JP3624713B2 - Electrophotographic photoreceptor and method for producing the same - Google Patents
Electrophotographic photoreceptor and method for producing the same Download PDFInfo
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Description
【０００１】
【発明の属する技術分野】
本発明は、塗布膜の形成方法及び電子写真感光体の製造方法に関するものである。詳しくは、特定の塗布液を施すことを特徴とする塗膜の形成方法及び特定の下引き塗布液を施すことを特徴とする電子写真感光体の製造方法に関するものである。
【０００２】
【従来の技術】
アルコール可溶性樹脂を含有する塗布膜を形成する方法は、アルコールのみに可溶する樹脂の場合は、当然溶媒としてアルコールを主とする溶媒が用いられるが、アルコール以外の溶媒にも溶解する樹脂についても、コスト及び安全性、更に特性向上のために、金属酸化物粒子等が含有する場合が多く、そして、その金属酸化物粒子の分散性等の理由で、溶媒として低級アルコールを主成分とする塗布液により形成されるのが一般的であった。
【０００３】
更に、その金属酸化物粒子も、更なる特性向上のために、有機化合物或いは金属原子を有する有機化合物で処理されたものも使用されるようになってきた。
尚、本明細書中で、低級アルコールとは、炭素数が８以下の直鎖及び分岐を有するアルコールを表す。
電子写真感光体分野においては、感光波長域の選択容易性、製造の容易性（塗布による製造が可能）、安全性の面でも無公害な材料を選択できる点などから有機光導電体（ＯＰＣ）が、感光体の主流になってきた。このＯＰＣの構成も電荷発生材料、電荷輸送材料をバインダー中に分散した単層型や電荷発生層、電荷輸送層と機能を分離した積層型など、種々の構成のものが開発されているが、基体の上に電荷発生層、電荷輸送層の順に積層された積層型が一般的である。
【０００４】
更に、近年では、電気特性、画像特性、機械特性の向上を図るために、基体上に下引き層を形成し、その後感光層を形成するものが、最も主流となってきている。
下引き層のバインダー樹脂としては、基体との接着性、耐溶剤性（電荷発生層及び電荷輸送層の溶剤）、塗工性、電気的バリア性といった点で、アルコール可溶性樹脂、特にアルコール可溶性ポリアミド樹脂が好ましい樹脂として検討、使用されることが多い。
【０００５】
更に、下引き層としての要求特性を満足させるために、下引き層に、金属酸化物粒子等の無機粒子、特に酸化チタン粒子等が含有されていることが多い。更に、下引き層としての性能を向上させるために、該金属酸化物粒子が有機化合物処理されているのが一般的になってきている。特に、有機珪素化合物のように、金属原子を含有する有機化合物で処理されているのが一般的になりつつある。
このような少なくともアルコール可溶性樹脂及び有機化合物処理された金属酸化物粒子を含有する下引き層を有する電子写真感光体を製造する場合は、溶媒として、低級アルコールを主成分とした塗布液で塗布を行い、下引き層を形成し、更に感光層を塗布することにより一般的には製造されていた。
【０００６】
【発明が解決しようとする課題】
ところで、有機化合物処理された金属酸化物粒子を含む下引き塗布液を作製する場合は、一般的には、分散処理及び加熱処理等を行うため、金属酸化物に処理を施している有機化合物が塗布液中に遊離してくる。
また、作製後も経時とともに、金属酸化物に処理を施している有機化合物が塗布液中に遊離してくる。現状では、有機化合物処理剤の遊離を完全に抑制するのは、困難である。また、特性を向上させる有機化合物処理剤は、一般的には、低級アルコールや水との相溶性が悪いものが多い。それ故に、有機化合物処理された金属酸化物粒子とアルコール可溶性樹脂を含む下引き層の製造方法において、溶媒として低級アルコールを主成分とした塗布液を用いた場合、金属酸化物から遊離してきた有機化合物の処理剤が、塗布液中で会合しやすく、そのため塗布時にハジキ等の塗布欠陥が発生しやすく、良好な塗布膜が形成されにくいという問題があった。特に電子写真感光体の場合は、これらの下引き層のハジキ等の欠陥は、画像欠陥に繋がることが多く、歩留まりの低下に繋がり、大きな問題となる。
【０００７】
【課題を解決するための手段】
以下に、対策及び効果として、電子写真感光体の製造方法に限定して記述するが、他の塗膜形成においても、必然的に同様の効果が得られる。
本発明者らは、上記問題を解決するため鋭意検討した結果、少なくともアルコール可溶性樹脂と有機化合物処理された金属酸化物粒子とを含有する下引き層を有する電子写真感光体を製造する方法において、金属酸化物粒子を予め洗浄処理することにより、下引き層塗布時の塗布性の改善、塗布液の保存安定性向上に特に有効であることを見出し、本発明を完成させた。
【０００８】
すなわち、本発明の要旨は、導電性基体上に少なくとも下引き層及び感光層を有し、該下引き層が有機化合物で表面処理された金属酸化物粒子とバインダー樹脂を有する電子写真感光体の製造方法において、該金属酸化物粒子を有機溶媒で洗浄処理した後にバインダー樹脂に分散させることを特徴とする電子写真感光体の製造方法に存する。
【０００９】
【発明の実施の形態】
以下、本発明を詳細に説明する。
本発明において作製される下引き層のアルコール可溶性樹脂としては、ポリビニルブチラール等のポリビニルアセタール、セルロース、ポリアミド等が挙げられるが、基体との接着性、耐溶剤性、電気的バリア性、塗工性等から、ポリアミド樹脂が好ましい。その中でも下引き層としての性能及び塗布液の安定性の面で、下記一般式（Ｉ）で示されるジアミン成分を構成成分として有する共重合ポリアミド樹脂が特に好ましい樹脂である。
【００１０】
【化１】
（式中、環Ａ、環Ｂはそれぞれ独立して置換基を有していても良いシクロヘキシル基を表し、Ｒ１、Ｒ２はそれぞれ独立して水素原子、アルキル基、アルコキシ基、アリール基を表す。）
もう一方の構成成分である金属酸化物粒子は、有機化合物処理されているが、好ましくは、金属原子を含有する有機化合物で処理されていることが好ましい。その中でも、有機珪素化合物が一般的であり、特にジメチルポリシロキサン及びメチル水素ポリシロキサン等のポリシロキサン化合物が好ましい。金属酸化物粒子としては、酸化チタンがより好ましい例として挙げられる。
【００１２】
金属酸化物粒子の洗浄に用いる有機溶媒としては炭化水素系溶媒が好ましく、例えばベンゼン、トルエン、キシレン等の芳香族炭化水素または直鎖状もしくは分岐状のペンタン、ヘキサン、ヘプタン、あるいはシクロヘキサン等の脂肪族炭化水素が挙げられ、特に好ましくはトルエン、ヘキサン等である。
【００１３】
下引き塗布液の溶媒としては、低級アルコールが主成分として用いられる。特に炭素数４以下のアルコールがバインダー樹脂の溶解性から一般的に用いられ、メタノール、エタノール、ｎ−プロパノール、イソプロパノール、ｎ−ブタノールが好ましい。
主成分以外の溶媒としては、それらの溶媒の役割に応じて、任意の溶媒を選択することができるが、炭素数９以上のアルコール、炭化水素、ケトン類、エーテル類等が好ましい。
【００１４】
有機化合物処理された金属酸化物粒子と、アルコール可溶性樹脂の比は任意に選択できるが、特性及び塗布液の安定性の面から、重量比で、０．５／１から１０／１の範囲が好ましく、より好ましくは、２／１から５／１の範囲である。
更に、塗布性、分散粒子の分散性を改良する目的で、各種の界面活性剤を添加しても良い。その他、レベリング剤や酸化防止剤を含んでいても良い。
【００１５】
上記、下引き塗布液は、下記のように作製される。有機化合物処理された金属酸化物粒子をボールミル、コボールミル、サンドミル等で分散処理を行った後、適度な濃度に希釈してスラリーを作製する。上記スラリーに、予め溶媒で溶解しておいたバインダー溶解液を加えて混合し、下引き塗布液を作製する。又は、上記スラリーにバインダーペレット及び粉末を直接添加し、混合、撹拌し、上記バインダーを溶解し、下引き塗布液とする。また、逆に、バインダー溶解液に有機化合物処理の金属酸化物粒子を添加し、上記分散処理を行うことでも作製できる。これらの製造過程において、各種添加物は、任意に添加できる。また、必要に応じて、加熱処理、超音波処理等が加えられても良い。
このようにして作製された下引き塗布液は、基体上に塗布され、乾燥することにより下引き層が形成されるが、この時の塗布方法としては、スプレー塗布、ノズル塗布、ブレード塗布、スピンコート、浸漬塗布等いずれの方法を用いても良いが、電子写真感光体の塗布については、浸漬塗布が一般的に用いられる。
【００１６】
【実施例】
以下、実施例、比較例により本発明を更に具体的に説明するが、本発明はその要旨を越えない限り、これらに限定されるものでは無い。なお、実施例中及び比較例中及び参考例中で用いる「部」は断りがない限り、「重量部」を示す。
尚、各実施例、比較例とも、バインダー樹脂として、下記の構造式を持つ共重合ポリアミドＡを用いた。
【００１７】
【化２】
分散液（Ｐ）の調液
酸化チタンとして、石原産業（株）製：商品名ＴＴＯ５５Ｎを用い、ＴＴＯ５５Ｎに、メチル水素ポリシロキサンを３重量％処理した酸化チタン１．２部をトルエン４部に混合し、４時間撹拌した後に、分離、乾燥した。この洗浄した酸化チタンを予めボールミルにより分散し、その酸化チタンスラリーに、共重合ポリアミドＡ溶解液を混合し、更に超音波分散処理を行い、溶媒組成が、メタノール／ｎ−プロパノール＝７／３で、酸化チタン／ナイロン＝３／１で、固形分濃度１８重量％の分散液を調整し、これを分散液（Ｐ）とした。
【００１９】
分散液（Ｑ）の調液
酸化チタンとして、石原産業（株）製：商品名ＴＴＯ５５Ｎを用い、ＴＴＯ５５Ｎに、メチル水素ポリシロキサンを３重量％処理した酸化チタンを洗浄することなく、予めボールミルにより分散し、その酸化チタンスラリーに、共重合ポリアミドＡ溶解液を混合し、更に超音波分散処理を行い、溶媒組成が、メタノール／ｎ−プロパノール＝７／３で、酸化チタン／ナイロン＝３／１で、固形分濃度１８重量％の分散液を調整し、これを分散液（Ｑ）とした。
【００２０】
実施例１
分散液（Ｐ）に、表面が鏡面仕上げされた外径６０ｍｍ、長さ３５０ｍｍ、肉厚１．０ｍｍのアルミニウム製シリンダーを浸漬塗布し、その乾燥膜厚が、０．７５μｍとなるように下引き層を設けた。このようにして、ドラムを２本作製し、そのドラムに発生したハジキ欠陥の数を数えたところ、１本あたりの平均として、７個のハジキ欠陥が発生していた。
【００２１】
比較例１
分散液（Ｑ）に、表面が鏡面仕上げされた外径６０ｍｍ、長さ３５０ｍｍ、肉厚１．０ｍｍのアルミニウム製シリンダーを浸漬塗布し、その乾燥膜厚が、０．７５μｍとなるように下引き層を設けた。このようにして、ドラムを２本作製し、そのドラムに発生したハジキ欠陥の数を数えたところ、１本あたりの平均として、６６４個のハジキ欠陥が発生していた。
以上の結果から、本発明の電子写真感光体の製造方法は、塗布時のハジキ発生の抑制に効果が有り、その結果、電子写真感光体の製造時の歩留まりが向上し、生産コストの低減に繋がる。よって、本発明の電子写真感光体の製造方法は、非常に優れた方法であるといえる。
【００２２】
【発明の効果】
本発明の電子写真感光体の製造方法によれば、従来の洗浄処理していない金属酸化物粒子を含有する下引き塗布液と比べ、下引き層塗布時のハジキ等の塗布欠陥が減少し、歩留まり向上に効果が有り、優れた電子写真感光体の製造方法を提供できる。尚、本明細書では、電子写真感光体の製造方法について、実施例を挙げて説明したが、他の用途の塗布膜の形成においても、同様な効果が得られる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for forming a coating film and a method for producing an electrophotographic photosensitive member. More specifically, the present invention relates to a method for forming a coating film characterized by applying a specific coating solution and a method for producing an electrophotographic photoreceptor characterized by applying a specific undercoat coating solution.
[0002]
[Prior art]
As a method of forming a coating film containing an alcohol-soluble resin, in the case of a resin that is soluble only in alcohol, naturally a solvent mainly composed of alcohol is used as a solvent, but a resin that is soluble in a solvent other than alcohol is also used. In order to improve cost, safety, and characteristics, metal oxide particles are often contained, and for reasons such as dispersibility of the metal oxide particles, a coating mainly containing a lower alcohol as a solvent. It was generally formed by a liquid.
[0003]
Further, the metal oxide particles have been used which are treated with an organic compound or an organic compound having a metal atom in order to further improve the characteristics.
In the present specification, the lower alcohol represents a linear and branched alcohol having 8 or less carbon atoms.
In the field of electrophotographic photoreceptors, organic photoconductors (OPCs) can be selected because of the ease of selection of the photosensitive wavelength range, ease of manufacturing (manufacturing by coating), and safety-friendly materials can be selected. However, it has become the mainstream of photoconductors. Various OPC configurations have been developed, such as a charge generation material, a single layer type in which a charge transport material is dispersed in a binder, a charge generation layer, and a stacked type in which the function is separated from the charge transport layer. A laminate type in which a charge generation layer and a charge transport layer are laminated in this order on a substrate is common.
[0004]
Further, in recent years, in order to improve electrical characteristics, image characteristics, and mechanical characteristics, an undercoat layer is formed on a substrate, and then a photosensitive layer is formed mainly.
The binder resin for the undercoat layer is an alcohol-soluble resin, particularly an alcohol-soluble polyamide, in terms of adhesion to the substrate, solvent resistance (solvent for the charge generation layer and charge transport layer), coating properties, and electrical barrier properties. Resins are often studied and used as preferred resins.
[0005]
Furthermore, in order to satisfy the required characteristics as the undercoat layer, the undercoat layer often contains inorganic particles such as metal oxide particles, particularly titanium oxide particles. Furthermore, in order to improve the performance as the undercoat layer, the metal oxide particles are generally treated with an organic compound. In particular, it is becoming common to treat with an organic compound containing a metal atom, such as an organosilicon compound.
When producing an electrophotographic photosensitive member having an undercoat layer containing at least an alcohol-soluble resin and an organic compound-treated metal oxide particle, the coating is performed with a coating solution mainly composed of a lower alcohol as a solvent. In general, it has been produced by forming an undercoat layer and further applying a photosensitive layer.
[0006]
[Problems to be solved by the invention]
By the way, in the case of preparing an undercoating coating solution containing metal oxide particles that have been treated with an organic compound, generally, an organic compound that has been treated with a metal oxide is used to perform a dispersion treatment, a heat treatment, and the like. Releases into the coating solution.
Further, with the passage of time even after the production, the organic compound that is treating the metal oxide is released into the coating solution. At present, it is difficult to completely suppress the release of the organic compound treating agent. In general, many organic compound treating agents that improve the properties have poor compatibility with lower alcohols and water. Therefore, in a method for producing an undercoat layer containing metal oxide particles treated with an organic compound and an alcohol-soluble resin, when a coating liquid containing a lower alcohol as a main component is used as a solvent, the organic released from the metal oxide The compound treating agent is likely to associate in the coating solution, so that coating defects such as repelling are likely to occur during coating, and a good coating film is difficult to form. In particular, in the case of an electrophotographic photosensitive member, defects such as repelling in the undercoat layer often lead to image defects, leading to a decrease in yield, which is a serious problem.
[0007]
[Means for Solving the Problems]
In the following, as a countermeasure and an effect, the description is limited to the production method of the electrophotographic photosensitive member, but the same effect is inevitably obtained in the formation of other coating films.
As a result of intensive studies to solve the above problems, the present inventors have obtained a method for producing an electrophotographic photoreceptor having an undercoat layer containing at least an alcohol-soluble resin and metal oxide particles treated with an organic compound. The present inventors completed the present invention by finding that the metal oxide particles are particularly effective for improving the coating property during coating of the undercoat layer and improving the storage stability of the coating solution by washing the metal oxide particles in advance.
[0008]
That is, the gist of the present invention is an electrophotographic photosensitive member having at least an undercoat layer and a photosensitive layer on a conductive substrate, the undercoat layer having metal oxide particles surface-treated with an organic compound and a binder resin. In the production method, the present invention resides in a method for producing an electrophotographic photoreceptor, wherein the metal oxide particles are washed with an organic solvent and then dispersed in a binder resin.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
Examples of the alcohol-soluble resin for the undercoat layer produced in the present invention include polyvinyl acetal such as polyvinyl butyral, cellulose, polyamide, etc., but adhesion to the substrate, solvent resistance, electrical barrier properties, and coating properties. From the above, a polyamide resin is preferable. Among them, a copolymerized polyamide resin having a diamine component represented by the following general formula (I) as a constituent component is a particularly preferable resin in terms of performance as an undercoat layer and stability of a coating solution.
[0010]
[Chemical 1]
(In the formula, ring A and ring B each independently represent a cyclohexyl group which may have a substituent, and R1 and R2 each independently represent a hydrogen atom, an alkyl group, an alkoxy group or an aryl group. )
The metal oxide particles as the other constituent component are treated with an organic compound, but are preferably treated with an organic compound containing a metal atom. Among these, organosilicon compounds are common, and polysiloxane compounds such as dimethylpolysiloxane and methylhydrogen polysiloxane are particularly preferable. As a metal oxide particle, a titanium oxide is mentioned as a more preferable example.
[0012]
The organic solvent used for washing the metal oxide particles is preferably a hydrocarbon solvent, for example, an aromatic hydrocarbon such as benzene, toluene or xylene, or a fat such as linear or branched pentane, hexane, heptane, or cyclohexane. Group hydrocarbon, and particularly preferably toluene, hexane and the like.
[0013]
As a solvent for the undercoat coating solution, a lower alcohol is used as a main component. In particular, alcohols having 4 or less carbon atoms are generally used because of the solubility of the binder resin, and methanol, ethanol, n-propanol, isopropanol, and n-butanol are preferred.
As the solvent other than the main component, any solvent can be selected according to the role of the solvent, but alcohols, hydrocarbons, ketones, ethers and the like having 9 or more carbon atoms are preferable.
[0014]
The ratio between the metal oxide particles treated with the organic compound and the alcohol-soluble resin can be arbitrarily selected. However, in terms of characteristics and stability of the coating solution, the weight ratio ranges from 0.5 / 1 to 10/1. Preferably, it is in the range of 2/1 to 5/1.
Furthermore, various surfactants may be added for the purpose of improving coating properties and dispersibility of dispersed particles. In addition, a leveling agent and an antioxidant may be included.
[0015]
The above undercoat coating solution is prepared as follows. The metal oxide particles treated with the organic compound are subjected to a dispersion treatment with a ball mill, a coball mill, a sand mill or the like, and then diluted to an appropriate concentration to prepare a slurry. A binder solution previously dissolved in a solvent is added to the slurry and mixed to prepare an undercoat coating solution. Alternatively, binder pellets and powder are directly added to the slurry, mixed and stirred, and the binder is dissolved to obtain an undercoat coating solution. Conversely, it can also be produced by adding organic compound-treated metal oxide particles to the binder solution and carrying out the dispersion treatment. In these production processes, various additives can be arbitrarily added. Moreover, heat processing, ultrasonic processing, etc. may be added as needed.
The undercoat coating solution thus prepared is applied onto a substrate and dried to form an undercoat layer. At this time, spray coating, nozzle coating, blade coating, spin coating, etc. Any method such as coating or dip coating may be used, but dip coating is generally used for coating the electrophotographic photosensitive member.
[0016]
【Example】
EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further more concretely, this invention is not limited to these, unless the summary is exceeded. In the examples, comparative examples and reference examples, “parts” means “parts by weight” unless otherwise specified.
In each Example and Comparative Example, copolymer polyamide A having the following structural formula was used as the binder resin.
[0017]
[Chemical formula 2]
Dispersed liquid (P) was prepared by using Ishihara Sangyo Co., Ltd. product name: TTO55N. Mixing 4 parts of toluene with 1.2 parts of titanium oxide treated with 3% by weight of methylhydrogenpolysiloxane. After stirring for 4 hours, it was separated and dried. This washed titanium oxide is dispersed in advance by a ball mill, the copolymerized polyamide A solution is mixed with the titanium oxide slurry, and further subjected to ultrasonic dispersion treatment. The solvent composition is methanol / n-propanol = 7/3. A dispersion having a solid content concentration of 18% by weight with titanium oxide / nylon = 3/1 was prepared, and this was designated as dispersion (P).
[0019]
Dispersed liquid (Q) was prepared by using Ishihara Sangyo Co., Ltd. product name: TTO55N. Dispersed in a ball mill in advance without washing titanium oxide treated with 3% by weight of methylhydrogenpolysiloxane in TTO55N. The titanium oxide slurry is mixed with a copolymerized polyamide A solution, further subjected to ultrasonic dispersion treatment, and the solvent composition is methanol / n-propanol = 7/3 and titanium oxide / nylon = 3/1. A dispersion having a solid content concentration of 18% by weight was prepared, and this was designated as dispersion (Q).
[0020]
Example 1
An aluminum cylinder having an outer diameter of 60 mm, a length of 350 mm, and a wall thickness of 1.0 mm is dip-coated on the dispersion liquid (P), and the coating is subbed so that the dry film thickness becomes 0.75 μm. A layer was provided. In this way, when two drums were produced and the number of cissing defects generated on the drums was counted, seven cissing defects occurred as an average per one drum.
[0021]
Comparative Example 1
An aluminum cylinder having an outer diameter of 60 mm, a length of 350 mm, and a wall thickness of 1.0 mm is dip-applied to the dispersion liquid (Q), and the coating is subbed so that the dry film thickness becomes 0.75 μm. A layer was provided. In this way, when two drums were produced and the number of cissing defects generated on the drum was counted, 664 cissing defects occurred as an average per one drum.
From the above results, the method for producing an electrophotographic photosensitive member of the present invention is effective in suppressing the occurrence of repelling during coating, and as a result, the yield during production of the electrophotographic photosensitive member is improved and the production cost is reduced. Connected. Therefore, it can be said that the method for producing an electrophotographic photoreceptor of the present invention is a very excellent method.
[0022]
【The invention's effect】
According to the method for producing an electrophotographic photoreceptor of the present invention, coating defects such as repellency during coating of a subbing layer are reduced, compared to a subbing coating solution containing metal oxide particles that have not been subjected to conventional cleaning treatment, It is effective in improving the yield and can provide an excellent method for producing an electrophotographic photosensitive member. In the present specification, the method for producing an electrophotographic photosensitive member has been described with reference to examples, but the same effect can be obtained in the formation of a coating film for other purposes.
Claims (5)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP28250298A JP3624713B2 (en) | 1998-10-05 | 1998-10-05 | Electrophotographic photoreceptor and method for producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP28250298A JP3624713B2 (en) | 1998-10-05 | 1998-10-05 | Electrophotographic photoreceptor and method for producing the same |
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| Publication Number | Publication Date |
|---|---|
| JP2000112164A JP2000112164A (en) | 2000-04-21 |
| JP3624713B2 true JP3624713B2 (en) | 2005-03-02 |
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| JP28250298A Expired - Fee Related JP3624713B2 (en) | 1998-10-05 | 1998-10-05 | Electrophotographic photoreceptor and method for producing the same |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| TWI453552B (en) * | 2008-12-16 | 2014-09-21 | Fuji Electric Co Ltd | An electrophotographic photoreceptor, a manufacturing method thereof, and an electrophotographic apparatus |
| JP6307899B2 (en) * | 2014-01-29 | 2018-04-11 | コニカミノルタ株式会社 | Method for producing electrophotographic photosensitive member |
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