JPH0643664A - Ionographic charge receiver and manufacture of photosensitive-body base body - Google Patents

Abstract

PURPOSE: To obtain an ionography charge receiver and photoreceptor which are easily producible, light in weight and low in cost by producing this ionography charge receiver by injection molding a dielectric material into a molding chamber thereby forming the molded dielectric layer. CONSTITUTION: When a core 22 is completely inserted into a cavity 21, the injection moldable material is extruded from an injection orifice 24. The moldable material is admitted preferably in a molten state into the mold cavity 21 and is cooled preferably before the core 22 is removed. The moldable material is cured to a cylindrical substrate 26 to be afterward removed from the metal molds. The substrate preferably includes the characteristic part of the end completely molded for easily operating or synchronizing the final device. For example, the characteristic part of the end has a gear device which is meshed with an operating device or synchronizing device. The formation of the photoreceptor is executed by injection molding a conductive material into a molding chamber to form a conductive layer and disposing a photoconductive material on the outer surface of the conductive layer.

Description

Detailed Description of the Invention

FIELD OF THE INVENTION This invention relates to ionographic charge receivers and methods of making photoreceptors. More specifically, the present invention relates to a method for producing an ionographic charge receiver and a photosensitive substrate, and more particularly to a method for producing an ionographic charge receiver and a photosensitive substrate formed by injection molding a molding material.

BACKGROUND OF THE INVENTION Ionographic charge receivers are designed to come into contact with a stream of ions generated by an ion source (eg, corona, needle, ionographic head, etc.) to form a charge image on the receiver that can be subsequently developed. To do. Ionographic charge receivers generally have two layers, an inner conductive layer and an outer dielectric layer. Previously, ionographic charge receivers were made by coating a dielectric material on a metal or alloy substrate or substrate with a conductive coating. The charge receiver manufactured in this way is heavy and expensive,
Manufacturing is complex and costly. When a heavy receiver stops, it produces high rotational moments, which can lead to poor mechanical performance. There is a need for inexpensive, lightweight ionographic charge receivers that have high resolution and are especially usable after use. Photoreceptors such as ionographic charge receivers have a surface on which a charge image can be formed and subsequently developed. Photoreceptors require a photoconductive material that conducts and charges when illuminated. The photoconductor was manufactured by the manufacturing technique as described above. Metal substrates or substrates with functional coatings are coated with various layers (typically on the outer surface) to form a composite photoreceptor. Like ionographic charge receivers, photoreceptors produced by such techniques require complex molding steps and expensive substrates. There is a demand for inexpensive and lightweight photoconductors that have high resolution and can be used especially.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an ionographic charge receiver and photoreceptor which is easy to manufacture, lightweight and inexpensive. A further object of the present invention is to provide an ionographic charge receiver and photoreceptor substrate that is easy to manufacture, lightweight and inexpensive. These and other features are provided by the present invention.

According to the present invention, an ionographic charge receiver is manufactured by injection molding a dielectric material into a molding chamber to form a molded dielectric layer. The dielectric material preferably comprises a dielectrically added polymeric material. Subsequently, a conductive material is molded on the inner surface of the dielectric layer to form the conductive layer. Other methods of disposing the conductive material layer include spray coating, dip coating, brush coating, powder coating or flow coating. Alternatively, the conductive material can be first molded to form the conductive layer and then the dielectric material can be injection molded to form the inductive layer outside the dielectric layer. According to the present invention, to form a photoreceptor, a conductive material is injection molded in a molding chamber to form a conductive layer and a photoconductive material is disposed on the outer surface of the conductive layer. The conductive material preferably comprises a conductively added polymeric material. Additional layers such as a conductive layer, blocking layer, adhesive layer, photogenerating layer, transport layer and overcoat layer may also be disposed outside the conductive layer. These layers are formed in any suitable order. Preferably the conductive layer is first molded, then the other layers are applied from the inside to the outside, and finally the outermost layer. In accordance with the present invention, it is possible to injection mold a dielectric layer for an ionographic charge receiver by tailoring the dielectric material to meet a particular need (eg, sufficient dielectric strength), and the receiver can be of a suitable electrical conductivity. It has mechanical and mechanical properties. The ability to injection mold such layers is a great advantage. In this way, the charge receiver can be manufactured very inexpensively and a high quality surface can be obtained. Similarly, the present invention provides an injection moldable conductive material for the manufacture of photoreceptors and a conductive layer suitable as a substrate for the photoreceptor. This makes the photoreceptor cheaper to manufacture and enables the photoreceptor to have high quality surface characteristics. The invention will be better understood with reference to the following drawings and description. It is to be understood that the invention is subject to all modifications within the skill of the ordinary artisan. 1 is a schematic representation of the mold used according to the invention in which the substrate is molded; FIG. 2 has the mold core rotating away from the mold cavity 1
Fig. 3 is a schematic diagram of the mold shown in Fig. 3; Fig. 3 is a schematic diagram of the mold used to manufacture the substrate according to the present invention; Fig. 4 is a schematic diagram of the mold shown in Fig. 3 further including a stripper member. 5 is a schematic diagram of a chain used to limit the extension of the mold cavity from the mold core; FIG. 6 is an end schematic diagram of a photoreceptor made in accordance with the present invention. FIG. 7 is an end schematic view of an ionographic charge receiver made in accordance with the present invention; FIG. 8 is
FIG. 9 is a graph showing charge level versus duty cycle number for ionographic substrates prepared according to the present invention; FIG. 9 shows the effective permittivity for initial charge acceptance of various weight additions of barium titanate in Lexan. FIG. 10 is a graph showing; FIG. 10, Celcon C
9 is a graph showing a photodischarge curve of a KX5200 (registered trademark) -coated substrate. High quality surface photoreceptors or ionographic charge receiver substrates are produced according to the present invention by injection molding the substrate, preferably in a cylindrical injection mold. The injection material is preferably a polymeric material that is either conductively (for the conductive layer) or dielectrically (for the dielectric layer) added. A good quality injection mold can improve the quality of the molded substrate. For example, the mold has a high tolerance of good surface finish (eg 5
It can be manufactured on the order of 0.8-127 μm (2-5 μin), which gives the substrate a similar surface quality. It is feasible to use a high quality mold according to the present invention, as the mold can be used repeatedly to make many substrates. Referring to FIGS. 1 to 4, the mold includes a cavity 21 provided on a base 19, a base 18 and a core 22 provided on a removing member 34. The material from which the mold is formed can be selected from metals, alloys and other materials that provide a high quality surface finish. Both the cavity 21 and the core 22 are cylindrical so that a tubular or cylindrical substrate is formed. As shown in FIG. 3, when the core 22 is fully inserted into the cavity 21, the injection moldable material is extruded through the injection orifice 24. The moldable material preferably enters the mold cavity 21 in the molten state and is preferably cooled before the core 22 is removed. The moldable material is subsequently cured into a cylindrical substrate 26 which can be demolded. The substrate preferably includes fully shaped end features for easy operation or synchronization of the final device. For example, the end feature has a gear device, which is meshed with a driving device or a synchronizing device. To move the molded substrate, the core 22 is pulled by moving the base 18 (to the left, as shown in Figure 1), and the entire base rotates about the pivot 36 (as shown in Figure 2). Counterclockwise). The connecting device 27 holds the mold cavity 21 and the mold core 22, and is arranged so that the core 22 can move from the cavity 21. The connecting device shown in FIGS. 1 and 2 has a collapsible device 27. A guide rod 28 is provided on the base 18 for accurately guiding the core 22 into the cavity 21 and maintaining a uniform gap therebetween, and the guide rod 28 moves in parallel with the core 22. It fits snugly into the provided guide cavity 29. The guide cavity 29 has almost the same depth as the mold cavity 21. Once the injection moldable material hardens in the mold to form the substrate 26, it becomes difficult to move the substrate 26 out of the mold, especially from the core 22 of the substrate 26. For this movement, a removing member 34 is provided as shown in FIGS. Extraction member 34
As shown in FIG. 5, the mold cavity 21 is held by the pin 50 while the mold is opened, and the molded product 26 is moved from the mold core 22. After the mold has opened the passage, the pin 50 moves the extraction member 34 to slide over the mold core 22. Then the mold is fully opened. Referring to FIG. 4, the extraction member 34 is a part of the extraction bar 33,
It includes a housing 35 to which a spring 32 is attached. The spring 32 works by contacting the base 18 at one end and the base 19 at the other end. The molding substrate 26 is removed by pushing the core 22 by the extracting member 34 so that the core 22 and the cavity 21 are separated from each other. The housing 35 is mounted so as to slide on the guide rod 28. The base 18 is the extension 3 of the housing 35.
It has a recess 18a that engages with 5a. When the core 22 is completely inserted into the cavity 21 (see FIG. 3), the extraction bar 33 flushes with the base 18 at one end and the other end 19 at 19. According to the present invention, a photoreceptor having one or more layers coated on the outside of a substrate is produced. Such functional layers are disclosed in detail in US Pat. No. 4,747,992 [Sypula et al.], The entire disclosure of which is incorporated herein. The functional layer is selected from the group consisting of a conductive layer, a blocking layer, an adhesive layer, a charge photogenerating layer, a charge transport layer, an overcoat protective layer and the like. FIG. 6 shows a photoreceptor made according to the present invention having a substrate 61 and a functional photoreceptor layer 62 (eg zinc oxide in a binder). The base material is polypropylene, nylon,
It may comprise polyester, or preferably polyacetal. Rear erase (backside)
A substrate made of a transparent material capable of erasing is suitable. In accordance with the present invention, the photoreceptor may be made with a ground plane, such as a transparent conductive coating such as copper iodide. An advantage of the polymeric substrate according to the present invention is that it also serves as a support surface for the developer housing (similar to substrates made of aluminum, for example). The photogenerating layer may have a single layer or multiple layers containing an inorganic or organic composition or the like. An example of a generator layer is disclosed in U.S. Pat. No. 3,121,006, in which fine particles of a photoconductive inorganic compound are dispersed in an electrically insulating organic resin binder. Useful binder materials disclosed therein are those that cannot carry injected charge carriers generated by the photoconductive particles that far. Therefore, the photoconductive particles must be in substantially continuous particle-particle contact within the layer to enable the charge distribution required for cyclic operation. Therefore, about 50% by volume photoconductive particles are usually needed to obtain sufficient photoconductive particle-particle contact for rapid discharge. Examples of photogenerating layers are trigonal selenium, various phthalocyanine pigments such as the X-form of the metal-free phthalocyanines disclosed in U.S. Pat. No. 3,357,989, metal phthalocyanines such as copper phthalocyanine, quinacridone ( Available from DuPont under the tradenames Monastral Red, Monastral Violet and Monastral Red Y), US Pat. No. 3,44.
Substituted 2,4-diaminotriazines disclosed in US Pat. No. 2,781, polynuclear aromatic quinones (trade names: India First Double Scarlet, India First Violet Lake B, India First Brilliant Scarlet, India First Orange, Allied Chemical Corporation) Available). Examples of photosensitive members having at least two electrically actuated layers are US Pat. No. 4,265,990, US Pat. No. 4,233,3.
84, US Pat. No. 4,306,008 and US Pat. No. 4,299,897; transport layer members;
Oxazole, pyrazolone, imidazole, bromopyrene, nitrofluorene and nitronaphthalimide derivatives and dye-containing generating layers containing the charge transport layer members disclosed in US Pat. No. 3,895,944; US Pat. No. 4,150,987. Hydrazones and charge generating layers including charge transport layer members disclosed in US Pat. No. 3,837,
No. 851, including a charge transport layer member disclosed in US Pat.
Including an arylpyrazoline and a generating layer. The disclosures of these patents are incorporated herein by reference in their entirety. The photogenerating layer containing the photoconductive composition and / or pigment and the resin binder material generally has a thickness of from about 0.1 μm to about 5.
0 μm range, and preferably from about 0.3 μm
Having about 1 μm. Thicknesses outside these ranges can be selected provided the objects of the invention are provided. The photogenerating composition or pigment may be present in the film forming the polymeric binder composition in various amounts. For example, about 10 to about 60% by volume pigment is dispersed in about 40 to about 90% by volume film-forming polymeric binder composition, and particularly preferably about 20 to about 30% by volume photogenerating pigment is about 70 to about 70% by volume. About 8
Dispersed in 0% by volume of the film-forming polymer binder composition. The particle size of the photogenerating composition and / or pigment is less than the thickness of the added solidification layer, more preferably between about 0.01 μm and about 0.5 μm to promote good coating uniformity. A suitable transport layer is provided as one of the coatings of the present invention to form a multilayer photoconductor. The transport layer comprises a film forming polymeric binder and a charge transport material. Suitable multilayer photoconductors have a charge generating layer having a layer of photoconductive material and a molecular weight of about 20,000 to about 120,000 with about 25 to about 75 wt% of the general formula dispersed therein. :

[Chemical 1] (In the formula, R ₁ and R ₂ are substituted or unsubstituted phenyl groups,
An aromatic group selected from the group consisting of a naphthyl group and a polyphenyl group; R ₄ has a substituted or unsubstituted biphenyl group, a diphenyl ether group, an alkyl group having 1 to 18 carbon atoms and 3 to 12 carbon atoms A continuous charge transport layer of a polycarbonate resin material having one or more compounds selected from the group consisting of alicyclic groups; X is selected from the group consisting of alkyl groups having 1 to about 4 carbon atoms and chlorine). And the photoconductive layer exhibits photogeneration of holes and hole injection, and the charge transport layer has substantially no absorption in the spectral range where the conductive layer produces and injects photogenerated holes. It is possible to support the injection of photogenerated holes from the photoconductive layer and move the holes within the charge transport layer. A charge-transporting aromatic amine of the above structural formula for a charge-transporting layer capable of supporting the injection of photogenerated holes in the charge-generating layer and allowing holes to move within the charge transport, and other examples are in inert resin binders. N, N'-bis (alkylphenyl)-[1,1'-biphenyl] -4,4'diamine (where alkyl is, for example, methyl, ethyl, propyl, n-butyl, etc.), N , N'-diphenyl-
N, N'-bis (chlorophenyl)-[1,1'-biphenyl] -4,4'-diamine, N, N'-diphenyl-N, N'-bis (3 "-methylphenyl)-(1,
1'-biphenyl) -4,4'-diamine. Examples of these transport materials are disclosed, for example, in US Pat. No. 4,265,990 to Storka et al.
All disclosures are incorporated herein by reference. Other examples of charge transport layers that support the injection of photogenerated holes in the charge generation layer and allow the migration of holes within the charge transport layer are triphenylmethane, bis, dispersed in an inert resin binder. (4-diethylamine-2-methylphenyl) -phenylmethane; 4'-4 "-bis (diethylamino)-
Including 2 ', 2 "-dimethyltriphenylmethane and the like.
Numerous inert resin materials, including, for example, the resins disclosed in US Pat. No. 3,121,006, may be used in the charge transport layer, the entire disclosure of which is incorporated herein by reference. . The resin binder for the charge transport layer is the same as the resin binder material used for the charge generation layer. Typical organic resin binders are polycarbonate, polyester, polyamide, polyurethane, polystyrene,
Polyaryl ether, polyaryl sulfone, polybutadiene, polysulfone, polyether sulfone, polyethylene, polypropylene, polyimide, polymethylpentene, polyphenylene sulfide, polyvinyl acetate, polysiloxane, polyacrylate, polyvinyl acetal, polyamide, polyimide, amino resin, phenylene oxide Resin, terephthalic acid resin, epoxy resin, phenol resin, polystyrene-acrylonitrile copolymer, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, acrylate copolymer, alkyd resin, cellulose film former (c
ellulosic film formers), poly (amide imide), styrene-butadiene copolymer, vinylidene chloride-vinyl chloride copolymer,
Vinyl acetate, -vinylidene chloride copolymer,
Includes thermoplastic or thermosetting resins such as styrene-alkyd resins. These polymers can be block, random or alternating copolymers. Generally, the thickness of the solidified transport layer is between about 5 and 100 microns, although thicknesses outside this range may be used. The charge transport layer should be insulating to the extent that it does not conduct at a rate sufficient to prevent the formation and retention of an electrostatic latent image on the transport layer when the electrostatic charge on the charge transport layer is not irradiated. Generally, the thickness ratio of the solidified charge transport layer to the charge generating layer is preferably maintained between about 2: 1 and 200: 1, and may be 400: 1. FIG. 7 shows an ionographic charge receiver made in accordance with the present invention. The receiver has a dielectric layer 10 and a conductive layer 11. The dielectric layer preferably has a high dielectric pigment dispersed in a binder resin. Barium titanate is a preferred pigment. Specific electrical properties are designed directly into the receiver by adjusting the pigment concentration in the binder resin, suitable design of the injection molding tool to control the wall thickness, or both. The pigment concentration is adjusted by adjusting the dielectric constant ε of the dispersion. Depending on the wall thickness, the receiver can be manufactured with a dielectric constant of 1.5. The combination of different pigments and / or conductive particles is also used to adjust the dielectric constant of the dispersion. In particular various metal oxides and combinations of oxides can be used. Metal particles are used to control the conductivity of the dispersion. Examples of compounds used to adjust the dielectric and conductive properties of dispersions are:
Barium titanate, titanium dioxide, molybdenum, molybdenum compounds, carbon black, other metal oxides, cadmium sulfoselenide, zinc oxide, cadmium sulfide, lead oxide, mercury sulfide, other photoactive pigments, electromagnetic radiation sensitive materials, trigonal selenium , Phthalocyanine-based pigments, metal cyanines, quinacridones, substituted 2,4-diaminotriazines, polynuclear aromatic quinones and combinations thereof. Various high dielectric solid pigments can be used in combination with various injection moldable polymers to form dielectric materials. Injection moldable polymers can be used alone if they exhibit suitable electrical properties. Polymer combinations may also be used in the dispersion. Preferably, these polymers are compatible with each other and provide suitable surface properties for injection molded ionographic charge receivers. Polycarbonates, polystyrenes and polypropylenes are useful as binder resins. The conductive layer on the inner surface of the dielectric layer can be any suitable conductive material. For example, carbon black in the form of pigments, fibers, etc. dispersed in a binder and applied by spray coating, dip coating, brush coating, powder coating or flow coating,
Coatings including silver, copper, aluminum, nickel, steel, etc. can be used. The coating is applied as a primer, preferably by brushing. Preferably the coating comprises an aliphatically unsaturated hydrocarbon polymer. Corona treatment of surfaces that are coated for good adhesion is also used. The conductive coating is also a two-part injection molding method (two-part injection method).
can be directly injection molded using conductive injection molding polymers currently available for ion molding processes. In this example, two injection units are mounted in a two-cavity mold with one press. The inner conductive layer is first molded onto the core to make the conductive layer, the mold is opened and the conductive layer is moved to the next cavity. The mold is then closed and the outer dielectric layer is injected. The increased wall thickness provided by this two-step injection method aids in the transfer of the finished ionographic charge receiver from the mold without having to move the conductive layer from the core until both the conductive and dielectric layers have been formed. When injection molding the dielectric layer, a gear can be advantageously and essentially formed at one end of the tube, providing a suitable means for rotational movement. The use of this method reduces costs considerably. Also, injection molding methods and machines are readily available in many stores and do not require a controlled environment to operate.

EXAMPLES Examples 1-3 below disclose experimental examples in which a conductive substrate for a photoreceptor is made of a material having a surface resistivity of less than 10 ⁴ Ω / □ (ohms / sq.).

Example 1 Two polymeric molding materials, ie about 40% by weight
Of Talc and polypropylene containing 1% by weight of carbon black, and a conductive material Stat-Con M-1® (Stat-Kon M-1) containing about 20% by weight of carbon black (Pennsylvania). The second material, a polypropylene copolymer available from LNP, Inc., Malvern, canton was conductive. These conductive materials have an outer diameter of 8.38 cm (3.3 in),
Each was molded in a mold designed to produce a molded substrate having a length of 39.75 cm (15.65 in) and a film thickness of 90 mil (2.286 mm). Talc filled polypropylene was used to determine if the mold was suitable. This test involved filling the mold and unloading the substrate from the core (no taper or draft). The resulting substrate is of good quality and
It does not have a dividing surface because it is a two-part type uniform cylindrical design with a withdrawal member. The Stat-Con M-1 conductive material was then used to make the substrate. It has been found to be of good quality with minimal surface waviness along the length of the substrate and with good uniformity and smoothness. 1.27 cm
A striped pattern of (0.5 in) wide glossy and matte areas was found on these substrates. It is clear that the pattern is the result of material flow into the 90 mil (2.286 mm) wall passages of the mold. In particular, it is clear that the material is cooled and then extruded along the mold passages. This development can probably be eliminated by using materials with good flow properties. Substrates made with talc-filled polypropylene have very low post-molding shrinkage, while substrates made with Stat-Con M-1 have relatively high post-molding shrinkage. In general, the dimensions of substrates molded from talc-filled polypropylene are very close to the intended ones. To obtain the predetermined dimensions on the Stat-Con M-1,
The mold must be fitted to compensate for shrinkage.
The surface of the Stat-Con M-1 substrate exhibits a rough surface due to the random presence of peaks and valleys, generally about 119.
The finish is 38 μm (4.7 μin). The surface showed measurements indicating that there was relatively little or no difference between streaks and areas without streaks. The substrate straightness from end to end was 6.2 mils (0.157 mm). Coating Stat-Con M-1 substrate with selenium by vacuum deposition,
A photoconductor was formed. When the substrate was heated to 55 ° C. during vapor deposition, gas evolution of low molecular weight components occurred from the substrate. This caused bubbling in the selenium coating that prevented further print testing. The electrical properties of this photoreceptor were measured and compared to standard selenium and arsenic alloy controls with an aluminum substrate. Initial cycle and electrophotographic discharge results for these photoreceptors are similar to those for Stat-Con M-1 substrates, which is comparable to standard selenium on aluminum, arsenic alloys.

[Embodiment 2] In this embodiment, Procond L (Proco
nd L) (registered trademark) and Procond Q (Proco
nd Q) (registered trademark) (Cincinnati, Ohio,
Conductively added polypropylene available from United Composites); Magnex EC22
3 (Magnex EC223) (registered trademark) (polypropylene / carbon black available from Mitec, Inc., Wilowby, Ohio); and Stud-Con M-2 (registered trademark).
(Conductively added polypropylene available from LNP Company, Malvern City, PA) was used as an injection molding component. Magnex EC223 did not give an acceptable surface quality. The substrate molded with Procond L had no striped pattern on the surface. Stat-Con M-
In No. 2, there was a striped pattern at the end of the substrate farthest from the place where the molten plastic entered the mold. Substrates molded with Procond Q had a corrugated surface. This may be because this material is softer and has a different main component compared to Procond L. Substrate shrinkage was observed within 24 hours of molding. The substrate had almost the desired dimensions immediately after molding,
It gradually contracted over time. Stat-Con M-
As described above for 1, the size of the mold can be chosen to compensate for this shrinkage. The above linearity measurements of the substrate showed that, while the material was soft, flare occurred at one end contacted by the extraction bar due to removal of the substrate from the mold. The linearity problem can be corrected by machining. SEM analysis of the substrate molded from Stat-Con M-2 and the substrate molded from Stat-Con M-1 from the first mold run during this mold run was performed, and the gloss and matte were alternately streaked. It was confirmed whether there was a microscopic difference between the marked parts. Analysis is Stat-Con M-
The matte part of one substrate was shown to have a noticeably rough surface condition with long and deep gouges as compared to the shiny surface. The differences between the respective counterparts of the Stat-Con M-2 samples are small, with the matte areas having a more irregular and smaller surface morphology compared to the glossy areas. Three Procond L substrates were coated with the organophotoreceptor material. Two were negatively charged devices with a generator layer in the bottom layer and one was a positively charged device with a generator layer in the top layer. The generator layer comprises 35% by weight of vanadyl phthalocyanine in PE-100® (polyester available from Goodyear) and the transport layer is Marlon M-50.
35% by weight of bistriarylamine in (registered trademark) (Merlon M-50) (a polycarbonate resin available from Mobay Chemical Company). Both negatively charged photoreceptors had very low charge acceptance, evidence of charge injection from the substrate, and the need for a charge blocking layer. Positively charged photoreceptor is standard Xerox 4045 (X
The electrical characteristics of the EROX 4045) (registered trademark) photoreceptor were comparable.

[Example 3] Procond OB
(Registered trademark) (conductively added polypropylene available from United Composites, Inc., Cincinnati, OH) and Vestamide X3666 (Vestam).
id X3666) (a conductively added nylon material available from Nudex, Inc., Piscataway, NJ) was used for the molded conductive layer. Further, the substrate was formed of talc-filled polypropylene. Some applications require substrates with non-conducting components; talc-filled propylene is very cheap,
It has enhanced good physical properties and imparts good mechanical properties. Procond OB (registered trademark) is Procond L
It gave a substrate with better surface quality than the substrate produced by the trade name. X3666® nylon has a striped pattern, but generally gave a substrate of good quality. The talc-filled polypropylene substrate had stripes on the surface, but the surface was very smooth with almost no waviness. This material had a small shrinkage due to the large amount of talc added. In addition to the usual measurements, the overall index run-out of the talc-filled polypropylene substrate was measured in relation to the stainless steel master cylinder. The latter has a run-out of about 0.5 mil (0.0127 mm), which indicates the quality of the measuring instrument. The former is rotational runout 2.
It was 4 mils (0.0610 mm). The other substrates that had shrunk after molding did not fit the end supports of the instrument due to their small internal diameter, and rotational runout could not be measured. A substrate molded with Vestamide X3666 (registered trademark) was spray-coated with an organic photosensitive material to produce a positively charged photosensitive material. When the electrical properties were measured, the photoreceptor showed good cycling and discharge properties. The unovercoated photoreceptor was print tested on a Xerox 4045® machine. Due to the fact that the photoreceptor was not overcoated, the machine was different from the electrical characteristics of the Xerox 4045® photoreceptor for which it was designed, and there was variation in the developed image. However, these results indicate that this photoreceptor is functional, and perhaps better than selenium, arsenic alloy overcoats. Another substrate made with Stat-Con M-2 described in the Examples was spray coated with an organophotoreceptor material to produce a positively charged photoreceptor. This photoconductor is made of selenium and arsenic alloy.
Further overcoating at 5 μm, a Xerox 4045 photoconductor was manufactured, and the electrical characteristics were measured. They showed good cycling and discharge characteristics. This photoreceptor gave very good print test results.

Example 4 Cercon CKX5200 (Celcon
CKX5200) (conductivity-added polyacetal of Cellanies Engineering Co., Chatham, NJ) and Barox 310 (Valox 310).
A conductive substrate was molded using (polybutylene terephthalate, a conductive additive based on polyester, manufactured by General Electric Co., Pittsfield, Mass.). Polyacetal materials are engineering grade resins that improve properties and processability. It is manufactured under controlled conditions compared to other molding resins that are blends of specially available resin materials.
The CKX5200 substrate had minor surface defects due to material non-uniformity, while Valox 310 had problems with demolding. Reshaping may be necessary to obtain acceptable results. The CKX5200 substrate was coated as a photoreceptor substrate in vacuum with selenium 40 μm at 65 ° C. for evaluation. The electrical characteristics are 150 nanocoulombs / cm ² (ncoul / cm
² ) Measured under ambient conditions with charging and photodischarge at 450 nm. The average charge voltage level of the photoreceptor was about 1000 volts and was uniform around the circumference with a dark decay of about 32V for 1 second. Residual potential gradually increased to 10 in cycle 1
It increased from V to almost 80 V in cycle 200. This was a corresponding increase in charging voltage level. The photoconductor has a low thickness corresponding to the thickness.
The sensitivity was 7.5 V / erg / cm ² . The photodischarge curve is shown in FIG. The following examples relate to the manufacture of ionographic charge receiver substrates.

Example 5 Lexan 3250 (registered trademark) (Lexa
n3250) (thermoplastic polycarbonate condensation product of bisphenol-A with phosgene of General Electric) and various weight additions of barium titanate were tested.
The dielectric constants of dielectric materials with various barium titanate concentrations were measured. The effective dielectric constants of the materials shown in Table I below were tested after corona charging. Samples are brush grained aluminum f
molded into lat plates), mounted on a portion of a 26.4 cm drum in a perimeter scanner and rotated at 60 and / or 120 RPM. Continuous charging of a 5 cm wide single wire corotron (+ and-) 0.1,0.
A constant current mode, which provides a charging current of 2, 0.5 and / or 1.0 μA, was used. Charging was stopped before the 40 V / μm field appeared on the sample. Positive and negative charging and brush grounding methods were used to erase the charge during the experiment. Not all currents and speeds were used for each sample, but various combinations plus charge loss time from several charge levels were performed for each sample to measure charge decay and saturation effects. Referring to FIG. 8, the dielectric constant is the first 4-
Calculated based on the initial slope charge from 0 volts as measured for 10 cycles. The sample used for the measurement illustrated in FIG. 8 was a 60% BaTiO ₃ addition sample. This sample is applied current (chargi
ng current) 0.5 μA and 60 RPM scanner rotation speed using dielectric constant 6.88
Met. In this example and the other examples, the voltage increase per charging cycle decreased as the charge increased. It was observed that some samples reached a saturation charge level where the voltage (and such charge) did not increase further. Field dependent dependence on charge loss (Field dependent)
Loss of charge is also seen in Figure 8. The effective dielectric constant gives a measure of the voltage level reached by applying corona ions to the surface of the sample, assuming charge capacity. The saturation effect (seen as non-capacitive charging) increases the apparent dielectric constant for high charging levels. Therefore, the voltage that reached the higher surface charge density is lower than the value calculated from the values listed below.

[Table 1] FIG. 9 shows the dielectric constant of the above material plotted as a function of the weight addition of BaTiO ₃ . For a binary system, the dielectric constant is calculated as follows: Log ε = V _a Log ε _a + V _b Log ε _b where V _x is the% capacitance of component x and ε _x is the dielectric constant of component x. . Each BaTiO ₃ in Lexan density 6.08 g / cm ³ and 1.22g / cm ³ ε _a = 5
Assuming 000 and ε _b = 2.00, the theoretical curve shown in Figure 9 is obtained. The measured dielectric constant is about half the value expected from this equation. When the sample is charged to 20 V / μm, the "average" dielectric constant is obtained as a factor of twice the initial value. This factor depends on the applied current and the cycle time. This non-linear charging is 0.5 μA, 60R
It is shown in FIG. 8 for the 60% BaTiO ₃ additive sample showing the PM charging curve. A material with an effective permittivity around 10 is achieved in this way. This effective permittivity is a useful number for increasing corona charge up to 5 V / μm. At higher electric fields, one expects a sub-linear charging of up to twice the "average" dielectric constant. Ionographic charge receivers made in accordance with the present invention were tested in Examples 6 and 7.

Example 6 75 wt% BaTiO ₃ is hot melt dispersed in polypropylene by extrusion and has an outer diameter of about 8.
38 cm (3.3 in), length about 7.62 cm (3i
n) and an average film thickness of 73 mils (1.85 mm) used as feedstock for casting. The inner surface of the tube was brushed using a conductive olefin primer that functions as a ground plane. Commercially available olefin primer used was LE 12644 available from Red Spot Paint and Burnish. The ε of this component is about 19.
It is 5.

[Example 7] A tube was manufactured in the same manner as in Example 6 and had a thickness of 750 µm and 87
The average thickness between 5 μm was scraped off. A conductive primer was applied to the inner surface as was done in Example 6.
A print test of this charge receiver gives a resolution of about 1
Images of 50 spi and high density were obtained. The effective dielectric thickness of the drum is between 38 and 45. Although the method according to the invention has been described in connection with the preferred embodiments, additions, modifications, substitutions and deletions not expressly stated without departing from the spirit of the invention and the scope of the claimed invention are made. Those of ordinary skill in the art will understand that this is possible.

[Brief description of drawings]

FIG. 1 is a schematic diagram of a mold used in accordance with the present invention.

2 is a schematic diagram of the mold of FIG. 1 with the mold core rotating away from the mold cavity.

FIG. 3 is a schematic diagram of a mold used to manufacture a substrate according to the present invention.

FIG. 4 is a schematic view of the mold of FIG. 3 further including an extraction member.

FIG. 5 is a schematic diagram of a chain used to limit the extension of the mold cavity from the mold core.

FIG. 6 is a schematic end view of a photoreceptor produced according to the present invention.

FIG. 7 is a schematic end view of an ionographic charge receiver made in accordance with the present invention.

FIG. 8 is a graph showing the charge level versus the number of duty cycles for an ionographic substrate made according to the present invention.

FIG. 9 is a graph showing the effective dielectric constant for initial charge acceptance of various weight additions of barium titanate in Lexan.

FIG. 10 is a graph showing a photodischarge curve of a Celcon CKX5200 coated substrate.

[Explanation of symbols]

10 ... Dielectric layer 11 Conductive layer 18,
19 ... Base 21 ... Cavity 22 ... Core 24 ...
Injection orifice 26 ... Cylindrical substrate 28 ... Guide rod 29 ...
Guide cavity 32 ... Spring 33 ... Extraction bar 34 ...
Extraction member 35 ... Housing 36 ... Pivot 50 ...
Pin 61 ... Base 62 ... Functional layer

 ─────────────────────────────────────────────────── ─── Continued Front Page (72) Inventor Dennis A. Abramson, New York, USA 14534 Pittsford Crestview Live 23 (72) Inventor, John Em Harts, USA New York, 14610 Rochester Astor Drive 130 (72) Inventor, Andrew Earl Melnik, USA New York 14610 Rochester Windmere Road 140 (72) Inventor John W. Spiurek United States New York 14580 Webster Saffron Lane 773 (72) Inventor Edward Sea Williams United States New York 14522 Palmyra Canaan Dig Road 126 (72) Inventor Eric Jay United States New York 14580 Webster Colonial Drive 253 (72) Inventor Kennis Ewood USA New York 14502 Macedan Macedan Center Road 1855 (72) Inventor Clifford H Griffith United States New York 14534 Pittsford Toby Road 230 (72) Inventor Joseph Manmino United States New York 14526 Penfield Bella Drive 59 (72) Inventor John Frank United States New York 14580 Webster Robin Hood Lane 1340 (72) Inventor Jay Michael Issler United States New York 14519 Ontario Appletree Drive 2141 (72) Inventor Merlin E Scarf New York, USA 14526 Penfield Valley Green Live 273 (72) Inventor Donald Jay Tenney New York, United States 14616 Rochester Tanglewood Drive 49 (72) Inventor Deborah Jay Nicol Landry United States New York 14612 Rochester Wood Run 176 (72) Inventor Antony F Lipani New York 14534 Pittsford Bridgewater Drive 10 (72) Inventor Paul Jay Black United States New York 14617 Rochester Oak Bend Lane 15

Claims (1)

[Claims] 1. An injection-molded conductive layer formed of a conductive material; and one or more functional layers disposed outside the conductive layer.
A photoconductor having.