Image forming apparatus and image forming method

An image forming apparatus includes an image bearing member and a charging roller that charges a circumferential surface of the image bearing member to a positive polarity. The image bearing member includes a conductive substrate and a photosensitive layer of a single layer, and satisfies formula (1) shown below. The charging roller includes a conductive shaft, a base layer covering a surface of the conductive shaft, and a surface layer covering a surface of the base layer. In formula (1), Q represents a charge amount of the circumferential surface of the image bearing member. S represents a charge area of the circumferential surface of the image bearing member. d represents a film thickness of the photosensitive layer. εr represents a specific permittivity of a binder resin contained in the photosensitive layer. ε0 represents a vacuum permittivity. V represents a value calculated according to formula (2) V=V0−Vr.

INCORPORATION BY REFERENCE

The present application claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2019-111502, filed on Jun. 14, 2019. The contents of the application are incorporated herein by reference in their entirety.

BACKGROUND

The present disclosure relates to an image forming apparatus and an image forming method.

Electrographic image forming apparatuses each use a charger for charging a circumferential surface of an image bearing member. An example of the charger is a charging roller including a conductive shaft, an elastic layer covering the conductive shaft, and a surface layer directly or indirectly covering the elastic layer. The charging roller is expected to inhibit occurrence of charge irregularity. Note that charge irregularity is minute image irregularity (specific examples include irregularities such as spots and streaks) occurring on for example a halftone image formed on a sheet. Charge irregularity is thought to occur due to non-uniform charging on the circumferential surface of the image bearing member by the charger.

SUMMARY

An image forming apparatus according to an aspect of the present disclosure includes an image bearing member and a charging roller that charges a circumferential surface of the image bearing member to a positive polarity. The image bearing member includes a conductive substrate and a photosensitive layer of a single layer, and satisfies formula (1) shown below. The photosensitive layer contains a charge generating material, a hole transport material, an electron transport material, and a first binder resin. The charging roller includes a conductive shaft, a base layer covering a surface of the conductive shaft, and a surface layer covering a surface of the base layer. The surface layer has a volume resistivity at a temperature of 32.5° C. and a relative humidity of 80% of at least 13.0 log Ω·cm. The charging roller has a circumferential surface having a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. The circumferential surface of the charging roller has a section curve including projections and recesses of which mean spacing Sm is at least 55 μm and no greater than 130 μM.

In formula (1), Q represents a charge amount [C] of the circumferential surface of the image bearing member. S represents a charge area [m2] of the circumferential surface of the image bearing member. d represents a film thickness [m] of the photosensitive layer. εrrepresents a specific permittivity of the first binder resin contained in the photosensitive layer. ε0represents a vacuum permittivity [F/m]. V is a value [V] calculated in accordance with formula (2) V=V0−Vr. Vrrepresents a first potential [V] of the circumferential surface of the image bearing member yet to be charged by the charging roller. V0represents a second potential [V] of the circumferential surface of the image bearing member charged by the charging roller.

An image forming method according to an aspect of the present disclosure includes charging a circumferential surface of an image bearing member to a positive polarity using a charging roller. The image bearing member includes a conductive substrate and a photosensitive layer of a single layer, and satisfies formula (1) below. The photosensitive layer contains a charge generating material, a hole transport material, an electron transport material, and a binder resin. The charging roller includes a conductive shaft, a base layer covering a surface of the conductive shaft, and a surface layer covering the base layer. The surface layer has a volume resistivity at a temperature of 32.5° C. and a relative humidity of 80% of at least 13.0 log Ω·cm. The charging roller has a circumferential surface having a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. The circumferential surface of the charging roller has a section curve including projections and recesses of which mean spacing Sm is at least 55 μm and no greater than 130 μm.

In formula (1), Q represents a charge amount [C] of the circumferential surface of the image bearing member. S represents a charge area [m2] of the circumferential surface of the image bearing member. d represents a film thickness [m] of the photosensitive layer. εrrepresents a specific permittivity of the binder resin contained in the photosensitive layer. ε0represents a vacuum permittivity [F/m]. V is a value calculated in accordance with formula (2) V=V0−Vr. Vrrepresents a first potential [V] of the circumferential surface of the image bearing member yet to be charged by the charging roller. V0represents a second potential [V] of the circumferential surface of the image bearing member charged by the charging roller.

DETAILED DESCRIPTION

The following first describes terms used in the present specification. The term “-based” may be appended to the name of a chemical compound in order to form a generic name encompassing both the chemical compound itself and derivatives thereof. Also, when the term “-based” is appended to the name of a chemical compound used in the name of a polymer, the term indicates that a repeating unit of the polymer originates from the chemical compound or a derivative thereof.

Hereinafter, a halogen atom, an alkyl group having a carbon number of at least 1 and no greater than 8, an alkyl group having a carbon number of at least 1 and no greater than 6, an alkyl group having a carbon number of at least 1 and no greater than 5, an alkyl group having a carbon number of at least 1 and no greater than 4, an alkyl group having a carbon number of at least 1 and no greater than 3, and an alkoxy group having a carbon number of at least 1 and no greater than 4 each refer to the following, unless otherwise stated.

Examples of the halogen atom (halogen group) include a fluorine atom (fluoro group), a chlorine atom (chloro group), a bromine atom (bromo group), and an iodine atom (iodo group).

The alkyl group having a carbon number of at least 1 and no greater than 8, the alkyl group having a carbon number of at least 1 and no greater than 6, the alkyl group having a carbon number of at least 1 and no greater than 5, the alkyl group having a carbon number of at least 1 and no greater than 4, and the alkyl group having a carbon number of at least 1 and no greater than 3 each are an unsubstituted straight chain or branched chain alkyl group. Examples of the alkyl group having a carbon number of at least 1 and no greater than 8 include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, a sec-butyl group, a tert-butyl group, an n-pentyl group, an isopentyl group, a neopentyl group, a 1,1-dimethylpropyl group, a 1,2-dimethylpropyl group, a straight chain or branched chain hexyl group, a straight chain or branched chain heptyl group, and a straight chain or branched chain octyl group. Out of the chemical groups listed as examples of the alkyl group having a carbon number of at least 1 and no greater than 8, the chemical groups having a carbon number of at least 1 and no greater than 6 are examples of the alkyl group having a carbon number of at least 1 and no greater than 6, the chemical groups having a carbon number of at least 1 and no greater than 5 are examples of the alkyl group having a carbon number of at least 1 and no greater than 5, the chemical groups having a carbon number of at least 1 and no greater than 4 are examples of the alkyl group having a carbon number of at least 1 and no greater than 4, and the chemical groups having a carbon number of at least 1 and no greater than 3 are examples of the alkyl group having a carbon number of at least 1 and no greater than 3.

The alkoxy group having a carbon number of at least 1 and no greater than 4 is an unsubstituted straight chain or branched chain alkoxy group. Examples of the alkoxy group having a carbon number of at least 1 and no greater than 4 include a methoxy group, an ethoxy group, an n-propoxy group, an isopropoxy group, an n-butoxy group, a sec-butoxy group, and a tert-butoxy group. Through the above, terms used in the present specification have been described.

An image forming apparatus according to a first embodiment of the present disclosure includes an image bearing member and a charging roller that charges a circumferential surface of the image bearing member to a positive polarity. The image bearing member includes a conductive substrate and a photosensitive layer of a single layer, and satisfies formula (1) shown below. The photosensitive layer contains a charge generating material, a hole transport material, an electron transport material, and a first binder resin. The charging roller includes a conductive shaft, a base layer covering a surface of the conductive shaft, and a surface layer converting a surface of the base layer. The surface layer has a volume resistivity at a temperature of 32.5° C. and a relative humidity of 80% of at least 13.0 log Ω·cm. The charging roller has a circumferential surface having a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. The circumferential surface of the charging roller has a section curve including projections and recesses of which mean spacing Sm is at least 55 μm and no greater than 130 μm.

In formula (1), Q represents a charge amount [C] of the circumferential surface of the image bearing member. S represents a charge area [m2] of the circumferential surface of the image bearing member. d represents a film thickness [m] of the photosensitive layer. εrrepresents a specific permittivity of the first binder resin contained in the photosensitive layer. ε0represents a vacuum permittivity [F/m]. V is a value calculated in accordance with formula (2) V=V0−Vr. Vrrepresents a first potential [V] of the circumferential surface of the image bearing member yet to be charged by the charging roller. V0represents a second potential [V] of the circumferential surface of the image bearing member charged by the charging roller.

The following describes the image forming apparatus according to the present embodiment with reference to the accompanying drawings. Note that elements that are the same or equivalent are indicated by the same reference signs in the drawings and description thereof is not repeated. In the present embodiment, an X axis, a Y axis, and a Z axis are perpendicular to one another. The X axis and the Y axis are parallel to a horizontal plane while the Z axis is parallel to a vertical line.

The following first describes an overview of an image forming apparatus1according to the present embodiment with reference toFIG. 1.FIG. 1is a cross-sectional view of the image forming apparatus1. The image forming apparatus1according to the present embodiment is a full-color printer. The image forming apparatus1includes a feeding section10, a conveyance section20, an image forming section30, a toner supply section60, and an ejection section70.

The feeding section10includes a cassette11that accommodates a plurality of sheets P. The feeding section10feeds the sheets P one at a time from the cassette11to the conveyance section20. The sheets P are for example paper or are made from synthetic resin. The conveyance section20conveys each sheet P to the image forming section30.

The image forming section30includes a light exposure device31, a magenta-color unit (also referred to below as an M unit)32M, a cyan-color unit (also referred to below as a C unit)32C, a yellow-color unit (also referred to below as a Y unit)32Y, a black-color unit (also referred to below as a BK unit)32BK, a transfer belt33, a secondary transfer roller34, and a fixing device35. The M unit32M, the C unit32C, the Y unit32Y, and the BK unit32BK each include a photosensitive member50, a charging roller51, a development roller52, a primary transfer roller53, a static elimination lamp54, and a cleaner55.

The light exposure device31irradiates each of the M unit32M, the C unit32C, the Y unit32Y, and the BK unit32BK with light based on image data to form respective electrostatic latent images on the M unit32M, the C unit32C, the Y unit32Y, and the BK unit32BK. The M unit32M forms a toner image in a magenta color from the electrostatic latent image formed thereon. The C unit32C forms a toner image in a cyan color from the electrostatic latent image formed thereon. The Y unit32Y forms a toner image in a yellow color from the electrostatic latent image formed thereon. The BK unit32BK forms a toner image in a black color from the electrostatic latent image formed thereon.

The photosensitive member50is in a drum shape. The photosensitive member50rotates about a rotation center50X (rotation axis, seeFIG. 2) thereof. The charging roller51, the development roller52, the primary transfer roller53, the static elimination lamp54, and the cleaner55are arranged around the photosensitive member50in the stated order from upstream to downstream in a rotational direction R of the photosensitive member50(seeFIG. 2). The charging roller51charges a circumferential surface50aof the photosensitive member50to a positive polarity. As has been described above, the light exposure device31exposes the charged circumferential surfaces50aof the respective photosensitive members50to light to form electrostatic latent images on the circumferential surfaces50aof the photosensitive members50. The development rollers52each attract a carrier CA carrying a toner T by magnetic force thereof to carry the toner T. A development bias (a development voltage) is applied to the development rollers52to generate a difference between a potential of each development roller52and a potential of the circumferential surface50aof a corresponding one of the photosensitive members50. As a result, the toner T is moved and attached to the electrostatic latent image formed on the circumferential surface50aof each photosensitive member50. In this manner, the development rollers52each supply the toner T to a corresponding one of the electrostatic latent images to develop the electrostatic latent image into a toner image. Through the above process, toner images are formed on the circumferential surfaces50aof the respective photosensitive members50. The toner images contain the toner T. The transfer belt33is in contact with the circumferential surfaces50aof the photosensitive members50. The primary transfer rollers53primarily transfer the respective toner images formed on the circumferential surfaces50aof the photosensitive members50to the transfer belt (specifically, an outer surface of the transfer belt33). Through the primary transfer by the primary transfer rollers53, the toner images in four colors are superimposed on one another on the outer surface of the transfer belt33. The toner images in the four colors are a magenta toner image, a cyan toner image, a yellow toner image, and a black toner image. Through primary transfer as above, a color toner image is formed on the outer surface of the transfer belt33. The secondary transfer roller34secondarily transfers the color toner image formed on the outer surface of the transfer belt33to the sheet P. The fixing device35fixes the color toner image to the sheet P by applying heat and pressure to the sheet P. The sheet P with the color toner image fixed thereto is ejected onto the ejection section70. After the primary transfer, the static elimination lamps54included in the M unit32M, the C unit32C, the Y unit32Y, and the BK unit32BK eliminate static electricity on the circumferential surfaces50aof the respective photosensitive members50. After the primary transfer (specifically, after the primary transfer and after the static elimination), the cleaners55collect residual toner T remaining on the circumferential surfaces50aof the respective photosensitive members50.

The toner supply section60includes a toner cartridge60M, a toner cartridge60C, a toner cartridge60Y, and a toner cartridge60BK. The toner cartridge60M contains a magenta toner T. The toner cartridge60C contains a cyan toner T. The toner cartridge60Y contains a yellow toner T. The toner cartridge60BK contains a black toner T. The toner cartridge60M, the toner cartridge60C, the toner cartridge60Y, and the toner cartridge60BK respectively supply the toner T to the development rollers52of the M unit32M, the C unit32C, the Y unit32Y, and the BK unit32BK.

Note that the photosensitive members50are each equivalent to what may be referred to as an image bearing member. The development rollers52are each equivalent to what may be referred to as a development device. The primary transfer rollers53are each equivalent to what may be referred to as a transfer device. The transfer belt33is equivalent to what may be referred to as a transfer target. The static elimination lamps54are each equivalent to what may be referred to as a static eliminator. The cleaners55are each equivalent to what may be referred to as a cleaning device.

The following further describes the image forming apparatus1according to the present embodiment with reference toFIGS. 2 and 3.FIG. 2illustrates the photosensitive member50and elements therearound. The image forming apparatus1according to the present embodiment includes charging rollers51, cleaners55, and photosensitive members50that are each equivalent to an image bearing member. The cleaners55each include a cleaning blade81equivalent to what may be referred to as a cleaning member. Each of the charging rollers51charges a circumferential surface50aof a corresponding one of the photosensitive members50to a positive polarity. The cleaning blade81is pressed against the circumferential surface50aof the photosensitive member50and collects residual toner T on the circumferential surface50aof the photosensitive member50.

The charging rollers51are further described next with reference toFIG. 3.FIG. 3illustrates a charging roller51. The charging roller51includes a conductive shaft51a, a base layer51bcovering a surface of the conductive shaft51a, and a surface layer51ccovering a surface of the base layer51b. The surface layer51cis an outermost layer of the charging roller51.

The photosensitive members50satisfying formula (1) has excellent charge characteristics. As a result of the image forming apparatus1including the photosensitive members50excellent in charge characteristics, occurrence of a ghost image can be inhibited. The term ghost image refers to a phenomenon described as appearance of a residual image along with an output image (an image formed on a sheet P), which in other words is reappearance of an image formed during a previous rotation of a photosensitive member50. A ghost image occurs due to non-uniform charging of the circumferential surface50aof the photosensitive member50. Examples of factors of non-uniform charging of the circumferential surface50aof the photosensitive member50include variation in charge injection to the photosensitive layer502of the photosensitive member50, presence of residual charge in the photosensitive layer502, and a phenomenon in which electric current flows into the photosensitive layer502non-uniformly according to presence or absence of a toner image on the photosensitive layer502in transfer.

A ghost image is likely to occur when using the photosensitive member50including the photosensitive layer502of a single layer as compared to when using a photosensitive member including a photosensitive layer of multiple layers. This is because the photosensitive layer502of a single layer is relatively thick. Specifically, electrons and holes generated from a charge generating material tend to remain in the photosensitive layer502of a single layer. The residual charge in the photosensitive layer502inhibits uniform charging of the photosensitive member50to induce a ghost image. As such, a ghost image is more likely to occur when using the photosensitive members50including the photosensitive layers502of a single layer than when using a photosensitive member including a photosensitive layer of multiple layers.

The inventers found that through use of the photosensitive member50that has excellent charge characteristics and that satisfies formula (1), uniform charging of the photosensitive member50can be achieved and occurrence of a ghost image can be inhibited accordingly. However, the inventors discovered that charge irregularity is likely to occur in an image forming apparatus including the photosensitive member50excellent in charge characteristics. It is thought that the main cause of occurrence of charge irregularity includes a first factor and a second factor described below.

The following describes the first factor. The first factor relates to concentrated electrical discharge to a photosensitive member from a charging roller. The charging roller51charges the circumferential surface50aof the photosensitive member50by discharging to the photosensitive member50from a surface51dof the charging roller51. In discharging, electric current in a radial direction is generated in the charging roller51from the conductive shaft51atoward the surface51d. However, an area that tends to discharge more than an area therearound can be present in the surface51dof the charging roller51. When such an area that tends to discharge more than an area therearound is present in a known charging roller, cross current may be generated on the surface layer thereof and concentrated electrical discharge to the photosensitive member occurs in an area where such electrical discharge is likely to occur. When concentrated electrical discharge occurs on the surface of the conventional charging roller, part of the circumferential surface of the photosensitive member is excessively charged. As such, the first factor is thought to serve as one of causes of charge irregularity (for example, spots of voids) that occurs in an image forming apparatus including the known charging roller.

The second factor will be described next. The second factor relates to backflow of charge from a photosensitive member to a charging roller. The charging roller51comes in contact with the photosensitive member50after electrical discharge to the photosensitive member50. A known charging roller has a large area in contact with the photosensitive member50. Alternatively, the number of contact points of the known charging roller that are in contact with the photosensitive member50is large. In the above configuration, charge of the photosensitive member50may flow into the known charging roller via the contact points between the charging roller and the photosensitive member50. When charge flows locally into the known charging roller, the photosensitive member is unevenly charged. As such, the second factor is thought to serve as one of causes of charge irregularity (for example, spots of voids) that occurs in an image forming apparatus including the known charging roller.

By contrast, the surface layer51cof the charging roller51in the present embodiment has a volume resistivity at a temperature of 32.5° C. and a relative humidity of 80% of at least 13.0 log Ω·cm. The circumferential surface of the charging roller51in the present embodiment has a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. Furthermore, the circumferential surface of the charging roller51in the present embodiment has a section curve including projections and recesses of which mean spacing Sm is at least 55 μm and no greater than 130 μm. The above configuration enables the charging roller51to discharge diffusely to the photosensitive member50. Also, generation of cross current as described above on the surface layer51ccan be inhibited. Furthermore, the contact area of the charging roller51in contact with the photosensitive member50is reduced, thereby inhibiting charge from flowing from the photosensitive member50to the charging roller51. For the above reasons, it is thought that occurrence of charge irregularity can be inhibited in the image forming apparatus1. Note that it is difficult for the charging roller51to sufficiently charge a known photosensitive member because the surface layer51cof the charging roller51has a relatively high volume resistivity. In view of the foregoing, the photosensitive member50included in the image forming apparatus1satisfies the above formula (1) and has excellent charge characteristic. With the above configuration, the charging roller51can sufficiently charge the photosensitive member50.

The following describes the photosensitive members50included in the image forming apparatus1with reference toFIGS. 4 to 6.FIGS. 4 to 6are partial cross-sectional views each illustrating an example of the photosensitive member50. Each photosensitive member50is for example an organic photoconductor (OPC) drum.

As illustrated inFIG. 4, the photosensitive member50includes for example a conductive substrate501and a photosensitive layer502. The photosensitive layer502is a single layer (one layer). The photosensitive member50is a single-layer electrophotographic photosensitive member including the photosensitive layer502of a single layer. The photosensitive layer502contains a charge generating material, a hole transport material, an electron transport material, and a first binder resin. Although no particular limitations are placed on film thickness of the photosensitive layer502, the photosensitive layer502has a film thickness of preferably at least 5 μm and no greater than 100 μm, more preferably at least 10 μm and no greater than 50 μm, further preferably at least 10 μm and no greater than 35 μm, and still further preferably at least 15 μm and no greater than 30 μm.

As illustrated inFIG. 5, the photosensitive member50may include a conductive substrate501, a photosensitive layer502, and an intermediate layer503(undercoat layer). The intermediate layer503is disposed between the conductive substrate501and the photosensitive layer502. As illustrated inFIG. 4, the photosensitive layer502may be disposed directly on the conductive substrate501. Alternatively, the photosensitive layer502may be disposed indirectly on the conductive substrate501with the intermediate layer503therebetween as illustrated inFIG. 5. The intermediate layer503may be a single-layer intermediate layer or a multi-layer intermediate layer.

The photosensitive member50may include a conductive substrate501, a photosensitive layer502, and a protective layer504as illustrated inFIG. 6. The protective layer504is disposed on the photosensitive layer502. The protective layer504may be a single-layer protective layer or a multi-layer protective layer.

The photosensitive member50satisfies formula (1) shown above. A value represented by formula (1′) in formula (1) is also referred to below as a chargeability ratio. The chargeability ratio expressed by the following formula (1′) represents a ratio of an actual chargeability (measured value) of the photosensitive member50to a theoretical chargeability (theoretical value) of the photosensitive member50when the circumferential surface50aof the photosensitive member50is charged by the charging roller51. The ratio of the actual chargeability of the photosensitive member50to the theoretical chargeability of the photosensitive member50will be described later in detail with reference toFIG. 8.

The photosensitive member50satisfying formula (1) offers the following first to third advantages. The following first describes the first advantage. As long as the photosensitive member50satisfies formula (1), chargeability of the photosensitive member50is close enough to the theoretical value thereof, and therefore, the circumferential surface50aof the photosensitive member50can be uniformly charged. This can inhibit occurrence of a ghost image.

The following describes the second advantage. The photosensitive layer502of the photosensitive member50may abrade away in the course of repeated image formation. The photosensitive layer502abrades away for example due to electrical discharge from the charging roller51to the photosensitive member50. As long as the photosensitive member50satisfies formula (1), chargeability of the photosensitive member50is close enough to the theoretical value thereof, and therefore, the circumferential surface50aof the photosensitive member50can be adequately charged even if a set amount of electrical discharge from the charging roller51to the photosensitive member50is low. As long as the amount of electrical discharge is set low, an abrasion amount of the photosensitive layer502can be reduced. Furthermore, as a result of reduction in abrasion amount of the photosensitive layer502, the film thickness of the photosensitive layer502can be set small, thereby achieving reduction in manufacturing cost.

The following describes the third advantage. As long as the photosensitive member50satisfies formula (1), chargeability of the photosensitive member50is close enough to the theoretical value thereof. Therefore, the circumferential surface50aof the photosensitive member50can be adequately charged even if a set value of electric current flowing through the charging roller51is low. As long as a set value of electric current flowing through the charging roller51is low, a decrease in conductivity of the material of the charging roller51(for example, rubber) through conduction can be inhibited.

In order to inhibit occurrence of a ghost image, the chargeability ratio in formula (1) is preferably at least 0.70, more preferably at least 0.80, and further preferably at least 0.90. That the chargeability ratio is 1.00 means that a measured value of chargeability of the photosensitive member50is equal to the theoretical value thereof. Therefore, an upper limit of the chargeability ratio is 1.00.

A chargeability ratio measurement method will be described next. V in formula (1) is a value [V] calculated in accordance with formula (2). The following describes a method for measuring a first potential Vrand a second potential V0in formula (2) with reference toFIG. 7. Note that the environment in which the first potential Vrand the second potential V0in formula (2) are measured is an environment at a temperature of 23° C. and a relative humidity of 50%.

The first potential Vrand a second potential V0can be measured using a measuring device100illustrated inFIG. 7. The measuring device100can be fabricated through first modification and second modification on the image forming apparatus1. In the first modification, a first potential probe101is mounted in the image forming apparatus1. The first potential probe101is arranged upstream of a charging roller51in a rotational direction R of a photosensitive members50. The first potential probe101is connected to a first surface electrometer (not illustrated, “SURFACE ELECTROMETER MODEL344”, product of TREK, INC.). In the second modification, a development roller52in the image forming apparatus1is replaced with a second potential probe102. The second potential probe102is arranged at a location where a rotation center52X (rotation axis) of the development roller52had been located. The second potential probe102is connected to a second surface electrometer (not illustrated “SURFACE ELECTROMETER MODEL344”, product of TREK, INC.).

The measuring device100includes at least a charging roller51, the second potential probe102, a static elimination lamp54, and the first potential probe101. The photosensitive member50that is a measurement target is set in the measuring device100. The charging roller51, the second potential probe102, the static elimination lamp54, and the first potential probe101are arranged around the photosensitive member50in the stated order from upstream to downstream in the rotational direction R of the photosensitive member50.

The second potential probe102is arranged so that an angle θ1between a first line L1and a second line L2is 120 degrees. Here, the first line L1is a line connecting the rotation center50X (rotation axis) of the photosensitive member50to a rotation center51X (rotation axis) of the charging roller51, and the second line L2is a line connecting the second potential probe102to the rotation center50X (rotation axis) of the photosensitive member50. An intersection point between the first line L1and the circumferential surface50aof the photosensitive member50is a charging point P1. An intersection point between the second line L2and the circumferential surface50aof the photosensitive member50is a development point P2.

The first potential probe101is arranged so that an angle θ2between a third line L3and the first line L1connecting the rotation center50X (rotation axis) of the photosensitive member50to the rotation center51X (rotation axis) of the charging roller51is 20 degrees. Here, the third line L3is a line connecting the first potential probe101to the rotation center50X (rotation axis) of the photosensitive member50. An intersection point between the third line L3and the circumferential surface50aof the photosensitive member50is a pre-charging point P3.

A point of the circumferential surface50aof the photosensitive member50that is irradiated with static elimination light of the static elimination lamp54is a static elimination point P4. The static elimination lamp54is arranged so that an angle θ3between a fourth line L4and the third line L3connecting the first potential probe101to the rotation center50X (rotation axis) of the photosensitive member50is 90 degrees. Here, the fourth line L4is a line connecting the static elimination point P4to the rotation center50X (rotation axis) of the photosensitive member50. Note that a modified version of a multifunction peripheral (“TASKalfa (registered Japanese trademark) 356Ci”, product of KYOCERA Document Solutions Inc.) can be used as the measuring device100.

In measurement of the first potential Vrand the second potential V0, a charging voltage to be applied to the charging roller51is set to any of +1,000 V, +1,100 V, +1,200 V, +1,300 V, +1,400 V, and +1,500 V. A light quantity of the static elimination light at a time when the static elimination light emitted from the static elimination lamp54reaches the circumferential surface50aof the photosensitive member50(also referred to below as a static elimination light intensity) is set to 5 μJ/cm2. The first potential Vrand the second potential V0are measured while the photosensitive member50is rotated about the rotation center50X (rotation axis) thereof. The charging roller51charges the circumferential surface50aof the photosensitive member50to a positive polarity at the charging point P1of the photosensitive member50. Next, the static elimination lamp54eliminates static electricity from the circumferential surface50aof the photosensitive member50at the static elimination point P4of the photosensitive member50. When the photosensitive member50has completed 10 rotations under the above-described charging and static elimination (also referred to below as a timing K), the first potential Vrand the second potential V0are measured at the same time. Specifically, with the timing K, a potential of the circumferential surface50aof the photosensitive member50(first potential Vr) is measured at the pre-charging point P3of the photosensitive member50using the first potential probe101. Also, with the timing K, a potential of the circumferential surface50aof the photosensitive member50(second potential V0) is measured at the development point P2of the photosensitive member50using the second potential probe102. In the manner as above, the first potentials Vrand the second potentials V0under the respective conditions that the charging voltage applied to the charging roller51is +1,000 V, +1,100 V, +1,200 V, +1,300 V, +1,400 V, and +1,500 V are measured.

Note that in measurement of the first potential Vrand the second potential V0, light exposure by the light exposure device31, development by the development roller52, primary transfer by the primary transfer roller53, and cleaning by the cleaning blade81are not performed. The cleaning blade81is set to have a linear pressure of 0 N/m. The method for measuring the first potential Vrand the second potential V0in formula (2) has been described so far. The following describes a chargeability ratio measurement method.

The charge amount Q in formula (1) is measured under environmental conditions of a temperature of 23° C. and a relative humidity of 50%. The charge amount Q is measured according to the following method when the first potential Vrand the second potential V0are measured. With the timing K when the first potential Vrand the second potential V0are measured at the same time, a current value E1of electric current flowing in the charging roller51is measured using an ammeter voltmeter (“MINIATURE PORTABLE AMMETER AND VOLTMETER MODEL 2051”, product of Yokogawa Meter & Measurement Corporation). The current values E1is measured under each of the conditions that the charging voltage applied to the charging roller51is +1,000 V, +1,100 V, +1,200 V, +1,300 V, +1,400 V, and +1,500 V. Charge amounts Q under the respective conditions that the charging voltage applied to the charging roller51is +1,000 V, +1,100 V, +1,200 V, +1,300 V, +1,400 V, and +1,500 V are calculated from the measured current values E1in accordance with the following formula (3).
Charge amountQ=current valueE1[A]×charging timet[second]  (3)

Note that the charging roller51is connected to a high-voltage substrate (not illustrated) of the measuring device100through the ammeter voltmeter. Each current value E1of the electric current flowing in the charging roller51and the charging voltage, which has been described in association with measurement of the first potential Vrand the second potential V0, can be monitored using the ammeter voltmeter all the time when the measuring device100is activated.

In formula (1), the charge area S is an area of a charged region of the circumferential surface50aof the photosensitive member50charged by the charging roller51. The charge area S is calculated in accordance with the following formula (4). A charge width in formula (4) is a length of the charged region of the circumferential surface50aof the photosensitive member50charged by the charging roller51in a longitudinal direction (a rotational axis direction D inFIG. 10) of the photosensitive member50.
Charge areaS[m2]=linear velocity [m/second] of photosensitive member 50×charge width [m]×charging timet[second]  (4)

Respective values of “V” in formula (1) are calculated from the first potentials Vrand the second potentials V0measured as described above. Respective values of “Q/S” in formula (1) are calculated from the charge amounts Q and the charge areas S measured as describe above. A graph is plotted with “Q/S” value on a horizontal axis and “V” value on a vertical axis. Six points are plotted in the graph representation as results of measurement under the respective conditions that the charging voltage applied to the charging roller51is +1,000 V, +1,100 V, +1,200 V, +1,300 V, +1,400 V, and +1,500 V. An approximate straight line of these six points is drawn. A gradient of the approximate straight line is determined from the approximate straight line. The determined gradient is taken to be “V/(Q/S)” in formula (1).

A film thickness d of the photosensitive layer502in formula (1) is measured under environmental conditions of a temperature of 23° C. and a relative humidity of 50%. The film thickness d of the photosensitive layer502is measured using a film thickness measuring device (“FISCHERSCOPE (registered Japanese trademark) MMS (registered Japanese trademark)”, product of FISCHER INSTRUMENTS K.K.). Note that the film thickness of the photosensitive layer502is set to 30×10−6m in the present embodiment.

In formula (1), CO represents a vacuum permittivity. The vacuum permittivity CO is constant and is 8.85×10−12[F/m].

The specific permittivity εrof the first binder resin in formula (1) corresponds to a specific permittivity of the photosensitive layer502on the assumption that full amount of charge supplied from the charging roller51is converted to potential (surface potential) of the circumferential surface50aof the photosensitive member50with no charge trapped within the photosensitive layer502. The specific permittivity εrof the first binder resin is measured using a photosensitive member for specific permittivity measurement. The photosensitive member for specific permittivity measurement includes a photosensitive layer containing only the first binder resin. The photosensitive member for specific permittivity measurement can be produced according to the same method as in the production of photosensitive members according to Examples described below in all aspects other than that any of a charge generating material, a hole transport material, an electron transport material, and an additive is not added. The specific permittivity εrof the first binder resin is calculated using the photosensitive member for specific permittivity measurement as a measurement target in accordance with formula (5) shown below. The specific permittivity εrof the first binder resin calculated in accordance with formula (5) is 3.5 in the present embodiment.

In formula (5), Qεrepresents a charge amount [C] of the photosensitive member for specific permittivity measurement. Sεrepresents a charge area [m2] of a circumferential surface of the photosensitive member for specific permittivity measurement. dεrepresents a film thickness [m] of the photosensitive layer of the photosensitive member for specific permittivity measurement. εrrepresents a specific permittivity of the first binder resin. ε0represents a vacuum permittivity [F/m]. Vεrepresents a value [V] calculated in accordance with formula V0ε−Vrε. Vrεrepresents a third potential of the circumferential surface of the photosensitive member for specific permittivity measurement yet to be charged by the charging roller51. V0εrepresents a fourth potential of the circumferential surface of the photosensitive member for specific permittivity measurement charged by the charging roller51.

The film thickness dεin formula (5) is calculated according to the same method as in the calculation of the film thickness d of the photosensitive member50in formula (1) in all aspects other than that the photosensitive member for specific permittivity measurement is used instead of the photosensitive member50. The film thickness dεin formula (5) is set to 30×10−6m in the present embodiment. The vacuum permittivity ε0in formula (5) is constant and is 8.85×10−12F/m. The theoretical value 0 V is substituted into the third potential Vrεin formula (5). The charging voltage Qεof the circumferential surface the photosensitive member for specific permittivity measurement is measured according to the same method as in the measurement of the charge amount Q of the circumferential surface50aof the photosensitive member50in formula (1) in all aspects other than that the photosensitive member for specific permittivity measurement is used instead of the photosensitive member50and the charging voltage is set to +1,000 V. The charge area Sεof the circumferential surface of the photosensitive member for specific permittivity measurement in formula (5) is calculated according to the same method as in the calculation of the charge area S of the circumferential surface50aof the photosensitive member50in formula (1) in all aspects other than that the photosensitive member for specific permittivity measurement is used instead of the photosensitive member50. The fourth potential V0εin formula (5) is measured according to the same method as in the measurement of the second potential V0of the photosensitive member50in formula (2) in all aspects other than that the photosensitive member for specific permittivity measurement is used instead of the photosensitive member50. Using the thus obtained values, the specific permittivity εrof the first binder resin is calculated in accordance with formula (5).

Through the above, a chargeability ratio measurement method has been described. The chargeability ratio will be further described below with reference toFIG. 8. As has been already described, the chargeability ratio indicates a ratio of an accrual chargeability (measured value) of the photosensitive member50to a theoretical chargeability (theoretical value) of the photosensitive member50when the circumferential surface50aof the photosensitive member50is charged by the charging roller51. The chargeability as used in the present specification indicates how much charge potential [V] of the photosensitive member50increases for surface charge density [C/m2] of charge supplied from the charging roller51. The theoretical chargeability (theoretical value) of the photosensitive member50is a value when full amount of charge supplied from the charging roller51to the photosensitive member50is converted to charge potential of the photosensitive member50. The charge potential of the photosensitive member50is equivalent to a difference between the potential (first potential Vr) of the circumferential surface50aof the photosensitive member50before a portion of the circumferential surface50aof the photosensitive member50passes the charging roller51and the potential (second potential V0) of the circumferential surface50aof the photosensitive member50after the portion of the circumferential surface50aof the photosensitive member50has passed the charging roller51.

FIG. 8is a graph representation illustrating a relationship between surface charge density [C/m2] and charge potential [V] of photosensitive members. The horizontal axis inFIG. 8represents surface charge density. The surface charge density is a value corresponding to “Q/S” in formula (1). The vertical axis inFIG. 8represents charge potential. The charge potential is a value corresponding to “V” in formula (1). The chargeability corresponds to the gradient “V/(Q/S)” of each graph shown inFIG. 8.

Circles on the plot inFIG. 8each indicate a measurement result of a photosensitive member (P-A1) having a chargeability ratio of at least 0.60. Triangles on the plot inFIG. 8each indicate a measurement result of a photosensitive member (P-B1) having a chargeability ratio of less than 0.60. Note that the photosensitive members (P-A1) and (P-B1) are produced according to a method described in association with Examples. A broken line indicated by A inFIG. 8represents theoretical chargeability (theoretical value) of the photosensitive member50. The theoretical chargeability (theoretical value) of the photosensitive member50is calculated in accordance with the following formula (6). The broken line indicated by A inFIG. 8is obtained by plotting values corresponding to “Qt/St” in formula (6) for the horizontal axis and plotting values corresponding to “Vt” in formula (6) for the vertical axis.

In formula (6), Qtrepresents a charge amount [C] of the circumferential surface50aof the photosensitive member50. Strepresents a charge area [m2] of the circumferential surface50aof the photosensitive member50. dtrepresents a film thickness [m] of the photosensitive layer502of the photosensitive member50. εrtrepresents a specific permittivity of the first binder resin contained in the photosensitive layer502of the photosensitive member50. ε0represents a vacuum permittivity [F/m]. Vtrepresents a value [V] calculated in accordance with formula “V0t−Vrt”. Vrtrepresents a fifth potential [V] of the circumferential surface50aof the photosensitive member50yet to be charged by the charging roller51. V0trepresents a sixth potential [V] of the circumferential surface50aof the photosensitive member50charged by the charging roller51.

The film thickness dtin formula (6) is calculated according to the same method as in the calculation of the film thickness d of the photosensitive member50in formula (1). The film thickness dtin formula (6) is set to 30×10−6m in the present embodiment. The vacuum permittivity ε0in formula (6) is constant and is 8.85×10−12F/m. The theoretical value 0 V is substituted into the fifth potential Vrtin formula (6). The charge amount Qtof the circumferential surface50aof the photosensitive member50in formula (6) is measured according to the same method as in the measurement of the charge amount Q of the circumferential surface50aof the photosensitive member50in formula (1). The charge area Stof the circumferential surface50aof the photosensitive member50in formula (6) is calculated according to the same method as in the calculation of the charge area S of the circumferential surface50aof the photosensitive member50in formula (1). The specific permittivity εrtof the first binder resin in formula (6) is measured according to the same method as in the measurement of the specific permittivity εrof the first binder resin in formula (1). The specific permittivity εrtof the first binder resin in formula (6) is 3.5, the same as the specific permittivity εrof the first binder resin in formula (1). Using the thus obtained values, the sixth potential V0t[V] and Vt[V] are calculated in accordance with formula (6).

As illustrated inFIG. 8, the chargeability (corresponding to the gradient of the graph inFIG. 8) approximates to the broken line indicated by A as the chargeability ratio increases to be close to 1.00. When the chargeability ratio is at least 0.60, occurrence of a ghost image can be sufficiently inhibited. Through the above, the chargeability ratio of the photosensitive member50has been described. The following further describes the photosensitive member50.

The circumferential surface50aof the photosensitive member50has a surface friction coefficient of preferably at least 0.20 and no greater than 0.80, more preferably at least 0.20 and no greater than 0.60, and further preferably at least 0.20 and no greater than 0.52. As a result of the circumferential surface50aof the photosensitive member50having a surface friction coefficient of no greater than 0.80, attachment strength of the toner T to the circumferential surface50aof the photosensitive member50decreases, so that production of cleaning defect can be further inhibited. Also, as a result of the circumferential surface50aof the photosensitive member50having a surface friction coefficient of no greater than 0.80, friction force of the cleaning blade81against the circumferential surface50aof the photosensitive member50decreases, so that abrasion of the photosensitive layer502of the photosensitive member50can be further inhibited. Although no particular limitations are placed on a lower limit of the surface friction coefficient of the circumferential surface50aof the photosensitive member50, the surface friction coefficient can be set to for example 0.20 or more. The surface friction coefficient of the circumferential surface50aof the photosensitive member50can be measured according to a method described in association with Examples.

In order to obtain output images having favorable image quality, the circumferential surface50aof the photosensitive member50has a post-irradiation potential of preferably at least +50 V and no greater than +300V, and more preferably at least +80 V and no greater than +200 V. The post-irradiation potential is a potential of a region of the circumferential surface50aof the photosensitive member50irradiated with exposure light by the light exposure device31. The post-irradiation potential is measured after light exposure and before development. The post-irradiation potential of the photosensitive member50can be measured according to a method described in association with Examples.

The photosensitive layer502has a Martens hardness of preferably at least 150 N/mm2, more preferably at least 180 N/mm2, further preferably at least 200 N/mm2, and further more preferably at least 220 N/mm2. As a result of the photosensitive layer502having a Martens hardness of at least 150 N/mm2, an abrasion amount of the photosensitive layer502decreases to increase abrasion resistance of the photosensitive member50. Although no particular limitations are placed on an upper limit of the Martens hardness of the photosensitive layer502, the upper limit of the Martens hardness of the photosensitive layer502can be set to for example 250 N/mm2. The Martens hardness of the photosensitive layer502can be measured according to a method described in association with Examples.

The photosensitive layer502contains a charge generating material, a hole transport material, an electron transport material, and a first binder resin. The photosensitive layer502may further contain an additive as necessary. The following describes the charge generating material, the hole transport material, the electron transport material, the first binder resin, the additive, and preferable combinations of the materials.

Preferable examples of a phthalocyanine-based pigment that can contribute to inhibition of occurrence of a ghost image include metal-free phthalocyanine, titanyl phthalocyanine, and chloroindium phthalocyanine. Out of the phthalocyanine-based pigments listed above, titanyl phthalocyanine is further preferable. Titanyl phthalocyanine is represented by chemical formula (CGM-1).

Titanyl phthalocyanine may have a crystal structure. Examples of titanyl phthalocyanine having a crystal structure include titanyl phthalocyanine having an α-form crystal structure, titanyl phthalocyanine having a β-form crystal structure, and titanyl phthalocyanine having a Y-form crystal structure (also referred to below as α-form titanyl phthalocyanine, β-form titanyl phthalocyanine, and Y-form titanyl phthalocyanine, respectively). Y-form titanyl phthalocyanine is preferable as the titanyl phthalocyanine.

Y-form titanyl phthalocyanine exhibits a main peak for example at a Bragg angle (2θ±0.2°) of 27.2° in a CuKα characteristic X-ray diffraction spectrum. The main peak in the CuKα characteristic X-ray diffraction spectrum refers to a peak having a highest or second highest intensity in a range of Bragg angles (2θ±0.2°) from 3° to 40°.

The following describes an example of a method for measuring the CuKα characteristic X-ray diffraction spectrum. A sample (titanyl phthalocyanine) is loaded into a sample holder of an X-ray diffractometer (for example, “RINT (registered Japanese trademark) 1100”, product of Rigaku Corporation), and an X-ray diffraction spectrum of the sample is measured using a Cu X-ray tube, a tube voltage of 40 kV, a tube current of 30 mA, and CuKα characteristic X-rays having a wavelength of 1.542 Å. The measurement range (2θ) is for example from 3° to 40° (start angle: 3°, stop angle: 40°), and the scanning speed is for example 10°/minute.

Y-form titanyl phthalocyanine is for example classified into the following three types (A) to (C) based on thermal characteristics in differential scanning calorimetry (DSC) spectra.

(A) Y-form titanyl phthalocyanine that exhibits a peak in a range of equal to or higher than 50° C. and equal to or lower than 270° C. in a differential scanning calorimetry spectrum thereof, other than a peak resulting from vaporization of adsorbed water.

(B) Y-form titanyl phthalocyanine that does not exhibit a peak in a range of from equal to or higher than 50° C. and equal to or lower than 400° C. in a differential scanning calorimetry spectrum thereof, other than a peak resulting from vaporization of adsorbed water.
(C) Y-form titanyl phthalocyanine that does not exhibit a peak in a range of equal to or higher than 50° C. and equal to or lower than 270° C. other than a peak resulting from vaporization of adsorbed water and that exhibits a peak in a range of higher than 270° C. and equal to or lower than 400° C., in a differential scanning calorimetry spectrum thereof.

Y-form titanyl phthalocyanine is preferable that does not exhibit a peak in a range of equal to or higher than 50° C. and equal to or lower than 270° C. other than a peak resulting from vaporization of adsorbed water and that exhibits a peak in a range of higher than 270° C. and equal to or lower than 400° C., in a differential scanning calorimetry spectrum thereof. Y-form titanyl phthalocyanine that exhibits such a peak is preferably Y-form titanyl phthalocyanine that exhibits one peak in a range of higher than 270° C. and equal to or lower than 400° C., and more preferably Y-form titanyl phthalocyanine that exhibits one peak at 296° C.

The following describes an example of a differential scanning calorimetry spectrum measuring method. A sample (titanyl phthalocyanine) is placed on a sample pan, and a differential scanning calorimetry spectrum of the sample is measured using a differential scanning calorimeter (for example, “TAS-200 MODEL DSC8230D”, product of Rigaku Corporation). The measurement range is for example from 40° C. to 400° C. The heating rate is for example 20° C./minute.

A content percentage of the charge generating material in the photosensitive layer502is preferably greater than 0.0% by mass and no greater than 1.0% by mass, and more preferably greater than 0.0% by mass and no greater than 0.5% by mass. As a result of the content percentage of the charge generating material in the photosensitive layer502being no greater than 1.0% by mass, the chargeability ratio can be increased. In content percentage calculation, mass of the photosensitive layer502is total mass of materials contained in the photosensitive layer502. In a case where the photosensitive layer502contains a charge generating material, a hole transport material, an electron transport material, and a first binder resin, the mass of the photosensitive layer502is total mass of the charge generating material, the hole transport material, the electron transport material, and the first binder resin. In a case where the photosensitive layer502contains a charge generating material, a hole transport material, an electron transport material, a first binder resin, and an additive, the mass of the photosensitive layer502is total mass of the charge generating material, the hole transport material, the electron transport material, the first binder resin, and the additive.

No particular limitations are placed on the hole transport material. Examples of the hole transport material include nitrogen-containing cyclic compounds and condensed polycyclic compounds. Examples of the nitrogen-containing cyclic compounds and condensed polycyclic compounds include triphenylamine derivatives; diamine derivatives (specific examples include an N,N,N′,N′-tetraphenylbenzidine derivative, an N,N,N′,N′-tetraphenylphenylenediamine derivative, an N,N,N′,N′-tetraphenylnaphtylenediamine derivative, a di(amnophenylethenyl)benzene derivative, and an N,N,N′,N′-tetraphenylphenanthrylenediamine derivative); oxadiazole-based compounds (specific examples include 2,5-di(4-methylaminophenyl)-1,3,4-oxadiazole); styryl-based compounds (specific examples include 9-(4-diethylaminostyryl)anthracene); carbazole-based compounds (specific examples include polyvinyl carbazole); organic polysilane compounds; pyrazoline-based compounds (specific examples include 1-phenyl-3-(p-dimethylaminophenyl)pyrazoline); hydrazone-based compounds; indole-based compounds; oxazole-based compounds; isoxazole-based compounds; thyazike-based compounds; thiadiazole-based compounds; imidazole-based compounds; pyrazole-based compounds; and triazole-based compounds. The photosensitive layer502may contain only one hole transport material or may contain two or more hole transport materials.

An example of a preferable hole transport material that can contribute to inhibition of occurrence of a ghost image is a compound represented by general formula (10) shown below (also referred to below as a hole transport material (10)).

In general formula (10), R13to R15each represent, independently of one another, an alkyl group having a carbon number of at least 1 and no greater than 4 or an alkoxy group having a carbon number of at least 1 and no greater than 4. m and n each represent, independently of one another, an integer of at least 1 and no greater than 3. p and r each represent, independently of one another, 0 or 1. q represents an integer of at least 0 and no greater than 2. When q represents 2, two chemical groups R14may be the same as or different from one another.

In general formula (10), R14is preferably an alkyl group having a carbon number of at least 1 and no greater than 4, more preferably a methyl group, an ethyl group, or an n-butyl group, and particularly preferably an n-butyl group. Preferably, q is 1 or 2. More preferably, q is 1. Preferably, p and r each are 0. Preferably, m and n each are 1 or 2. More preferably, m and n each are 2.

A preferable example of the hole transport10) is a compound represented by chemical formula (HTM-1) shown below (also referred to below as a hole transport material (HTM-1)).

A content percentage of the hole transport material in the photosensitive layer502is preferably greater than 0.0% by mass and no greater than 35.0% by mass, and more preferably at least 10.0% by mass and no greater than 30.0% by mass.

Examples of the first binder resin include thermoplastic resins, thermosetting resins, and photocurable resins. Examples of the thermoplastic resin include polycarbonate resins, polyarylate resins, styrene-butadiene copolymers, styrene-acrylonitrile copolymers, styrene-maleic acid copolymers, acrylic acid polymers, styrene-acrylic acid copolymers, polyethylene resins, ethylene-vinyl acetate copolymers, chlorinated polyethylene resins, polyvinyl chloride resins, polypropylene resins, ionomer resins, vinyl chloride-vinyl acetate copolymers, alkyd resins, polyamide resins, urethane resins, polysulfone resins, diallyl phthalate resins, ketone resins, polyvinyl butyral resins, polyester resins, and polyether resins. Examples of the thermosetting resins include silicone resins, epoxy resins, phenolic resins, urea resins, and melamine resins. Examples of the photocurable resins include acrylic acid adducts of epoxy compounds and acrylic acid adducts of urethane compounds. The photosensitive layer502may contain only one first binder resin or may contain two or more first binder resins.

In order to inhibit occurrence of a ghost image, the first binder resin preferably includes a polyarylate resin (also referred to below as a polyarylate resin (20)) including a repeating unit represented by general formula (20) shown below (also referred to below as a repeating unit (20)).

In general formula (20), R20and R21each represent, independently of one another, a hydrogen atom or an alkyl group having a carbon number of at least 1 and no greater than 4. R22and R23each represent, independently of one another, a hydrogen atom, a phenyl group, or an alkyl group having a carbon number of at least 1 and no greater than 4. R22and R23may be bonded to one another to form a divalent group represented by general formula (W) shown below. Y represents a divalent group represented by chemical formula (Y1), (Y2), (Y3), (Y4), (Y5), or (Y6) shown below.

In general formula (W), t represents an integer of at least 1 and no greater than 3. * represents a bond.

In chemical formulas (Y1) to (Y6), * represents a bond. Specifically, * in chemical formulas (Y1) to (Y6) represents a bond to a carbon atom to which Y in general formula (20) is bonded.

In general formula (20), R20and R21each are preferably an alkyl group having a carbon number of at least 1 and no greater than 4, and more preferably a methyl group. R22and R23are preferably bonded to one another to form a divalent group represented by general formula (W). Preferably, Y is a divalent group represented by chemical formula (Y1) or (Y3). Preferably, tin general formula (W) is 2.

The polyarylate resin (20) preferably includes only the repeating unit represented by general formula (20), but may additionally include another repeating unit. A ratio (mole fraction) of the number of the repeating units (20) to a total number of repeating units in the polyarylate resin (20) is preferably at least 0.80, more preferably, at least 0.90, and further preferably 1,00. The polyarylate resin (20) may include only one type of the repeating unit (20) or may include two or more types (for example, two types) of the repeating unit (20).

Note that the ratio (mole fraction) of the number of the repeating units (20) to the total number of repeating units in the polyarylate resin (20) is a number average value obtained from the entirety (a plurality of resin chains) of the polyarylate resin (20) contained in the photosensitive layer502, rather than a value obtained from one resin chain thereof. The mole fraction can be calculated for example from a1H-NMR spectrum of the polyarylate resin (20) plotted using a proton nuclear magnetic resonance spectrometer.

Preferable examples of the repeating unit (20) include a repeating unit represented by chemical formula (20-a) shown below and a repeating unit represented by chemical formula (20-b) shown below (also referred to below as repeating units (20-a) and (20-b), respectively). The polyarylate resin (20) preferably includes at least one of the repeating units (20-a) and (20-b), and more preferably includes both of the repeating units (20-a) and (20-b).

In a case where the polyarylate resin (20) includes both of the repeating units (20-a) and (20-b), no particular limitations are placed on the sequence of the repeating units (20-a) and (20-b). The polyarylate resin (20) including the repeating units (20-a) and (20-b) may be a random copolymer, a block copolymer, a periodic copolymer, or an alternating copolymer.

In a case where the polyarylate resin (20) includes both of the repeating units (20-a) and (20-b), a preferable example of the polyarylate resin (20) is a polyarylate resin having a main chain represented by general formula (20-1) shown below.

In general formula (20-1), u and v each represent, independently of one another, a number of at least 30 and no greater than 70. A sum of u and v is 100.

Independently of one another, u and v each are preferably a number of at least 40 and no greater than 60, more preferably, a number of at least 45 and no greater than 55, still more preferably a number of at least 49 and no greater than 51, and particularly preferably 50. Note that u represents a percentage of the number of the repeating units (20-a) to a sum of the number of the repeating units (20-a) and the number of the repeating units (20-b) included in the polyarylate resin (20). Also, v represents a percentage of the number of the repeating units (20-b) to the sum of the number of the repeating units (20-a) and the number of the repeating units (20-b) included in the polyarylate resin (20). A preferable example of a polyarylate resin having the main chain represented by general formula (20-1) is a polyarylate resin having a main chain represented by general formula (20-1a) shown below.

The polyarylate resin (20) may have a terminal group represented by chemical formula (Z) shown below. In chemical formula (Z), * represents a bond. Specifically, * in chemical formula (Z) represents a bond to a main chain of the polyarylate resin (20). In a case where the polyarylate resin (20) includes the repeating unit (20-a), the repeating unit (20-b), and a terminal group represented by chemical formula (Z), the terminal group may be bonded to the repeating unit (20-a) or the repeating unit (20-b).

In order to inhibit occurrence of a ghost image, the polyarylate resin (20) preferably includes a polyarylate resin having a main chain represented by general formula (20-1) and a terminal group represented by chemical formula (Z). More preferably, the polyarylate resin (20) includes a main chain represented by general formula (20-1a) and having a terminal group represented by chemical formula (Z). In the following description, the polyarylate resin including a main chain represented by general formula (20-1a) and having a terminal group represented by chemical formula (Z) may be referred to as a polyarylate resin (R-1).

The first binder resin has a viscosity average molecular weight of preferably at least 10,000, more preferably at least 20,000, further preferably at least 30,000, further more preferably at least 50,000, and particularly preferably at least 55,000. As a result of the first binder resin having a viscosity average molecular weight of at least 10,000, abrasion resistance of the photosensitive member50tends to increase. By contrast, the first binder resin has a viscosity average molecular weight of preferably no greater than 80,000, and more preferably no greater than 70,000. As a result of the first binder resin having a viscosity average molecular weight of no greater than 80,000, the first binder resin readily dissolves in a solvent for photosensitive layer formation, thereby showing a tendency to facilitate formation of the photosensitive layer502.

A content percentage of the first binder resin in the photosensitive layer502is preferably at least 30.0% by mass and no greater than 70.0% by mass, and more preferably at least 40.0% by mass and no greater than 60.0% by mass.

Preferable examples of an electron transport materials that can contribute to inhibition of occurrence of a ghost image include compounds represented by general formulas (31), (32), and (33) shown below (also referred to below as electron transport materials (31), (32), and (33), respectively).

In general formulas (31) to (33), R1to R4and R9to R12each represent, independently of one another, an alkyl group having a carbon number of at least 1 and no greater than 8. R5to R8each represent, independently of one another, a hydrogen atom, a halogen atom, or an alkyl group having a carbon number of at least 1 and no greater than 4.

In general formulas (31) to (33), an alkyl group having a carbon number of at least 1 and no greater than 8 that may be represented by any of R1to R4and R9to R12is preferably an alkyl group having a carbon number of at least 1 and no greater than 5, and more preferably a methyl group, a tert-butyl group, or a 1,1-dimethylpropyl group. Preferably, R5to R8each are a hydrogen atom.

The electron transport material (31) is preferably a compound represented by chemical formula (ETM-1) shown below (also referred to below as an electron transport material (ETM-1)). The electron transport material (32) is preferably a compound represented by chemical formula (ETM-3) shown below (also referred to below as an electron transport material (ETM-3)). The electron transport material (33) is preferably a compound represented by chemical formula (ETM-2) shown below (also referred to below as an electron transport material (ETM-2)).

In order to inhibit occurrence of a ghost image, the photosensitive layer502preferably contains at least one of the electron transport material (31) and the electron transport material (32) as the electron transport material, and more preferably contains both (two) of the electron transport material (31) and the electron transport material (32).

In order to inhibit occurrence of a ghost image, the photosensitive layer502preferably contains at least one of the electron transport material (ETM-1) and the electron transport material (ETM-3) as the electron transport material, and more preferably contains both (two) of the electron transport material (ETM-1) and the electron transport material (ETM-3).

A content percentage of the electron transport material in the photosensitive layer502is preferably at least 5.0% by mass and no greater than 50.0% by mass, and more preferably at least 20.0% by mass and no greater than 30.0% by mass. In a case of the photosensitive layer502containing two or more electron transport materials, the content percentage of the electron transport material refers to a total content percentage of the two or more electron transport materials.

The photosensitive layer502may further contain a specific compound represented by general formula (40) shown below (also referred to below as an additive (40)) as necessary. However, in order to increase the chargeability ratio, it is preferable that the photosensitive layer502does not contain the additive (40). In a situation in which the additive (40) is used according to necessity, a content percentage of the additive (40) in the photosensitive layer502is set to greater than 0.0% by mass and no greater than 1.0% by mass. The additive (40) can be used for example to adjust the chargeability ratio.

In general formula (40), R40and R41each represent, independently of one another, a hydrogen atom or a monovalent group represented by general formula (40a) shown below.

In general formula (40a), X represents a halogen atom. Examples of the halogen atom represented by X include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom. Preferably, the halogen atom represented by X is a chlorine atom. * represents a bond. Specifically, * in general formula (40a) represents a bond to a carbon atom to which R40or R41in general formula (40a) is bonded.

In general formula (40), A represents a divalent group represented by chemical formula (A1), (A2), (A3), (A4), (A5), or (A6) shown below. In chemical formulas (A1) to (A6), * represents a bond. Specifically, * in chemical formulas (A1), (A2), (A3), (A4), (A5), and (A6) represents a bond to a carbon atom to which A in general formula (40) is bonded. Preferably, the divalent group represented by A is a divalent group represented by chemical formula (A4).

A specific example of the additive (40) is a compound represented by chemical formula (40-1) shown below (also referred to below as an additive (40-1)).

The photosensitive layer502may further contain an additive other than the additive (40) (also referred to below as an additional additive) as necessary. Examples of the additional additive include antidegradants (specific examples include antioxidants, radical scavengers, quenchers, and ultraviolet absorbing agents), softeners, surface modifiers, extenders, thickeners, dispersion stabilizers, waxes, donors, surfactants, and leveling agents. In a case where the additional additive is contained in the photosensitive layer502, the photosensitive layer502may contain only one additional additive or may contain two or more additional additives.

In order to inhibit occurrence of a ghost image, the photosensitive layer502preferably contains: materials of types and content percentages indicated in Combination example Nos. 1 to 3 in Table 1 below; materials of types and content percentages indicated in Combination example Nos. 4 to 6 in Table 2 below; or materials of types and content percentages indicated in Combination example Nos. 7 to 9 in Table 3 below.

In Tables 1 to 3, “wt %”, “CGM”, “HTM”, “ETM”, and “Resin” respectively represent “% by mass”, “charge generating material”, “hole transport material”, “electron transport material”, and “first binder resin”. In Tables 1 to 3, “Content percentage” represents a content percentage of a corresponding material in the photosensitive layer502. In Tables 1 to 3, “ETM-1/ETM-3” indicates that both the electron transport material (ETM-1) and the electron transport material (ETM-3) are contained as the electron transport material. In Tables 1 to 3, a sign “-” indicates that no corresponding material is contained. In Table 3, “CGM-1” indicates Y-form titanyl phthalocyanine represented by chemical formula (CGM-1). The Y-form titanyl phthalocyanine in Table 3 is preferably Y-form titanyl phthalocyanine that exhibits no peak in a range of 50° C. or higher and 270° C. or lower other than a peak resulting from vaporization of adsorbed water and that exhibits a peak in a range of 270° C. or higher and 400° C. or lower (specifically, one peak at 296° C.), in a differential scanning calorimetry spectrum thereof.

The intermediate layer503contains for example inorganic particles and a resin used for the intermediate layer503(intermediate layer resin). Provision of the intermediate layer503can facilitate flow of electric current generated when the photosensitive member50is exposed to light and inhibit increasing resistance, while also maintaining insulation to a sufficient degree so as to inhibit occurrence of leakage current.

Examples of the inorganic particles include particles of metals (specific examples include aluminum, iron, and copper), particles of metal oxides (specific examples include titanium oxide, alumina, zirconium oxide, tin oxide, and zinc oxide), and particles of non-metal oxides (specific examples include silica). One type of the inorganic particles listed above may be used independently. Alternatively, two or more types of the inorganic particles listed above may be used in combination. Note that the inorganic particles may be surface-treated. No particular limitations are placed on the intermediate layer resin as long as it can be used for formation of the intermediate layer503.

In an example of a method for producing the photosensitive member50, an application liquid for forming the photosensitive layer502(also referred to below as an application liquid for photosensitive layer formation) is applied onto the conductive substrate501. The photosensitive layer502is formed through the above application to produce the photosensitive member50. The application liquid for photosensitive layer formation is prepared by dissolving or dispersing a charge generating material, a hole transport material, an electron transport material, a first binder resin, and an optional component as necessary in a solvent.

No particular limitations are placed on the solvent contained in the application liquid for photosensitive layer formation so long as each component contained in the application liquid can be dissolved or dispersed therein. Examples of the solvent include alcohols (for example, methanol, ethanol, isopropanol, and butanol), aliphatic hydrocarbons (for example, n-hexane, octane, and cyclohexane), aromatic hydrocarbons (for example, benzene, toluene, and xylene), halogenated hydrocarbons (for example, dichloromethane, dichloroethane, carbon tetrachloride, and chlorobenzene), ethers (for example, dimethyl ether, diethyl ether, tetrahydrofuran, ethylene glycol dimethyl ether, diethylene glycol dimethyl ether, and propylene glycol monomethyl ether), ketones (for example, acetone, methyl ethyl ketone, and cyclohexanone), esters (for example, ethyl acetate and methyl acetate), dimethyl formaldehyde, dimethyl formamide, and dimethyl sulfoxide. Only one of the solvents listed above may be used independently, or two or more of the solvents listed above may be used in combination. In order to increase workability in production of the photosensitive member50, a non-halogen solvent (a solvent other than a halogenated hydrocarbon) is preferably used as the solvent.

The application liquid for photosensitive layer formation is prepared by mixing each component to disperse the components in the solvent. Mixing or dispersion can be done by using for example a bead mill, a roll mill, a ball mill, an attritor, a paint shaker, or an ultrasonic disperser.

In order to increase dispersibility of each component, the application liquid for photosensitive layer formation may contain a surfactant, for example.

No particular limitations are placed on a method for applying the application liquid for photosensitive layer formation as long as the method enables uniform application of the application liquid onto the conductive substrate501. Examples of the application method includes blade coating, dip coating, spray coating, spin coating, and bar coating.

No particular limitations are placed on a method for drying the application liquid for photosensitive layer formation as long as the solvent in the application liquid can be evaporated through the method. Examples of the method for drying the application liquid for photosensitive layer formation include heat treatment (hot-air drying) using a high-temperature dryer or a reduced pressure dryer. The heat treatment may be performed for example at a temperature of 40° C. or higher and 150° C. or lower. The heat treatment may be performed for example for 3 minutes or longer and 120 minutes or shorter.

Note that the method for producing the photosensitive member50may further involve either or both formation of the intermediate layer503and formation of the protective layer504as necessary. Respective known methods are appropriately selected for the formation of the intermediate layer503and the formation of the protective layer504.

Through the above, the photosensitive member50has been described. Referring again toFIG. 2, description will be made next about the toners T for the image forming apparatus1, and the charging rollers51, the primary transfer rollers53, the static elimination lamps54, and the cleaners55each included in the image forming apparatus1.

The following describes the toners T that are contained in the toner cartridges60M to60BK illustrated inFIG. 1and that are supplied to the circumferential surfaces50aof the respective photosensitive members50. Each of the toners T includes toner particles. The toner T is a collection (powder) of the toner particles. The toner particles each include a toner mother particle and an external additive. The toner mother particle contains at least one of a binder resin, a releasing agent, a colorant, a charge control agent, and a magnetic powder. The external additive is attached to a surface of the toner mother particle. Note that the external additive may not be contained if unnecessary. In a case where no external additive is contained, the toner mother particle corresponds to a toner particle. The toner T may be a capsule toner or a non-capsule toner. A toner T that is a capsule toner can be produced by forming shell layers on the surfaces of the toner mother particles.

The toner T preferably has a number average circularity of at least 0.960 and no greater than 0.998. As a result of the toner T having a number average circularity of at least 0.960, development and transfer can be done favorably, resulting in output of a closer image. As a result of the toner T having a number average circularity of no greater than 0.998, it is difficult for the toner T to pass through a gap between the cleaning blade81and the circumferential surface50aof the photosensitive member50. The number average circularity of the toner T is preferably at least 0.960 and no greater than 0.980, more preferably at least 0.965 and no greater than 0.980, further preferably at least 0.970 and no greater than 0.980, and particularly preferably at least 0.975 and no greater than 0.980. The number average circularity of the toner T can be measured using a flow particle imaging analyzer (for example, “FPIA (registered Japanese trademark) 3000”, product of SYSMEX CORPORATION).

The toner T preferably has a volume median diameter (also referred to below as D50) of at least 4.0 μm and no greater than 7.0 μm. As a result of the toner T having a D50of no greater than 7.0 μm, a high-definition image with no granular appearance can be output. The smaller the D50of the toner T is, the smaller the amount of the toner T necessary for formation of an image with a desired image density is. As such, when the toner T has a D50of no greater than 7.0 μm, an amount of the toner T used can be reduced. As a result of the toner T having a D50of at least 4.0 μm, it is difficult for the toner T to pass through the gap between the cleaning blade81and the circumferential surface50aof the photosensitive member50. The D50of the toner T is preferably at least 4.0 μm and no greater than 6.0 μm, and more preferably at least 4.0 μm and no greater than 5.0 μm. The D50of the toner T can be measured using a particle size distribution analyzer (for example, “COULTER COUNTER MULTISIZER 3”, product of Beckman Coulter, Inc.). Note that the D50of the toner T is a value of particle diameter at 50% of cumulative distribution of a volume distribution of the toner T measured using a particle size distribution analyzer.

Each of the charging rollers51is located in contact with or adjacent to the circumferential surface50aof a corresponding one of the photosensitive members50. The image forming apparatus1adopts a direct discharge process or a proximity discharge process. The charging time is shorter and the charge amount to the photosensitive member50is smaller in a configuration including the charging roller51located in contact with or adjacent to the circumferential surface50aof the photosensitive member50than in a configuration including a scorotron charger. In image formation using the image forming apparatus1including the charging roller51located in contact with or adjacent to the circumferential surface50aof the photosensitive member50, it is difficult to uniformly charge the circumferential surface50aof the photosensitive member50and a ghost image is likely to occur. However, as already described, the image forming apparatus1according to the present embodiment can inhibit occurrence of a ghost image. Accordingly, it is possible to sufficiently inhibit occurrence of a ghost image even if the charging roller51is located in contact with or adjacent to the circumferential surface50aof the photosensitive member50.

A distance between the charging roller51and the circumferential surface50aof the photosensitive member50is preferably no greater than 50 μm, and more preferably no greater than 30 μm. The image forming apparatus1according to the present embodiment can sufficiently inhibit occurrence of a ghost image even if the distance between the charging roller51and the circumferential surface50aof the photosensitive member50is in the above-specified range.

Preferably, the charging voltage (charging bias) that is applied to the charging roller51is a direct current voltage. The amount of electrical discharge from the charging roller51to the photosensitive member50can be smaller and the abrasion amount of the photosensitive layer502of the photosensitive member50can be smaller in a configuration in which the charging voltage is a direct current voltage than in a configuration in which the charging voltage is a composite voltage obtained by superimposing an alternating current voltage on a direct current voltage.

A ghost image is likely to occur particularly when the charging roller51is located in contact with or adjacent to the circumferential surface50aof the photosensitive member50and the charging voltage is a direct current voltage. However, as long as the photosensitive member50satisfies formula (1), the image forming apparatus1according to the present embodiment can inhibit occurrence of a ghost image even if the charging roller51is located in contact with or adjacent to the circumferential surface50aof the photosensitive member50and the charging voltage is a direct current voltage.

An upper limit of the ten-point average roughness Rz of the circumferential surface of the charging roller51is 25 μm. A lower limit of the ten-point average roughness Rz of the circumferential surface of the charging roller51is 6 μm, and preferably 18 μm. As a result of the circumferential surface of the charging roller51having a ten-point average roughness Rz of greater than 25 μm and less than 6 μm, image formation on a sheet P using the image forming apparatus1leads to occurrence of charge irregularity on an image formed on the sheet P. As long as the circumferential surface of the charging roller51has a ten-point average roughness Rz of at least 18 μm, occurrence of charge irregularity can be inhibited for a long period of time. Specifically, when the image forming apparatus1is used, the external additive of the toner T, part of the sheet P, or the like may adhere to recesses in the surface of the charging roller51. When the external additive of the toner T or the like adheres to the recesses in the surface of the charging roller51, the ten-point average roughness Rz of the circumferential surface of the charging roller51tends to decrease. For example, once the cumulative number of images formed by the image forming apparatus1on sheets P reaches a maximum number of sheets on which an image is formable (formable sheet number), the ten-point average roughness Rz of the circumferential surface of the charging roller51tends to decrease by approximately 10 μm from the ten-point average roughness in an initial state. The formable sheet number is for example 200,000. The initial state is a state in which the image forming apparatus1has not performed image formation on a sheet P. As such, when the lower limit of the ten-point average roughness Rz of the circumferential surface of the charging roller51is 18 μm, the image forming apparatus1can inhibit occurrence of charge irregularity until the cumulative number of sheets P on which the image forming apparatus1performs image formation reaches the formable sheet number. The ten-point average roughness Rz of the circumferential surface of the charging roller51can be measured according to a method described in association with Examples.

An upper limit of the mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51is 130 μm. A lower limit of the mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51is 55 μm. As a result of the mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51being greater than 130 μm or less than 55 μm, image formation on a sheet P using the image forming apparatus1leads to occurrence of charge irregularity on an image formed on a sheet P. The mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51has a tendency not to change with use of the image forming apparatus1. The mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51can be measured according to a method described in association with Examples.

An upper limit of the hardness of the charging roller51is preferably 81 degrees. A lower limit of the hardness of the charging roller51is preferably 62 degree, and more preferably 75 degrees. As a result of the upper limit of the hardness of the charging roller51being 81 degrees, occurrence of charge irregularity can be further inhibited and progress of shaving of the photosensitive member50resulting from contact with the charging roller51can be inhibited. As a result of the lower limit of the hardness of the charging roller51being 62 degrees, uniform charging of the photosensitive member50can be achieved even in a configuration in which the charging roller51adopts a direct discharge process. The hardness of the charging roller51can be measured according to a method described in association with Examples.

The charging roller51has an outer diameter of at least 5 mm and no greater than 20 mm, for example. The base layer51bof the charging roller51has a thickness of at least 1 mm and no greater than 5 mm, for example. The conductive shaft51aof the charging roller51is made from metal, for example.

The surface layer51chas a thickness of preferably at least 5 μm and no greater than 30 μm, and more preferably at least 10 μm and no greater than 20 μm. As a result of the surface layer51chaving a thickness of at least 5 μm, occurrence of insulation breakdown of the surface layer51ccan be inhibited. As a result of the surface layer51chaving a thickness of no greater than 30 μm, occurrence of irregularity in film thickness of the surface layer51ccan be inhibited.

A lower limit of the volume resistivity of the surface layer51cis 13.0 log Ω·cm. An upper limit of the volume resistivity of the surface layer51cis preferably 17.8 log Ω·cm, and more preferably 16.0 log Ω·cm. As a result of the surface layer51chaving a volume resistivity of less than 13.0 log Ω·cm, image formation on a sheet P using the image forming apparatus1leads to occurrence of charge irregularity in an image formed on the sheet P. As a result of the surface layer51chaving a volume resistivity of no greater than 17.8 log Ω·cm, charge tends to be further discharged from the surface51dof the charging roller51to the photosensitive member50. As a result of the surface layer51chaving a volume resistivity of no greater than 16.0 log Ω·cm, charge tends to be further discharged from the surface51dof the charging roller51to the photosensitive member50. The volume resistivity of the surface layer51ccan be measured according to a method described in association with Examples.

The base layer51bcontains for example rubber. Examples of the rubber contained in the base layer51binclude polyurethane-based elastomer, hydrin rubber (specifically, epichlorohydrin rubber), styrene-butadiene rubber (SBR), polynorbornene rubber, ethylene propylene diene monomer rubber (EPDM), acrylonitrile-butadiene rubber (NBR), hydrogenated acrylonitrile-butadiene rubber (H-NBR), butadiene rubber (BR), isoprene rubber (IR), natural rubber (NR), and silicone rubber. Any one of the rubbers listed above may be used independently, or any two or more of the rubbers listed above may be used in combination. A preferable rubber that the base layer51bcontains is epichlorohydrin rubber. The base layer51bmay further contain a conducting agent in order to increase conductivity. Examples of the conducting agent include carbon black, graphite, potassium titanate particles, iron oxide particles, titanium oxide particles, zinc oxide particles, tin oxide particles, and ion conducing agents (examples include quaternary ammonium salts, borates, and surfactants). Any one of the conducting agents listed above may be used independently, or any two or more of the conducting agents listed above may be used in combination. A preferable conducting agent is an ion conducting agent. The base layer51bmay further contain any of a foaming agent, a crosslinking agent, a crosslinking accelerator, and an oil as necessary.

It is favorable that the surface layer51ccontains a second binder resin. Examples of the second binder resin include polyamide resins, acrylic fluorine-based resins, and acrylic silicone-based resins. Examples of the polyamide resins include N-methoxymethylated nylon resins, ethoxymethylated nylon resins, and copolymerized nylon resins. One of the second binder resins listed above may be used independently, or two or more of the second binder resins listed above may be used in combination. A polyamide resin is preferable as the second binder resin. Selection of an appropriate second binder resin or the like can result in adjustment of the hardness of the charging roller51to a specific range.

The surface layer51cmay contain resin particles as necessary. A material of the resin particles includes an acrylic acid-based resin, for example. Examples of the acrylic acid-based resin include acrylic resins, methacrylic resins, styrene-acrylate copolymers, styrene-methacrylate copolymers, and styrene-α-chloromethyl methacrylate copolymers. Preferably, the material of the resin particles is an acrylic resin. The resin particles preferably have an average particle diameter of at least 10 μm and no greater than 35 μm. The average particle diameter of the resin particles is a value obtained according to the following method. First, equivalent circle diameters of primary particles of 20 resin particles (Heywood diameter: diameters of circles having the same areas as projected areas of the particles) are measured using a microscope (for example, a transmission electron microscope). Then, an arithmetic mean value of the equivalent circle diameters is taken to be an average particle diameter of the resin particles.

In a case where the surface layer51ccontains resin particles, a content percentage of the resin particles in the surface layer51cmay be adjusted as appropriate for example according to the average particle diameter of the resin particles and a film thickness of the surface layer51c. The content percentage of the resin particles is a ratio of mass of the resin particles to mass of the second binder resin. When the average particle diameter of the resin particles is 10 μm, the content percentage of the resin particles is preferably at least 13% by mass and no greater than 20% by mass relative to 100% by mass of the second binder resin. When the average particle diameter of the resin particles is 20 μm, the content percentage of the resin particles is preferably at least 3% by mass and no greater than 18% by mass relative to 100% by mass of the second binder resin. When the average particle diameter of the resin particles is 30 μm, the content percentage of the resin particles is preferably at least 3% by mass and no greater than 13% by mass relative to 100% by mass of the second binder resin.

Adjustment of for example the film thickness of the surface layer51c, the average particle diameter of the resin particles, and the content percentage of the resin particles can result in adjustment of the ten-point average roughness Rz of the circumferential surface of the charging roller51and the mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51to the respective specific ranges. Surface treatment on the surface layer51ccan also result in adjustment of the ten-point average roughness Rz of the circumferential surface of the charging roller51and the mean spacing Sm of projections and recesses included in a section curve of the circumferential surface of the charging roller51to the respective specific ranges.

The surface layer51cmay further contain a conductive filler as necessary. Examples of the conductive filler include carbon black, graphite, potassium titanate particles, iron oxide particles, titanium oxide particles, zinc oxide particles, phosphorus-doped tin oxide particles, and zinc oxide particles. The conductive filler is preferably tin oxide particles, phosphorous-doped tin oxide particles, or titanium oxide particles. The conductive filler preferably has an average particle diameter of at least 5 nm and no greater than 200 nm. The surface layer51cmay further contain any of a foaming agent, a crosslinking agent, a crosslinking accelerator, and an oil as necessary. The average particle diameter of the conductive filler is a value obtained according to the following method. First, equivalent circle diameters of primary particles of 20 particles of the conductive filler (Heywood diameter: diameters of circles having the same areas as projected areas of the particles) are measured using a microscope (for example, a transmission electron microscope). An arithmetic mean value of the equivalent circle diameters is taken to be an average particle diameter of the conductive filler.

In a case where the surface layer51ccontains a conductive filler, a content percentage of the conductive filler in the surface layer51ccan be adjusted as appropriate for example according to a material of the surface layer51c. The content percentage of the conductive filler is a ratio of mass of the conductive filler to mass of the second binder resin. In a case where the surface layer51ccontains a nylon resin and tin oxide particles being a conductive filler, the content percentage of the conductive filler is preferably at least 10% by mass and no greater than 30% by mass. In a case where the surface layer51ccontains a nylon resin and phosphorous-doped tin oxide particles being a conductive filler, the content percentage of the conductive filler is preferably at least 10% by mass and no greater than 30% by mass. For example, adjustment of a material of the conductive filler, an amount of the conductive filler, and a type of the second binder resin can result in adjustment of the volume resistivity of the surface layer51cto the specific range.

The following describes the primary transfer rollers53, which are under constant-voltage control, with reference toFIG. 9.FIG. 9is a diagram illustrating a power supply system for the four primary transfer rollers53. As illustrated inFIG. 9, the image forming section30further includes a power source56connected to the four primary transfer rollers53. The power source56can charge each of the primary transfer rollers53. The power source56includes a single constant voltage source57connected to the four primary transfer rollers53. The constant voltage source57applies a transfer voltage (transfer bias) to the primary transfer rollers53in primary transfer to charge each of the primary transfer rollers53. The constant voltage source57generates a constant transfer voltage (for example, a constant negative transfer voltage). That is, the primary transfer rollers53are under constant-voltage control. A toner image carried on the circumferential surface50aof each photosensitive member50is primarily transferred to the outer circumferential surface of the rotating transfer belt33due to presence of a potential difference (transfer field) between a surface potential of the circumferential surface50aof each photosensitive member50and a surface potential of a corresponding one of the primary transfer rollers53.

Electric current (for example, negative electric current) flows into the photosensitive members50from the respective primary transfer rollers53through the transfer belt33in primary transfer. In a configuration in which the primary transfer rollers53are disposed directly above the respective photosensitive members50, electric current flowing into the photosensitive members50flows in a thickness direction of the transfer belt33from the respective primary transfer rollers53. The electric current flowing into the photosensitive members50(flow-in current) changes as the volume resistivity of the transfer belt33changes provided that a constant transfer voltage is applied to the primary transfer rollers53. The tendency of a ghost image to occur increases with an increase in the flow-in current. That is, a ghost image is more likely to occur in an image formed by the image forming apparatus1including the primary transfer rollers53, which are under constant-voltage control, than in an image formed by an image forming apparatus that adopts constant-current control. However, as a result of the image forming apparatus1including the photosensitive members50that can inhibit occurrence of a ghost image, occurrence of a ghost image can be inhibited even if an image is formed using the image forming apparatus1including the primary transfer rollers53under constant-voltage control. Furthermore, in the image forming apparatus1including the primary transfer rollers53under constant-voltage control, the number of constant voltage sources57can be smaller than the number of primary transfer rollers53. Thus, the image forming apparatus1can be simplified and miniaturized.

In order to stably perform primary transfer of the toners T from the primary transfer rollers53to the transfer belt33, electric current (transfer current) flowing in the primary transfer rollers53in transfer voltage application is preferably at least −20 μA and no greater than −10 μA.

Each of the static elimination lamps54is located downstream of a corresponding one of the primary transfer rollers53in the rotational direction R of a corresponding one of the photosensitive members50. Each of the cleaners55is located downstream of a corresponding one of the static elimination lamps54in the rotational direction R of a corresponding one of the photosensitive members50. Each of the charging rollers51is located downstream of a corresponding one of the cleaners55in the rotational direction R of a corresponding one of the photosensitive members50. As a result of the respective static elimination lamps54being located between the primary transfer rollers53and the cleaners55, time between static elimination on the circumferential surfaces50aof the photosensitive members50by the static elimination lamps54to completion of charging of the circumferential surfaces50aof the photosensitive members50by the charging rollers51(also referred to below as static elimination-charging time) can be elongated. Thus, time in which excitation carrier generated within the photosensitive layers502is extinguished can be secured. The static elimination-charging time is preferably 20 ms or longer, and more preferably 50 ms or longer.

A static elimination light intensity of each static elimination lamp54is preferably at least 0 μJ/cm2and no greater than 10 μJ/cm2, and more preferably at least 0 μJ/cm2and no greater than 5 μJ/cm2. As a result of the static elimination light intensity of each static elimination lamp54being no greater than 10 μJ/cm2, an amount of charge trapped within the photosensitive layers502of the photosensitive member50decreases, so that chargeability of the photosensitive members50can be increased. A smaller static elimination light intensity of each static elimination lamp54is more preferable. The static elimination lamps54having a static elimination light intensity of 0 μJ/cm2means that static electricity on the photosensitive members50is not eliminated by the static elimination lamps54. That is, the static elimination lamps54do not perform static elimination. The static elimination light intensity of each static elimination lamp54can be measured according to a method described in association with Examples.

Each of the cleaners55includes a cleaning blade81and a toner seal82. Each of the cleaning blades81is located downstream of a corresponding one of the primary transfer rollers53in the rotational direction R of a corresponding one of the photosensitive members50. The cleaning blade81is pressed against the circumferential surface50aof the photosensitive member50and collects residual toner T on the circumferential surface50aof the photosensitive member50. The residual toner T is toner T remaining on the circumferential surface50aof the photosensitive member50after primary transfer. Specifically, an edge of the cleaning blade81is pressed against the circumferential surface50aof the photosensitive member50, and a direction from a base end toward the edge of the cleaning blade81is opposite to the rotational direction R at a contact point between the edge of the cleaning blade81and the circumferential surface50aof the photosensitive member50. The cleaning blade81is in generally-called counter-contact with the circumferential surface50aof the photosensitive member50. In the above configuration, the cleaning blade81is tightly pressed against the circumferential surface50aof the photosensitive member50such that the cleaning blade81digs into the photosensitive member50as the photosensitive member50rotates. Insufficient cleaning can be further prevented through the cleaning blade81being tightly pressed against the circumferential surface50aof the photosensitive member50. The cleaning blade81is for example a plate-shaped elastic body, more specifically, is a rubber plate. The cleaning blade81is in line-contact with the circumferential surface50aof the photosensitive member50.

Preferably, a linear pressure of the cleaning blade81on the circumferential surface50aof the photosensitive member50is at least 10 N/m and no greater than 40 N/m. As a result of the linear pressure of the cleaning blade81on the circumferential surface50aof the photosensitive member50being at least 10 N/m, insufficient cleaning can be prevented. As a result of the linear pressure of the cleaning blade81on the circumferential surface50aof the photosensitive member50being no greater than 40 N/m, occurrence of a ghost image can be further inhibited. In order to further inhibit occurrence of a ghost image and further prevent insufficient cleaning, the linear pressure of the cleaning blade81on the circumferential surface50aof the photosensitive member50is preferably at least 15 N/m and no greater than 40 N/m, more preferably at least 20 N/m and no greater than 40 N/m, further preferably at least 25 N/m and no greater than 40 N/m, further more preferably at least 30 N/m and no greater than 40 N/m, and particularly preferably at least 35 N/m and no greater than 40 N/m. The linear pressure of the cleaning blade81on the circumferential surface50aof the photosensitive member50may be within a range of two values selected from 10 N/m, 15 N/m, 20 N/m, 25 N/m, 30 N/m, 35 N/m, and 40 N/m.

The cleaning blade81has a hardness of preferably at least 60 degrees and no greater than 80 degrees, and more preferably at least 70 degrees and no greater than 78 degrees. As a result of the cleaning blade81having a hardness of at least 60 degrees, insufficient cleaning can be favorably prevented because the cleaning blade81is not excessively soft. As a result of the cleaning blade81having a hardness of no greater than 80 degrees, an abrasion amount of the photosensitive layer502of the photosensitive member50can be reduced because the cleaning blade81is not excessively hard. The hardness of the cleaning blade81can be measured according to a method described in association with Examples.

The cleaning blade81has a rebound rate of preferably at least 20% and no greater than 40%, and more preferably at least 25% and no greater than 35%. The rebound rate of the cleaning blade81can be measured according to a method described in association with Examples.

The toner seal82is in contact with the circumferential surface50aof the photosensitive member50at a location between the primary transfer roller53and the cleaning blade81, and inhibits scattering of toner T collected by the cleaning blade81.

The following describes a drive mechanism90for implementing a thrust mechanism with reference toFIG. 10.FIG. 10is a plan view describing the photosensitive members50, the cleaning blades81, and the drive mechanism90. Each of the photosensitive members50is a cylindrical member extending in the rotational axis direction D of the photosensitive member50. Each of the cleaning blades81is a plate-shaped member extending in parallel to the rotational axis direction D.

The image forming apparatus1further includes the drive mechanism90. The drive mechanism90moves either one of the photosensitive member50and the cleaning blade81in parallel to the rotational axis direction D in a reciprocal manner. In the present embodiment, the drive mechanism90reciprocally moves each photosensitive member50in the rotational axis direction D. The drive mechanism90includes a gear train, cams, elastic members, and a power supply such as a motor. The cleaning blades81are secured to a housing of the image forming apparatus1.

As described with reference toFIG. 10, the photosensitive members50are reciprocally moved in the rotational axis direction D relative to the respective cleaning blades81in the present embodiment. In the above configuration, local accumulation on and around the edge of each cleaning blade81can be moved in the rotational axis direction D, preventing a scratch in a circumferential direction of the corresponding photosensitive member50(referred to below as “a circumferential scratch”) from occurring on the circumferential surface50athereof. As a result, a streak that may occur in output images due to the toner T stuck in such a circumferential scratch is prevented. Thus, good quality of output images can be maintained over a long period of time.

Furthermore, the photosensitive members50are moved reciprocally in the present embodiment. Accordingly, drive power for reciprocal movement can be easily obtained as compared to a configuration in which the cleaning blades81are moved reciprocally, and toner leakage from opposite ends of the cleaning blades81can be inhibited.

The thrust amount of each photosensitive member50refers to a distance by which the photosensitive member50travels in one way of one back-and-forth motion. Note that an outward thrust amount and a return thrust amount are equal to each other in the present embodiment. The thrust amount of the photosensitive member50is preferably at least 0.1 mm and no greater than 2.0 mm, and more preferably at least 0.5 mm and no greater than 1.0 mm. As a result of the thrust amount of the photosensitive members50being within the above-specified range, a circumferential scratch on the photosensitive member50can be favorably prevented.

The thrust period of each photosensitive member50refers to a time taken by the photosensitive member50to make one back-and-forth motion. In the present specification, the thrust period of the photosensitive member50is expressed in terms of the number of rotations of the photosensitive member50per back-and-forth motion of the photosensitive member50. The rotation speed of the photosensitive member50is constant. Accordingly, a longer thrust period of the photosensitive member50(i.e., more rotations of the photosensitive member50per back-and-forth motion of the photosensitive member50) means that the photosensitive member50reciprocates more slowly. By contrast, a shorter thrust period of the photosensitive member50(i.e., fewer rotations of the photosensitive member50per back-and-forth motion of the photosensitive member50) means that the photosensitive member50reciprocates faster.

The thrust period of each photosensitive member50is preferably at least 10 rotations and no greater than 200 rotations, and more preferably at least 50 rotations and no greater than 100 rotations. As a result of the thrust period of the photosensitive member50being at least 10 rotations, it is easy to clean the circumferential surface50aof the photosensitive member50. Furthermore, as a result of the thrust period of the photosensitive member50being at least 10 rotations, the color image forming apparatus1tends not to undergo unintended coloristic shift. As a result of the thrust period of the photosensitive member50being no greater than 200 rotations by contrast, a circumferential scratch on the photosensitive member50can be prevented.

Through the above, an example of the image forming apparatus1according to the present embodiment has been described. However, as long as the image forming apparatus1according to the present embodiment includes an image bearing member and a charging roller, other members (for example, a static elimination device and a cleaning device) may be dispensed with. Although a configuration in which the charging voltage is a direct current voltage has been described, the present disclosure is also applicable to a configuration in which the charging voltage is an alternating current voltage or a composite voltage. The composite voltage refers to a voltage obtained by superimposing an alternating current voltage on a direct current voltage. Although the development rollers52each using a two-component developer containing the carrier CA and the toner T have been described, the present disclosure is also applicable to development devices each using a one-component developer. Although the image forming apparatus1adopting an intermediate transfer process has been described, the present disclosure is also applicable to an image forming apparatus adopting a direct transfer process.

An image forming method according to a second embodiment of the present disclosure includes charging a circumferential surface of an image bearing member to a positive polarity using a charging roller (a charging process). The image bearing member includes a conductive substrate and a photosensitive layer of a single layer, and satisfies formula (1) shown below. The photosensitive layer contains a charge generating material, a hole transport material, an electron transport material, and a binder resin. The charging roller includes a conductive shaft, a base layer covering a surface of the conductive shaft, and a surface layer covering a surface of the base layer. The surface layer has a volume resistivity at a temperature of 32.5° C. and a relative humidity of 80% of at least 13.0 log Ω·cm. The charging roller has a circumferential surface having a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. The circumferential surface of the charging roller has a section curve including projections and recesses of which mean spacing Sm is at least 55 μm and no greater than 130 μm.

In formula (1), Q represents a charge amount [C] of the circumferential surface of the image bearing member. S represents a charge area [m2] of the circumferential surface of the image bearing member. d represents a film thickness [m] of the photosensitive layer. εrrepresents a specific permittivity of the binder resin contained in the photosensitive layer. ε0represents a vacuum permittivity [F/m]. V is a value [V] calculated in accordance with formula (2) V=V0−Vr. Vrrepresents a first potential [V] of the circumferential surface of the image bearing member yet to be charged by the charging roller in the charging. V0represents a second potential [V] of the circumferential surface of the image bearing member charged by the charging roller in the charging. The image forming method according to the present embodiment can be implemented for example by the image forming apparatus1according to the first embodiment. According to the image forming method in the present embodiment, occurrence of a ghost image and charge irregularity can be inhibited.

EXAMPLES

The following further describes the present disclosure using examples. Note that the present disclosure is not limited to the scope of Examples.

The following first describes methods for measuring physical properties exhibited in tests of Reference Examples, Examples, and Comparative Examples.

An optical power meter (“OPTICAL POWER METER 3664”, product of HIOKI E.E. CORPORATION) was embedded in a circumferential surface of a target photosensitive member at a position opposite to a static elimination lamp. Static elimination light having a wavelength of 660 nm was irradiated onto the photosensitive member using the static elimination lamp, and the intensity of the static elimination light at the circumferential surface of the photosensitive member was measured using the optical power meter.

(Linear Pressure of Cleaning Blade)

A linear pressure of a cleaning blade was measured using a load cell. Specifically, a jig was fabricated that was an evaluation apparatus of which a photosensitive member has been replaced with the load cell such that the load cell was disposed in a position of contact between a cleaning blade and the circumferential surface of the photosensitive member. The angle of contact between the cleaning blade and the load cell was set to 23 degrees. The cleaning blade was pressed against the load cell. The linear pressure of the cleaning blade was measured using the load cell after ten seconds from a start of the pressing. The thus measured linear pressure was taken to be the linear pressure of the cleaning blade.

(Hardness of Cleaning Blade)

The hardness of the cleaning blade was measured using a rubber hardness tester (“ASKER RUBBER HARDNESS TESTER Type JA”, product of KOBUNSHI KEIKI CO., LTD.) by a method in accordance with Japanese Industrial Standards (JIS) K 6301.

(Rebound Rate of Cleaning Blade)

The rebound rate of the cleaning blade was measured using a rebound resilience tester (“RT-90”, product of KOBUNSHI KEIKI CO., LTD) in accordance with Japanese Industrial Standards (JIS) K 6255 (corresponding to ISO 4662). The rebound rate was measured under environmental conditions of a temperature of 25° C. and a relative humidity of 50%.

The following describes an evaluation apparatus used for testing Reference Examples, Examples, and Comparative Examples described below. The evaluation apparatus was a modified version of a multifunction peripheral (“TASKalfa (registered Japanese trademark) 356Ci, product of KYOCERA Document Solutions Inc.). A configuration and settings of the evaluation apparatus were as follows.

Diameter of photosensitive member: 30 mm

Film thickness of photosensitive layer of photosensitive member: 30 μm

Thrust amount of photosensitive member: 0.8 mm

Thrust period of photosensitive member: 70 rotations per back-and-forth motion

Charging voltage: positive direct current voltage

Material of charging roller: epichlorohydrin rubber with an ion conductor dispersed therein

Diameter of charging roller: 12 mm

Thickness of rubber-containing layer of charging roller: 3 mm

Resistance of charging roller: 5.8 log Ω where a charging voltage of +500 V is applied thereto

Distance between charging roller and circumferential surface of photosensitive member: 0 μm (direct discharge process)

Effective charge length: 226 mm

Transfer process: intermediate transfer process

Transfer voltage: negative direct current voltage

Material of transfer belt: polyimide

Angle of contact of cleaning blade: 23 degrees

Material of cleaning blade: polyurethane rubber

Hardness of cleaning blade: 73 degrees

Rebound rate of cleaning blade: 30%

Thickness of cleaning blade: 1.8 mm

Pressing method of cleaning blade: by fixing digging amount of cleaning blade in photosensitive member (fixed deflection)

Amount of cleaning blade digging into photosensitive member: in a range of at least 0.8 mm and no greater than 1.5 mm (value varying according to linear pressure of cleaning blade)

Subsequently, photosensitive members were produced. The photosensitive members were produced using materials of photosensitive layers of photosensitive members according to methods as described below.

A charge generating material, a hole transport material, electron transport materials, a first binder resin, and an additive described below were prepared as the materials of the photosensitive layers of the photosensitive members.

The Y-form titanyl phthalocyanine represented by chemical formula (CGM-1) described in association with the first embodiment was prepared as the charge generating material. The Y-form titanyl phthalocyanine did not exhibit a peak in a range of 50° C. or higher and 270° C. or lower other than a peak resulting from vaporization of adsorbed water and exhibited a peak in a range of 270° C. or higher and 400° C. or lower (specifically, one peak at 296° C.), in a differential scanning calorimetry spectrum thereof.

The hole transport material (HTM-1) described in association with the first embodiment was prepared as the hole transport material.

The electron transport materials (ETM-1) and (ETM-3) described in association with the first embodiment were prepared as the electron transport material.

The polyarylate resin (R-1) described in association with the first embodiment was prepared as the first binder resin. The polyarylate resin (R-1) had a viscosity average molecular weight of 60,000.

The additive (40-1) described in association with the first embodiment was prepared as the additive.

(Production of Photosensitive Member (P-A1))

A vessel of a ball mill was charged with 1.0 part by mass of the Y-form titanyl phthalocyanine as the charge generating material, 20.0 parts by mass of the hole transport material (HTM-1), 12.0 parts by mass of the electron transport material (ETM-1), 12.0 parts by mass of the electron transport material (ETM-3), 55.0 parts by mass of the polyarylate resin (R-1) as the first binder resin, and tetrahydrofuran as a solvent. The vessel contents were mixed for 50 hours using the ball mill to disperse the materials (the charge generating material, the hole transport material, the electron transport material, and the first binder resin) in the solvent. Through the above, an application liquid for photosensitive layer formation was obtained. The application liquid for photosensitive layer formation was applied onto a drum-shaped aluminum support as a conductive substrate by dip coating to form a liquid film. The liquid film was hot-air dried at 100° C. for 40 minutes. Through the above processes, a photosensitive layer of a single layer (film thickness 30 μm) was formed on the conductive substrate. As a result, a photosensitive member (P-A1) was obtained.

(Production of Photosensitive Members (P-A2) and (P-B1))

Each of photosensitive members (P-A2) and (P-B1) was produced according to the same method as in the production of the photosensitive member (P-A1) in all aspects other than that the charge generating material in an amount specified in Table 4 was used, the hole transport material in an amount specified in Table 4 was used, the electron transport material(s) of type and in an amount specified in Table 4 was/were used, and the first binder resin in an amount specified in Table 4 was used.

(Production of Photosensitive Members (P-A3) and (P-B2))

Each of photosensitive members (P-A3) and (P-B2) was produced according to the same method as in the production of the photosensitive member (P-A1) in all aspect other than that the first binder resin of type and in an amount specified in Table 4 and the additive of type and in an amount specified in Table 4 were used. Note that the additive (40-1) was added in order to adjust chargeability of the photosensitive members.

Chargeability ratios of the respective photosensitive members (P-A1) to (P-A3), (P-B1), and (P-B2) were measured in accordance with the chargeability ratio measurement method described in association with the first embodiment. Table 4 shows measurement results of the chargeability ratio.

In Table 4, “wt %”, “CGM”, “HTM”, “ETM”, and “Resin” respectively represent “% by mass”, “charge generating material”, “hole transport material”, “electron transport material”, and “first binder resin”. “ETM-1/ETM-3” and “12.0/12.0” indicate that both 12.0 parts by mass of the electron transport material (ETM-1) and 12.0 parts by mass of the electron transport material (ETM-3) were added each as the electron transport material. Also, “-” indicates that no corresponding material is added. Amounts of the materials are each expressed in terms of a content percentage [% by mass] thereof in a corresponding photosensitive layer. Mass of each photosensitive layer is equivalent to total mass of solids (more specifically, the charge generating material, the hole transport material, the electron transport material(s), the binder resin, and the additive) contained in a corresponding one of the application liquids for photosensitive layer formation.

The photosensitive member (P-B1) was mounted in the evaluation apparatus. The transfer current of a primary transfer roller of the evaluation apparatus was set to −20 μA. The linear pressure of a cleaning blade of the evaluation apparatus was set to 40 N/m. A charging roller of the evaluation apparatus was used to charge the circumferential surface of the photosensitive member to a potential of +500 V. The potential (+500 V) of the circumferential surface of the photosensitive member was taken to be a surface potential VA[+V]. Next, the primary transfer roller of the evaluation apparatus was used to apply a transfer voltage to the circumferential surface of the photosensitive member. The potential of the circumferential surface of the photosensitive member after the application of the transfer voltage was measured using a surface electrometer (not shown, “MODEL 344 ELECTROSTATIC VOLTMETER”, product of TREK, INC.) and taken to be the surface potential VB[+V]. A surface potential drop ΔVB-A[V] due to transfer was calculated from the thus measured surface potential VBin accordance with the following formula: “ΔVB-A=surface potential VB−surface potential VA=surface potential VB−500”. A surface potential drop ΔVB-Adue to transfer of each of the photosensitive members (P-A1), (P-A2), (P-A3), and (P-B2) was measured according to the same method as in the measurement of the surface potential drop ΔVB-Adue to transfer of the photosensitive member (P-B1).

FIG. 11shows measurement results of the surface potential drop ΔVB-Adue to transfer for the photosensitive members. A ghost image tends to occur in an output image when an absolute value of the surface potential drop ΔVB-Adue to transfer is 10 V or greater. The photosensitive members were evaluated as being capable of inhibiting occurrence of a ghost image (denoted by “OK”) if the absolute value of the surface potential drop ΔVB-Adue to transfer was lower than 10 V inFIG. 11. The photosensitive members were evaluated as being incapable of inhibiting occurrence of a ghost image (denoted by “NG”) if the absolute value of the surface potential drop ΔVB-Adue to transfer was 10 V or higher inFIG. 11.

As shown inFIG. 11, each of the photosensitive members (P-B1) and (P-B2) having a chargeability ratio of less than 0.60 had an absolute value of the surface potential drop ΔVB-Adue to transfer of 10 V or greater. It is therefore decided that the photosensitive members (P-B1) and (P-B2) are incapable of inhibiting occurrence of a ghost image when used to form images. As shown inFIG. 11, each of the photosensitive members (P-A1) to (P-A3) having a chargeability ratio of at least 0.60 had an absolute value of the surface potential drop ΔVB-Adue to transfer of less than 10 V. It is therefore decided that the photosensitive members (P-A1) to (P-A3) are capable of inhibiting occurrence of a ghost image when used to form images.

With respect to each of the photosensitive members, surface friction coefficient, Martens hardness of the photosensitive layer, and sensitivity were measured.

(Surface Friction Coefficient of Circumferential Surface of Photosensitive Member)

Non-woven fabric (“KIMWIPES S-200”, product of NIPPON PAPER CRECIA CO., LTD.) was placed on the circumferential surface of each photosensitive member, and a weight (load: 200 gf) was placed on the non-woven fabric. A contact area between the weight and the circumferential surface of the photosensitive member with the non-woven fabric therebetween was 1 cm2. The photosensitive member was caused to laterally slide at a rate of 50 mm/second with the weight fixed. Lateral friction force in the lateral sliding was measured using a load cell. The surface friction coefficient of the circumferential surface of the photosensitive member was calculated in accordance with the following formula: “Surface friction coefficient=measured lateral friction force/200”. The surface friction coefficients of the circumferential surfaces of the photosensitive members (P-A1) to (P-A3) were 0.45, 0.52, and 0.50, respectively. By contrast, the surface friction coefficients of the circumferential surfaces of the photosensitive members (P-B1) and (P-B2) were 0.55 and 0.53, respectively.

Martens hardness measurement was carried out according to nano-indentation in accordance with ISO14577 using a hardness tester (“FISCHERSCOPE (registered Japanese trademark) HM2000XYp”, product of FISCHER INSTRUMENTS K.K.). The measurement was carried out as described below under environmental conditions of a temperature of 23° C. and a relative humidity of 50%. That is, a square pyramidal diamond indenter (opposite sides angled at 135 degrees) was brought into contact with the circumferential surface of the photosensitive layer, a load gradually increasing at a rate of 10 mN/5 seconds was applied to the indenter, the load was retained for one second once the load reached 10 mN, and the load was gradually removed over five seconds after the retention. The thus measured Martens hardness of the photosensitive layer of the photosensitive member (P-A1) was 220 N/mm2.

With respect to each of the photosensitive members (P-A1) to (P-A3), sensitivity was evaluated. Evaluation of sensitivity was carried out under environmental conditions of a temperature of 23° C. and a relative humidity of 50%. First, the circumferential surface of the photosensitive member was charged to +500 V using a drum sensitivity test device (product of Gen-Tech, Inc.). Next, monochromatic light (wavelength: 780 nm, half-width: 20 nm, light intensity: 1.0 μJ/cm2) was obtained from white light of a halogen lamp using a bandpass filter. The thus obtained monochromatic light was irradiated onto the circumferential surface of the photosensitive member. A surface potential of the circumferential surface of the photosensitive member was measured when 50 milliseconds elapsed from termination of the irradiation. The thus measured surface potential was taken to be a post-irradiation potential [+V]. The measured post-irradiation potentials of the photosensitive members (P-A1), (P-A2), and (P-A3) were +110 V, +108 V, and +98 V, respectively.

These results demonstrate that the photosensitive members (P-A1) to (P-A3)) each have a surface friction coefficient of the circumferential surface, a Martens hardness of the photosensitive layer, and sensitivity that are suitable for image formation.

Next, charging rollers each including a surface layer were produced.

(Production of Charging Roller (A-1))

The surface of a conductive shaft made from aluminum (diameter 9 mm) was covered with a base layer. The base layer contained epichlorohydrin rubber and an ion conducting agent. The base layer had a resistance of 2.3×104Ω and a thickness of 3 mm. Through the covering, a member including the conductive shaft and the base layer covering the conductive shaft was obtained.

A vessel of a ball mill was charged with a conductive filler, a solvent (mixed liquid of methanol, butanol, and toluene), acrylic beads (average particle diameter 10 μm) as the resin particles, and zirconia beads. The vessel contents were stirred for 24 hours using the ball mill. Subsequently, the vessel was further charged with a nylon resin solution as the second binder resin. The amount of the conductive filler was 20% by mass. The amount of the resin particles was 10.00% by mass. The vessel contents were stirred for 24 hours using the ball mill. The vessel contents were filtered to remove the zirconia beads. Through the above processes, a surface layer coating liquid was obtained.

The surface layer coating liquid was applied onto the base layer of the member including the conductive shaft and the base layer covering the conductive shaft by dip coating to form a liquid film. The liquid film was hot-air dried at 120° C. for 40 minutes. Through the above processes, a surface layer (film thickness 10 μm) was formed on the base layer. Thus, the charging roller (A-1) was obtained.

(Production of Charging Rollers (A-2) to (A-6) and (a-1) to (a-6))

Charging rollers (A-2) to (A-6) and (a-1) to (a-6) were produced according to the same method as in the production of the charging roller (A-1) in all aspects other than changes in type and amount of the resin particles. Table 5 shows an average particle diameter and an amount of the resin particles contained in each charging roller. In Table 5, “wt %” indicates an amount of the resin particles in terms of “% by mass” when the amount of the second binder resin is 100% by mass.

(Production of Charging Roller (A-7))

The surface of a conductive shaft made from aluminum (diameter 9 mm) was covered with a base layer. The base layer contained epichlorohydrin rubber and an ion conducting agent. The base layer had a resistance of 2.3×104Ω and a thickness of 3 mm. Through the covering, a member including the conductive shaft and the base layer covering the conductive shaft was obtained.

A vessel of a ball mill was charged with a conductive filler, a solvent (a mixed liquid of methanol, butanol, and toluene), acrylic beads (average particle diameter 10 μm) as the resin particles, and zirconia beads. The vessel contents were mixed for 24 hours using the ball mill. Subsequently, the vessel was further charged with a nylon resin solution as the second binder resin. The amount of the conductive filler was 20% by mass. The amount of the resin particles was 10.00% by mass. The vessel contents were mixed for 24 hours using the ball mill. The vessel contents were filtered to remove the zirconia beads. Through the above processes, a surface layer coating liquid was obtained.

The surface layer coating liquid was applied onto the base layer of the member including the conductive shaft and the base layer covering the conductive shaft by dip coating to form a liquid film. The liquid film was hot-air dried at 120° C. for 40 minutes. Through the above processes, a surface layer (film thickness 10 μm) was formed on the base layer. Thus, the charging roller (A-7) was obtained.

(Production of Charging Rollers (a-7) to (a-15))

Charging rollers (a-7) to (a-15) were produced according to the same method as in the production of the charging roller (A-7) in all aspects other than changes in type and amount of the resin particles. Table 6 shows a type of the second binder resin and types and an amount of resin fillers contained in each charging roller. In Table 6, “wt %” indicates an amount of the resin particles in terms of “% by mass” when the amount of the second binder resin is 100% by mass.

(Ten-Point Average Roughness Rz and Mean Spacing Sm of Projections and Recesses in Section Curve of Circumferential Surface of Charging Roller)

The ten-point average roughness Rz and the mean spacing Sm of projections and recesses in a section curve of the circumferential surface of each of the charging rollers (A-1) to (A-6) and (a-1) to (a-15) were measured in accordance with a method defined in “Japanese Industrial Standards (JIS) B 0601:1994”. Measurement results are shown in Tables 5 and 6.

The hardness of each of the charging rollers (A-1) to (A-6) and (a-1) to (a-15) was measured using an Asker C hardness tester (product of KOBUNSHI KEIKI CO., LTD). Each of the charging rollers (A-1) to (A-6) and (a-1) to (a-15) had a hardness of 78 degrees.

(Volume Resistivity of Surface Layer)

The volume resistivity of the surface layer of each charging roller (A-1) to (A-6) and (a-1) to (a-15) was measured according to the following method. Note that the volume resistivity of the surface layer was measured under high-temperature and high-humidity environmental conditions of a temperature of 32.5° C. and a relative humidity of 80%.

A surface layer coating liquid for surface layer formation was applied onto a cylindrical aluminum tube to form a liquid film. The liquid film was hot-air dried at 120° C. for 40 minutes. Through the above processes, a surface layer (film thickness 10 μm) was formed on the aluminum tube. The surface resistance of the surface layer was measured using a resistivity meter (HIRESTA-UX (registered Japanese trademark) MCP-HT800, product of Mitsubishi Chemical Analytech Co., Ltd.). Specifically, two metal electrodes were brought into contact with the surface layer with a 20-mm distance apart from each other and a direct current voltage of 10 V, 100 V, or 1,000 V was applied thereto. After 10 seconds elapsed from the application of the direct current voltage, the resistance of the surface layer was measured with the direct current voltage applied.

The volume resistivity of the surface layer was calculated from the film thickness of the surface layer and the measured value of the surface resistance of the surface layer in accordance with the following formula. Measurement results are shown in Tables 5 and 6.
Volume resistivity (log Ω·cm)=surface resistance of surface layer (log Ω/□)×film thickness (cm)
<Production of Image Forming Apparatuses N1to N21>

Each of image forming apparatuses N1to N21were produced according to the following method. The photosensitive member (PA-1) was mounted in the evaluation apparatus first. A charging roller was removed from the evaluation apparatus, and one of the charging rollers (A-1) to (A-6) and (a-1) to (a-15) was mounted in the evaluation apparatus in place of the removed charging roller. Through the above replacement, the image forming apparatuses N1to N21were prepared that each are an evaluation apparatus for charge irregularity evaluation. Note that the image forming apparatuses N1to N21were set to have a transfer current of −20 μA, a linear pressure of its cleaning blade of 40 N/m, and a potential of the circumferential surface of its photosensitive member of +500 V.

Image evaluation for each of the image forming apparatuses N1to N21was carried out according to the following method.

<Evaluation of Charge Irregularity>

Each of the image forming apparatuses N1to N21was left to stand in environmental conditions of a temperature of 32.5° C. and a relative humidity of 80% for 24 hours. A halftone image (density 25%) was formed on a sheet P under environmental conditions of a temperature of 32.5° C. and a relative humidity of 80% using one of the image forming apparatuses N1to N21(an image formation test). After the image formation test, the formed halftone image was visually observed to determine the presence or absence of charge irregularity (spots of voids). Charge irregularity was evaluated in accordance with the following criteria. Measurement results are shown in Tables 5 and 6 below.

A (Good): No charge irregularity was observed.

B (Poor): Charge irregularity was observed.

The image forming apparatuses N2, N4, N6, N8, N9, and N11each included an image bearing member and a charging roller that charges the circumferential surface of the image bearing member to a positive polarity. The image bearing member included a conductive substrate and a photosensitive layer of a single layer, and satisfied formula (1) shown above. The photosensitive layer contained a charge generating material, a hole transport material, an electron transport material, and a first binder resin. The charging roller included a conductive shaft, a base layer covering a surface of the conductive shaft, and a surface layer covering a surface of the base layer. The surface layer had a volume resistivity at a temperature of 32.5° C. and a relative humidity of 80% of at least 13.0 log Ω·cm. The charging roller had a circumferential surface having a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. The circumferential surface of the charging roller had a section curve including projections and recesses of which mean spacing Sm was at least 55 μm and no greater than 130 μm. As a result, the image forming apparatuses N2, N4, N6, N8, N9, and N11inhibited occurrence of charge irregularity even under the high-temperature and high-humidity environmental conditions. It is determined that the image forming apparatuses N2, N4, N6, N8, N9, and N11, each of which included the photosensitive member (PA-1), can inhibit occurrence of a ghost image.

By contrast, the image forming apparatuses N1, N3, N5, N7, N10, N12, and N13to N21did not have the above configuration. Specifically, the image forming apparatuses N1and N12each did not include a charging roller with a circumferential surface having a ten-point average roughness Rz of at least 6 μm and no greater than 25 μm. The image forming apparatuses N3, N5, N7, and N10each did not include a charging roller with a circumferential surface having a section curve including projections and recesses of which mean spacing Sm was at least 55 μm and no greater than 130 μm. The image forming apparatuses N13to N21each did not include a surface layer having a volume resistivity of at least 13.0 log Ω·cm. As a result, the image forming apparatuses N1, N3, N5, N7, N10, N12, and N13to N21did not inhibit occurrence of charge irregularity.