) and image exposure is performed, positive (negative) electrostatic latent images are formed on the surface of the photoreceptor. Positive images are obtained when the latent images are developed with negatively-charged (positively-charged) toners and negative images are obtained when the latent images are developed with positively-charged (negatively-charged) toners. As the developing method, known developing methods can be applied. In addition, known discharging methods can be used for discharging the charges remaining on the photoreceptor.

[0108]
FIG. 5 shows another embodiment of the electrophotographic process of the present invention. A photoreceptor 21 has the photosensitive layer of the present invention, and is driven by driving rollers 22a and 22b. The photoreceptor 21 is charged by a charger 23, and exposed to light emitted by a light source 24 to form a latent image thereon. Then the latent image is developed by an image developer (not illustrated) to form a toner image thereon. The toner image is transferred on a transfer paper (not shown) using a charger 25. The photoreceptor 21 is then subjected to a cleaning pre-exposure treatment using a light source 26, a cleaning treatment using a brush 27 and a discharging treatment using a light source 28. These processes are repeatedly performed to produce images. In FIG. 5, pre-cleaning light irradiates the photoreceptor 21 from the substrate side. (In this case, the substrate is transparent.) For instance, in FIG. 5, although the cleaning pre-exposure is made from the substrate side, the cleaning pre-exposure may be made from the photosensitive layer side. In addition, irradiation of image exposure and discharging can be made from the substrate side. With respect to the light irradiation processes, the image exposure, cleaning pre-exposure and discharging exposure are illustrated. However, light irradiation such as pre-transfer exposure, pre-exposure of image exposure and other known light irradiation processes can be made to the photoreceptors.

[0109] The electrophotographic device as mentioned above can be fixedly installed into copiers, facsimiles and printers. In addition, they can be installed into these devices in the form of a process cartridge as well. The process cartridge is a device (part) containing at least a photoreceptor, and at least one of a charger, an image irradiator, an image developer, an image transfer, a cleaner and a discharger. There are many types of process cartridges, however, FIG. 6 is a schematic view illustrating an embodiment of the process cartridge of the present invention. A photoreceptor 16 has a photosensitive layer of the present invention.

[0110] Having generally described this invention, further understanding can be obtained by reference to certain specific examples which are provided herein for the purpose of illustration only and are not intended to be limiting. In the descriptions in the following examples, the numbers represent weight ratios in parts, unless otherwise specified.

EXAMPLES

Example 1

[0111] After 100 parts of a polyamide resin (FR101 from Namariichi Co., Ltd.) and 100 parts of a melamine resin (Super Bekkamin G-821-50 from Dainippon Ink & Chemicals, Inc.) were dissolved in 850 parts of methanol, 600 parts of a fine powder of titanium oxide (TP-2 from Fuji Titanium Industry Co., Ltd.) were added into the solution and the solution was stirred for 120 hrs by a ball mill. Then, 350 parts of methanol was further added into the solution to dilute the solution and prepare a coating liquid for an intermediate layer. The liquid was coated on an aluminium-deposited polyester film (Lumirror from Toray Industries, Inc.), and dried for 20 min at 150° C. to form an intermediate layer having a thickness of 5 μm. The relative mirror reflectance of the thus formed intermediate layer against an aluminium-deposited mirror at an incident angle of 50 was measured by a self-recording spectrophotometer (UV-3100 from Shimadzu Corp.). The results were as follows:

[0112] 3.5% at a wavelength of 780 nm; and

[0113] 3.1% at a wavelength of 650 nm.

Example 2

[0114] After 100 parts of a polyamide resin (FR101 from Namariichi Co., Ltd.) and 100 parts of a melamine resin (Super Bekkamin G-821-50 from Dainippon Ink & Chemicals, Inc.) were dissolved in 1000 parts of methanol, 900 parts of a fine powder of titanium oxide (TP-2 from Fuji Titanium Industry Co., Ltd.) were added into the solution and the solution was stirred for 72 hrs by a ball mill. Then, 700 parts of methanol was further added into the solution to dilute the solution and prepare a coating liquid for an intermediate layer. The liquid was coated on an aluminium-deposited polyester film (Lumirror from Toray Industries, Inc.), and dried for 20 min at 150° C. to form an intermediate layer having a thickness of 5 am. The relative mirror reflectance of the thus formed intermediate layer against an aluminium-deposited mirror at an incident angle of 50 was measured by a self-recording spectrophotometer (UV-3100 from Shimadzu Corp.). The results were as follows:

[0115] 4.1% at a wavelength of 780 nm; and

[0116] 3.7% at a wavelength of 650 nm.

Examples 3 and 4

[0117] On the intermediate layers formed in Examples 1 and 2, a coating liquid for a charge generation layer having the following components which were mixed and stirred by a ball mill for 120 hrs, was coated and dried to form a charge generation layer having a thickness of 0.5 μm.

[0118] A disazo pigment 5 having the following formula (A)

26A polyvinylbutyral resin1(S-LEC BM-S from Sekisui Chemical Co., Ltd.)Cyclohexanone250

[0119] The relative mirror reflectance of the thus formed intermediate layers and charge generation layers against an aluminium-deposited mirror at an incident angle of 50 was measured by a self-recording spectrophotometer (UV-3100 from Shimadzu Corp.). The results were as follows:

[0120] 2.8% and 3.1% respectively at a wavelength of 780 nm; and

[0121] 2.6% and 2.9% respectively at a wavelength of 650 nm.

Examples 5 and 6

[0122] On the intermediate layers formed in Examples 1 and 2, a coating liquid for a charge generation layer having the following components which were mixed and stirred by a ball mill for 120 hrs, was coated and dried to form a charge generation layer having a thickness of 0.5 μm.

[0123] A disazo pigment 1.5 having the following formula (A)

27A poly-vinylbutyral resin1(XYHL from Union Carbide Corp.)Cyclohexanone250

[0124] The relative mirror reflectance of the thus formed intermediate layers and charge generation layers against an aluminium-deposited mirror at an incident angle of 50 was measured by a self-recording spectrophotometer (Uv-3100 from Shimadzu Corp.). The results were as follows:

[0125] 2.6% and 2.9% respectively at a wavelength of 780 nm; and

[0126] 2.4% and 2.7% respectively at a wavelength of 650 nm.

Comparative Examples 1 and 2

[0127] On the intermediate layers formed in Examples 1 and 2, a coating liquid for a charge generation layer having the following components which were mixed and stirred by a ball mill for 24 hrs, was coated and dried to form a charge generation layer having a thickness of 0.3 μm.

28A-type titanylphthalocyanine5A polyvinylbutyral resin5(S-LEC BM-S from Sekisui Chemical Co., LTD.)Methyl ethyl ketone350

[0128] The relative mirror reflectance of the thus formed intermediate layers and charge generation layers against an aluminium-deposited mirror at an incident angle of 5° was measured by a self-recording spectrophotometer (UV-3100 from Shimadzu Corp.). The results were as follows:

[0129] 4.0% and 4.5% respectively at a wavelength of 780 nm; and

[0130] 3.6% and 4.1% respectively at a wavelength of 650 nm.

Examples 7 and 8

[0131] On the intermediate layers formed in Examples 1 and 2, a coating liquid for a charge generation layer having the following components which were mixed and stirred by a ball mill for 120 hrs, was coated and dried to form a charge generation layer having a thickness of 0.4 μm.

29A-type titanylphthalocyanine5A disazo pigment5

[0132] having the following formula (B)

30A polyvinylbutyral resin5(S-LEC BM-S from Sekisui Chemical Co., LTD.)Cyclohexanone250

[0133] The relative mirror reflectance of the thus formed intermediate layers and charge generation layers against an aluminium-deposited mirror at an incident angle of 5° was measured by a self-recording spectrophotometer (UV-3100 from Shimadzu Corp.). The results were as follows:

[0134] 2.9% and 3.3 respectively at a wavelength of 780 nm; and

[0135] 2.7% and 3.1% respectively at a wavelength of 650 nm.

Examples 9 to 14 and Comparative Examples 3 to 4

[0136] The procedures of Examples 3 to 8 and Comparative Examples 1 to 2 were repeated except that each coating liquid was coated on a non-cut aluminium tube formed by an ED method, having an outer diameter of 30 mm and a length of 340 mm. A coating liquid for a charge transport layer having the following components was further coated on each coated tube, and dried to form a charge transport layer having a thickness of 20 μm.

314-diethylaminobenzaldehyde-1-benzyl-1-phenylhydrazne7Polycarbonate10(Iupilon from Mitsubishi Gas Chemical Co., Inc.)Tetrahydrofuran76

[0137] Thus, photoreceptors of Examples 9 to 14 and Comparative Examples 3 to 4 were prepared.

Examples 15 to 20 and Comparative Examples 5 to 6

[0138] The procedures for preparation of photoreceptors of Examples 9 to 14 and Comparative Examples 3 to 4 were repeated except for using a cut aluminium having an outer diameter of 30 mm and a length of 340 mm.

[0139] After the thus prepared photoreceptors of Examples 9 to 20 and Comparative Examples 3 to 6 were installed in the electrophotographic process cartridge shown in FIG. 6, each process cartridge was installed in the following electrophotographic processes A to E shown in FIG. 4.

32Wavelength oflight source forDiameter of imageimage irradiatorwriting light beamLight spot interval/(LD)by a polygon mirroroverlapped areaA780 nm75 × 85 μm64 μm/44%B780 nm50 × 60 μm42 μm/50%C780 nm55 × 70 μm55 μm/70%D650 nm30 × 40 μm21 μm/95%E650 nm16 × 20 μm11 μm/98%

[0140] A halftone image was produced from each electrophotographic process and the image-density irregularity due to light interference was evaluated. The results are shown in Table 17.

33TABLE 17RMR-RMR-Sub-IDIILCGstrateABCDEEx. 93.5/3.12.8/2.6Non-cut◯◯◯◯◯Ex. 104.1/3.73.1/2.9Non-cut◯◯◯◯ΔEx. 113.5/3.12.6/2.4Non-cut◯◯◯◯◯Ex. 124.1/3.72.9/2.7Non-cut◯◯◯◯ΔCom. Ex.3.5/3.14.0/3.6Non-cutΔΔXΔX3Com. Ex.4.1/3.74.5/4.1Non-cutXXXXX4Ex. 133.5/3.12.9/2.7Non-cut◯◯◯◯◯Ex. 144.1/3.73.3/3.1Non-cut◯ΔΔΔXEx. 153.5/3.12.8/2.6Cut◯◯◯◯◯Ex. 164.1/3.73.1/2.9Cut◯◯◯◯◯Ex. 173.5/3.12.6/2.4Cut◯◯◯◯◯Ex. 184.1/3.72.9/2.7Cut◯◯◯◯◯Com. Ex.3.5/3.14.0/3.6CutΔΔΔΔX5Com. Ex.4.1/3.74.5/4.1CutXXXXX6Ex. 193.5/3.12.9/2.7Cut◯◯◯◯◯Ex. 204.1/3.73.3/3.1Cut◯◯◯◯ΔRMR-IL: Relative mirror reflectance of intermediate layer RMR-CGL: Relative mirror reflectance of charge generation layer IDI: Image-density irregularity ◯: Image-density irregularity did not occur Δ: Image-density irregularity slightly occurred X: Image-density irregularity occurred

[0141] On the other hand, durability test for Example 9 and Comparative Example 15 was performed by producing continuous 50,000 images. It was observed that the end of the photosensitive layer of the photoreceptor of Example 15 was partly peeled off, and that the non-cut aluminium tube used in Example 9 had higher adherence to the photosensitive layer than that of Example 15.

[0142] This document claims priority and contains subject matter related to Japanese Patent Application No. 2001-086067 filed on Mar. 23, 2001, incorporated herein by reference.

[0143] Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit and scope of the invention as set forth therein.

Electrophotographic image forming apparatus and process cartridge, and electrophotographic photoreceptor therefor

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