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(12) Patent Application Publication (10) Pub. No.: US 2002/0197549 A1 Sakon Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2002/0197549 A1 Sakon Et Al US 2002O197549A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2002/0197549 A1 Sakon et al. (43) Pub. Date: Dec. 26, 2002 (54) MULTILAYER ELECTROPHOTOGRAPHIC (30) Foreign Application Priority Data PHOTORECEPTOR, AND IMAGE FORMING METHOD, IMAGE FORMING APPARATUS Nov. 10, 2000 (JP)...................................... 2OOO-342999 AND PROCESS CARTRIDGE USING THE Apr. 4, 2001 (JP)...................................... 2001-105675 PHOTORECEPTOR Oct. 4, 2001 (JP)...................................... 2001-308556 Publication Classification (76) Inventors: Yohta Sakon, Numazu-shi (JP); Akio (51) Int. Cl. ................................................ G03G 5/147 Kosuge, Yokohama-shi (JP); Tatsuya (52) U.S. Cl. ............................... 430/66; 430/125; 430/67 Niimi, Numazu-shi (JP); Narihito Kojima, Numazu-shi (JP) (57) ABSTRACT An electrophotographic photoreceptor including at least an electroconductive Substrate; and a photoSensitive layer over Correspondence Address: lying the electroconductive Substrate and including at least OBLON SPIVAK MCCLELLAND MAIER & a charge generation layer, a charge transport layer, and a NEUSTADT PC protective layer including a filler, wherein the filler is FOURTH FLOOR dispersed in the protective layer So as to occupy an area of 1755JEFFERSON DAVIS HIGHWAY from 3 to 5% of a cross section of the protective layer; the ARLINGTON, VA 2.2202 (US) filler has particle diameter distribution having a peak at a diameter of from 0.2 to 0.3 um; and the particles of the filler (21) Appl. No.: 09/985,368 having a particle diameter of not leSS than 0.3 um occupies an area of from 10 to 30% of the area of all the filler in the (22) Filed: Nov. 2, 2001 croSS Section of the protective layer. Patent Application Publication Dec. 26, 2002 Sheet 1 of 3 US 2002/0197549 A1 FIG. 1 aus FIG. 2 Patent Application Publication Dec. 26, 2002 Sheet 2 of 3 US 2002/0197549 A1 FIG. 3 15 Patent Application Publication Dec. 26, 2002 Sheet 3 of 3 US 2002/0197549 A1 US 2002/0197549 A1 Dec. 26, 2002 MULTILAYER ELECTROPHOTOGRAPHIC resistance; good chemical Stability against heat, light and PHOTORECEPTOR, AND IMAGE FORMING discharge-induced products (e.g. oZone and Nox), etc. METHOD, IMAGE FORMINGAPPARATUS AND 0017. Above all, a need exists for a photoreceptor having PROCESS CARTRIDGE USING THE a Small diameter because there is a demand for downsizing PHOTORECEPTOR electrophotographic Systems. Therefore, there is a demand for a photoreceptor having good durability against abrasion BACKGROUND OF THE INVENTION increasing in proportion to the number of copies. 0001) 1. Field of the Invention 0018 Thus, mechanical durability, which typically 0002 The present invention relates to a multilayer elec means abrasion resistance, is in Strong demand. However, trophotographic photoreceptor, and to an image forming the conventional organic photoreceptors and the electropho method, an image forming apparatus and a process cartridge tographic processes using these photoreceptors do not have for an image forming apparatus using the photoreceptor. high durability due to the low abrasion resistance of the organic materials used. In addition, the demand for a pho 0.003 2. Discussion of the Background toreceptor having good abrasion resistance has increased 0004 Electrophotographic methods such as the Carlson because the thickness of a photosensitive layer has to be proceSS and its various modified processes are widely used decreased So as to produce higher definition images. for copiers, printers, etc. AS an electrophotographic photo receptor (hereinafter referred to as a photoreceptor) for use 0019. The reason why the thickness of a photosensitive in the electrophotographic method, an organic photoreceptor layer has a particularly big influence on producing higher has been typically used because of its low cost, the ease of definition images is considered as follows. mass producing it, and because it is non-polluting. A mecha 0020. Among positive and negative carriers formed in the nism of forming an electrostatic latent image on a photore charge generation layer of a negatively chargeable multi ceptor include: layer organic photoreceptor by light irradiation, the negative carrier (an electron) is absorbed in the Substrate and the 0005 (1) irradiating a photoreceptor after it has been positive carrier (a hole) is transported through the charge charged; transport layer to the Surface of the photoreceptor to be 0006 (2) the irradiated light is then absorbed in a combined with an electron thereat, resulting in disappear charge generation material of the photoreceptor; ance of the hole. 0007 (3) the light-absorbed charge generation material 0021. Due to the disappearance, the electric field to generates a charge carrier; attract the hole gradually decreases, and the hole moves toward a non-lighted area. 0008 (4) the charge carrier is injected into a charge 0022. This is called a carrier scattering phenomenon in a transport material and transported through the charge direction of the Surface of the photoreceptor, and because of transport layer (or the photosensitive layer) along an it formation of a latent image faithful to the irradiated light electric field generated by the charge, and is prevented. This results in formation of a poor image 0009 (5) the charge carrier neutralizes the charge on having low resolution. the Surface of the photoreceptor to form an electroStatic 0023 The thickness of the charge transport layer has a latent image. big influence on the carrier Scattering phenomenon, and 0.010 Specific examples of organic photoreceptors making the thickneSS Smaller is very effective relative to include the following photoSensitive layers: maintaining good image resolution. 0011 (1) photoconductive resin layers typified by 0024. In addition, laser irradiation is different from irra diation by a halogen lamp, etc. because the incident photon polyvinylcarbazole (PVK); current speed of a laser is about 10 times as fast as that of 0012 (2) charge transfer complex type photosensitive a halogen lamp. Therefore, the density of the formed carriers layers typified by 2,4,7-trinitrofluorenon (PVK-TNF); is extremely high, and the electric field Strength of the charge generation layer decreases because charges flow into the 0013 (3) pigment dispersion type photosensitive lay charge transport layer. Thus, the carrier transport Speed is erS typified by phthalocyanine-binder, and influenced, resulting in late arrival of the carrier formed by 0014 (4) functionally-separated photosensitive layers irradiation of the center portion of the laser beam to the using a combination of a charge generation material Surface of the photoreceptor. The thus formed Space charge and a charge transport material. distribution tends to cause carrier Scattering in a direction parallel to the Surface of the photoreceptor, resulting in 0.015 Among these photoreceptors, the functionally deterioration of image resolution. Separated photoreceptors have attracted attention and come 0025 Japanese Laid-Open Patent Publication No. into practical use. 57-30846 discloses a method for improving abrasion resis 0016 Various organic photoreceptors have been devel tance of an organic photoreceptor, which includes a protec oped. However, in order to make a good photoreceptor tive layer including a filler formed from a metal or a metal requires good electrophotographic properties Such as high oxide. The object of this method is to increase the transpar Sensitivity, high potential, high potential retainability, good ency of the protective layer and prevent an increase of potential Stability, low residual potential and proper spectral residual potential by using a filler having an average particle properties, good mechanical durability Such as high abrasion diameter of not greater than 0.3 um. In addition, Japanese US 2002/0197549 A1 Dec. 26, 2002 Laid-Open Patent Publication No. 4-281461 discloses a using the photoreceptor, by which images having good method, in which a charge transport material is included in image qualities can be produced for a long period of time a protective layer together with a filler to prevent an increase without producing an abnormal image Such as image tailing of residual potential while maintaining good abrasion resis which is produced by a conventional high-abrasion-resis tance. Japanese Laid-Open Patent Publications Nos. tance photoreceptor. 53-133444 and 55-157748 disclose a method, in which an organic acid is included in a protective layer together with 0035 A further object of the present invention is to a filler, and Japanese Laid-Open Patent Publication No. provide a photoreceptor having a Surface layer which is 2-4275 discloses a method, in which an electron accepting abraded in a very Small amount to remove Surface-deterio material is included in a protective layer, to prevent an rating Substances adhered on the Surface layer, and to increase of residual potential. Japanese Laid-Open Patent provide an image forming apparatus and method including Publication No. 8-234455 discloses a method, in which the a cleaner cleaning the deteriorating Substances. It cannot be difference in refractive indeX between a filler in a charge Said that a photoreceptor having the highest possible abra transport layer and the charge transport layer is not less than Sion resistance is always good. It is, instead, preferable that 0.1, and the layer includes 1x10" to 2x10 pieces of filler the Surface of a photoreceptor is abraded in a very Small particles
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