Compliant photoconductive image-forming sleeve member and process for making same
A photoconductive primary image-forming sleeve member for use in an electrophotographic apparatus includes: a cylindrical conductive substrate, a compliant layer formed on the substrate, an electrically conducting protective layer including dispersed tin oxide particles formed on the compliant layer, a barrier layer formed on the protective layer, a charge-generating layer formed on the barrier layer, and a charge-transport layer formed on the charge-generating layer.
1 . A compliant photoconductive primary image-forming sleeve member for use in an electrophotographic apparatus, said member comprising:
a cylindrical conductive substrate;
a compliant layer formed on said substrate;
an electrically conducting protective layer including dispersed tin oxide particles formed on said compliant layer;
a barrier layer formed on said protective layer;
a charge-generating layer formed on said barrier layer, and
a charge-transport layer formed on said charge-generating layer.
2 . The primary image-forming sleeve member of claim 1 wherein said cylindrical conductive substrate is formed from a metal or a plastic.
3 . The primary image-forming sleeve member of claim 2 wherein said cylindrical conductive substrate is formed from a metal selected from the group consisting of nickel, aluminum, and steel.
4 . The primary image-forming sleeve member of claim 3 wherein said cylindrical conductive substrate comprises a tubular nickel belt.
5 . The primary image-forming sleeve member of claim 4 wherein said nickel belt has a thickness of about 5 mils.
6 . The primary image-forming sleeve member of claim 1 wherein said compliant layer formed on said substrate comprises a polyurethane.
7 . The primary image-forming sleeve member of claim 1 wherein said compliant layer has a thickness of about 0.5 mm to about 20 mm.
8 . The primary image-forming sleeve member of claim 1 wherein said electrically conducting protective layer further comprises a polymeric binder.
9 . The primary image-forming sleeve member of claim 8 wherein said polymeric binder comprises 2-hydroxyethyl cellulose.
10 . The primary image-forming sleeve member of claim 1 wherein said electrically conducting protective layer comprises said tin oxide particles in an amount of about 50 wt. % to about 90 wt. %.
11 . The primary image-forming sleeve member of claim 10 wherein said electrically conducting protective layer comprises said tin oxide particles in an amount of about 70 wt. % to about 80 wt. %.
12 . The primary image-forming sleeve member of claim 1 wherein said electrically conducting protective layer has a thickness of about 0.5 μm to about 10 μm.
13 . The primary image-forming sleeve member of claim 12 wherein said electrically conducting protective layer has a thickness of about 1 μm to about 5 μm.
14 . The primary image-forming sleeve member of claim 1 wherein said barrier layer comprises a polyamide resin.
15 . The primary image-forming sleeve member of claim 1 wherein said barrier layer has a thickness of about 0.5 μm to about 1.0 μm.
16 . The primary image-forming sleeve member of claim 1 wherein said charge-generating layer comprises a titanyl phthalocyanine/titanyl fluorophthalocyanine co-crystal dispersion.
17 . The primary image-forming sleeve member of claim 1 wherein said charge-generating layer has a thickness of about 0.5 μm to about 1.0 μm.
18 . The primary image-forming sleeve member of claim 1 wherein said charge-transport layer comprises tri-tolylamine, 1,1-bis(4-di-p-tolylaminophenyl) methane, and a polycarbonate.
19 . The primary image-forming sleeve member of claim 1 wherein said charge-transport layer has a thickness of about 10 μm to about 40 μm.
20 . A process for forming a compliant photoconductive primary image-forming sleeve member for use in an electrophotographic apparatus, said process comprising:
forming a compliant layer on a cylindrical conductive substrate;
forming an electrically conducting protective layer including dispersed tin oxide particles on said compliant layer;
forming a barrier layer on said electrically conducting protective layer;
forming a charge-generating layer on said barrier layer; and
forming a charge-transport layer coated on said charge-generating layer.
21 . The process of claim 20 wherein said forming said compliant layer comprises coating said cylindrical conductive substrate with a solution containing a polyurethane and an organic solvent, and removing said solvent.
22 . The process of claim 20 wherein said forming said electrically conducting protective layer comprises:
preparing an aqueous dispersion including said tin oxide particles and a polymeric binder;
applying a coating of said aqueous dispersion to said compliant layer; and
drying said coating of said aqueous dispersion.
23 . The process of claim 22 wherein said polymeric binder comprises 2-hydroxyethyl cellulose.
24 . The process of claim 20 wherein said forming said barrier layer comprises applying to said electrically conducting protective layer a solution containing a polyamide and an organic solvent, and removing said solvent.
25 . The process of claim 20 wherein said forming said charge-generating layer comprises applying to said barrier layer a mixture containing a titanyl phthalocyanine/titanyl fluorophthalocyanine co-crystalline dispersion, a polyesterionomer, and an organic solvent, and removing said solvent.
26 . The process of claim 20 wherein said forming said charge-transport layer comprises applying to said charge-generating layer a mixture containing tri-tolylamine, 1,1-bis(4-di-p-tolylaminophenyl) methane, a polycarbonate, and an organic solvent, and removing said solvent.