# Patent

## Title
Charging member, process cartridge, and image forming apparatus for reducing production of micro-chromatic line

## Abstract

A charging member includes a support member, a conductive elastic layer disposed on the support member, and a front surface layer disposed on the conductive elastic layer. Irregularities with a cycle of shorter than 0.1 mm and irregularities with a cycle of 0.1 mm or longer are distributed on an entirety of an outer circumferential surface of the charging member, and satisfy the following conditions of (1) and (2):
(1) The irregularities with the cycle of shorter than 0.1 mm have an average height of 5 μm to 8 μm; and
(2) The irregularities with the cycle of 0.1 mm or longer have an average height of 6 μm to 30 μm.
A half-value width of a maximum frequency value of a height distribution on the outer circumferential surface is 1 μm to 3 μm.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims priority under 35 USC 119 from Japanese Patent Applications No. 2016-057370 filed Mar. 22, 2016, No. 2016-057371 filed Mar. 22, 2016, and No. 2016-057372 filed Mar. 22, 2016.
BACKGROUND
Technical Field
The present invention relates to a charging member, a process cartridge, and an image forming apparatus.
SUMMARY
According to an aspect of the invention, a charging member includes a support member, a conductive elastic layer disposed on the support member, and a surface layer disposed on the conductive elastic layer. Irregularities with a cycle of shorter than 0.1 mm and irregularities with a cycle of 0.1 mm or longer are distributed on an entirety of an outer circumferential surface of the charging member, and satisfy the following conditions of (1) and (2):
(1) The irregularities with the cycle of shorter than 0.1 mm have an average height of 5 μm to 8 μm; and
(2) The irregularities with the cycle of 0.1 mm or longer have an average height of 6 μm to 30 μm.
A half-value width of a maximum frequency value of a height distribution on the outer circumferential surface is 1 μm to 3 μm.



BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein:
FIG. 1 is a view of a schematic configuration showing an example of a charging member according to an exemplary embodiment;
FIG. 2A is a view schematically showing an example of irregularities which are distributed on an outer circumferential surface of the charging member according to the exemplary embodiment;
FIG. 2B shows an example of an approximate curve for obtaining a “half-value width of the maximum frequency value of a height distribution on the outer circumferential surface”;
FIG. 3 is a view of a schematic configuration showing an example of an image forming apparatus according to an exemplary embodiment;
FIG. 4 is a view of a schematic configuration showing an example of another image forming apparatus according to another exemplary embodiment;
FIG. 5 is a view of a schematic configuration showing an example of still another image forming apparatus according to still another exemplary embodiment; and
FIG. 6 is a view of a schematic configuration showing an example of a process cartridge according to an exemplary embodiment.



DETAILED DESCRIPTION
Hereinafter, exemplary embodiments of the invention will be described. Description and Example thereof are provided as an example of the exemplary embodiment, and thus a range of the invention is not limited thereto.
In the specification, an “electrophotographic photoreceptor” is also simply referred to as a “photoreceptor”.
In the specification, a “micro-chromatic line” indicates an unintended image that appears on a halftone image, that is, a linear image that extends in a direction orthogonal to a transport direction of a recording medium and that has a length in millimeter order.
Charging Member
A charging member according to the exemplary embodiment includes a support member, a conductive elastic layer disposed on the support member, and a surface layer disposed on the conductive elastic layer. In other words, the charging member according to the exemplary embodiment includes at least the conductive elastic layer and the surface layer which are laminated on the support member.
Then, irregularities with a cycle of shorter than 0.1 mm and irregularities with a cycle of 0.1 mm or longer, are distributed on the entirety of the outer circumferential surface of the charging member according to the exemplary embodiment. Also, the charging member according to the exemplary embodiment satisfies the following conditions of (1) and (2). A half-value width of the mode of the height distribution on the outer circumferential surface is in a range of 1 μm to 3 μm.
(1) The irregularities with the cycle of shorter than 0.1 mm have an average height of 5 μm to 8 μm.
(2) The irregularities with the cycle of 0.1 mm or longer have an average height of 6 μm to 30 μm.
There is no particular limitation to a shape of the charging member according to the exemplary embodiment. For example, examples of the shape of the charging member according to the exemplary embodiment include a roll shape shown in FIG. 1, and a belt shape.
Hereinafter, a configuration of the charging member according to the exemplary embodiment and geometric quantities of the outer circumferential surface of the charging member will be described with reference to the figures.
FIG. 1 is a view showing an example of the charging member according to the exemplary embodiment. A charging member 208 shown in FIG. 1 includes a support member 30 which is a bar-shaped member (shaft) having a cylindrical shape or a column shape, a conductive elastic layer 31 disposed on an outer circumferential surface of the support member 30, and a surface layer 32 disposed on an outer circumferential surface of the conductive elastic layer 31.
FIG. 2A is a view schematically showing an example of irregularities which are distributed on the outer circumferential surface of the charging member according to the exemplary embodiment. FIG. 2A shows a shape viewed when the surface layer 32 and the conductive elastic layer 31 of the charging member 208 are cut in a thickness direction and in an axial direction of the support member 30. The outer circumferential surface of the charging member 208 is shaped by the surface layer 32 disposed on undulation formed on the conductive elastic layer 31. According to a non-limiting embodiment shown in FIG. 2A, irregularities with the cycle of shorter than 0.1 mm (roughness components) which are distributed on the outer circumferential surface of the charging member are the irregularities originating from the surface layer 32. Further, according to a non-limiting embodiment shown in FIG. 2A, the irregularities with the cycle of 0.1 mm or longer (waviness components) which are distributed on the outer circumferential surface of the charging member are the irregularities originating mainly from the conductive elastic layer 31.
In the exemplary embodiment, a surface texture of the outer circumferential surface of the charging member is measured using a confocal laser microscope. As measurement conditions, a measurement cycle in a rotating direction (referred to as an “X direction”) of the charging member is 0.05 μm, a measurement cycle in a direction (referred to as an “Y direction”) orthogonal to the rotating direction of the charging member is 0.05 μm, a measurement range in X and Y directions is at least 400 μm by 600 μm, and a measurement range in a height directions (Z direction) is 50 μm. Then, when the charging member has the roll shape, measurement data is subjected to surface correction with curvature of a roll and noise correction in which an abnormal value is removed, and the geometric quantities of the outer circumferential surface of the charging member is obtained from the corrected correction data. Detailed description thereof is provided in the Example section.
The “half-value width of the maximum frequency value of the height distribution on the outer circumferential surface” is obtained as the half-value width (entire width at a half value), with the lowest measurement point in the corrected data as a reference (zero in height), by creating a histogram in the height of all of the measurement points in the X and Y directions and approximation of the histogram to a curve. FIG. 2B shows an example of an approximate curve for obtaining the half-value width.
An average height of the “irregularities with the cycle of shorter than 0.1 mm” and an average height of the “irregularities with the cycle of 0.1 mm or longer” are obtained by drawing a profile curve (that is, a curve formed by connecting heights in the measurement cycle of 0.05 μm, and referred to as a “Y-directional profile curve”) in the Y direction in the correction data and by analyzing the Y-directional profile curve. The cycle of the irregularities means a length between peaks of two adjacent convex portions.
The height of the “irregularities with the cycle of shorter than 0.1 mm” is obtained by removing a long-wavelength component using a wavelength of 0.1 mm as a cutoff value and creating a “roughness profile”. Heights of all convex portions on one “roughness profile” created from one Y-directional profile curve are measured. Here, a height of a convex portion means a height from the bottom of a concave portion which is the lower of the bottoms of concave portions positioned on the right and left sides of the convex portion to the vertex of the convex portion. Then, an average of heights of all convex portions on one “roughness profile” is obtained, further, an average of all “roughness profiles” in the X direction is obtained, and then the average value thereof is an average height of the “irregularities with the cycle of shorter than 0.1 mm”.
The height of the “irregularities with the cycle of 0.1 mm or longer” is obtained by removing a short-wavelength component using the wavelength of 0.1 mm as a cutoff value and creating a “waviness profile”. Heights of all of the convex portions on one “waviness profile” created from one Y-directional profile curve are measured. Here, a height of a convex portion means a height from the bottom of a concave portion which is the lower of the bottoms of a concave portion positioned on the right and left sides of the convex portion, to the convex portion. Then, an average of heights of all convex portions on one “waviness profile” is obtained, further, an average of all “waviness profiles” in the X direction is obtained, and then the average value thereof is an average height of the “irregularities with the cycle of 0.1 mm or longer”.
In the specification, the “irregularities with the cycle of shorter than 0.1 mm” is also referred to as a “roughness component”, and the “irregularities with the cycle of 0.1 mm or longer” is also referred to as a “waviness component”.
The image forming apparatus employs a charging method in which only a DC voltage is applied to the charging member, or a charging method in which a voltage obtained by superimposing an AC voltage to a DC voltage is applied to the charging member. In a case where only the DC voltage is applied to the charging member and the photoreceptor is charged by a contact charging method, an unintended micro-chromatic line is produced on an image in some cases. The charging member of the exemplary embodiment reduces production of the micro-chromatic line. As a mechanism for less production thereof, the following description is assumed.
Hereinafter, a micro-chromatic line produced when the photoreceptor is subjected to contact charging by the charging member, to which only the DC voltage is applied, is simply referred to as the micro-chromatic line.
It is considered that the micro-chromatic line is produced due to a low discharge frequency of discharge phenomena (post-discharge) that occurs immediately after a contact between the photoreceptor and the charging member. In the case where only the DC voltage is applied, it is considered that the discharge frequency of the post-discharge is low, has regions, which is not sufficiently charged, are irregularly formed on the outer circumferential surface of the charging member, and, as a result, the micro-chromatic line is likely to be produced, compared to the case where the AC voltage is superimposed to the DC voltage. When the charging member is continuously used, toner or the like is accumulated on the outer circumferential surface of the charging member. Thus, it is considered that the discharge frequency of the post-discharge is further lowered and the micro-chromatic line is more clearly viewed.
The micro-chromatic line is likely to be produced and more clearly viewed in a case where an image is formed at a higher speed and in a case where an image is formed using toner having a smaller particle diameter.
In order to reduce the production of the micro-chromatic line, it is effective that the irregularities are distributed on the outer circumferential surface of the charging member, thereby increasing a discharge space between the photoreceptor and the charging member and promoting the post-discharge. However, only the distribution of the irregularities on the outer circumferential surface of the charging member does not result in effective reduction in the production of the micro-chromatic line. In addition, when the irregularities are distributed on the outer circumferential surface of the charging member, a contact area with the photoreceptor is decreased. Thus, a property of being driven by the photoreceptor is degraded, and the higher a rotating speed of the photoreceptor is, the more the property of being driven by the photoreceptor is degraded.
Although the mechanism is not entirely clear, according to the charging member of the exemplary embodiment, the “irregularities with the cycle of shorter than 0.1 mm” (roughness components) and the “irregularities with the cycle of 0.1 mm or longer” (waviness components) are distributed on the outer circumferential surface of the charging member so as to have the average heights of 5 μm to 8 μm and of 6 μm to 30 μm, respectively, the combination of the both promotes the post-discharge when only the DC voltage is applied, causes the toner or the like to be unlikely to be attached to the outer circumferential surface, and ensures the properties of following the photoreceptor, and, as a result, the production of the micro-chromatic line is suppressed, and the charging member has a good property of being readily driven by to have a property of being readily driven by the photoreceptor.
The average height of the roughness components is preferably 5 μm to 8 μm, more preferably 5.5 μm to 7.5 μm, and still more preferably 6 μm to 7 μm.
The average height of the waviness components is preferably 6 μm to 30 μm, more preferably 8 μm to 25 μm, and still more preferably 10 μm to 20 μm.
In the exemplary embodiment, the “half-value width of the maximum frequency value of the height distribution on the outer circumferential surface” is 1 μm to 3 μm. The half-value width of wider than 3 μm or more means variations in the height of the irregularities on the outer circumferential surface.
In this case, it is difficult to reduce the production of the micro-chromatic line. It is considered that it is more desirable as the half-value width is narrower in terms of low variations in the height of the irregularities on the outer circumferential surface. However, when the half-value width is decreased to be narrower than 1 μm, the heights of the irregularities, which are distributed on the outer circumferential surface, are lowered, the outer circumferential surface becomes close to an even surface, and it is difficult to reduce the production of the micro-chromatic line. In addition, the conductive elastic layer is manufactured by extrusion molding which is suitable for mass production, and it is difficult to have the half-value width of narrower than 1 μm.
A mean cycle of the “irregularities with the cycle of shorter than 0.1 mm” (roughness components) which are distributed on the outer circumferential surface of the charging member is preferably longer than 2 μm, more preferably longer than 3 μm, and still more preferably longer than 5 μm, and is preferably 50 μm or shorter, more preferably 20 μm or shorter, and still more preferably 15 μm or shorter.
A mean cycle of the “irregularities with the cycle of 0.1 mm or longer” (waviness components) which are distributed on the outer circumferential surface of the charging member is preferably 0.15 mm or longer, more preferably 0.20 mm or longer, and still more preferably 0.25 mm or longer, and is preferably 0.45 mm or shorter, more preferably 0.35 mm or shorter, and still more preferably 0.30 mm or shorter.
A control method of the heights and the cycles of the roughness components and the waviness components which are distributed on the outer circumferential surface of the charging member will be described below.
Next, each configurational element of the charging member according to the exemplary embodiment will be described.
Support Member
The support member is a conductive member that functions as an electrode and a support of the charging member. The support member may be a hollow member (cylindrical member) or may be a non-hollow member.
Examples of the support member include a metal member formed of iron (free-machining steel or the like), copper, brass, stainless steel, aluminum, nickel, or the like; an iron member subjected to coating processing using chrome, nickel, or the like; a member subjected to plating processing on an outer circumferential surface of a resin or ceramic member; a resin or ceramic member which contains a conductive agent; or the like.
Conductive Elastic Layer
The conductive elastic layer is a layer disposed on the outer circumferential surface of the support member. The conductive elastic layer may be directly disposed on the outer circumferential surface of the support member or may be disposed on the outer circumferential surface of the support member with an adhesive layer interposed therebetween.
The conductive elastic layer may be a single layer or may be a laminated body in which plural layers are laminated. The conductive elastic layer may be a foamed conductive elastic layer, may be a non-foamed conductive elastic layer, or may also be formed by laminating the foamed conductive elastic layer and the non-foamed conductive elastic layer.
An exemplary embodiment of the conductive elastic layer contains an elastic material, a conductive agent, and other additives.
Examples of the elastic material include, for example, polyurethane, nitrile rubber, isoprene rubber, butadiene rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, epichlorohydrin rubber, epichlorohydrin-ethylene oxide rubber, epichlorohydrin-ethylene oxide-allyl glycidyl ether rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, chlorinated polyisoprene, hydrogenated polybutadiene, butyl rubber, silicone rubber, fluororubber, natural rubber, and an elastic material obtained by mixing the above substances. Of the elastic materials, it is preferable to use polyurethane, silicone rubber, nitrile rubber, epichlorohydrin rubber, epichlorohydrin-ethylene oxide rubber, epichlorohydrin-ethylene oxide-allyl glycidyl ether rubber, ethylene-propylene-diene rubber, acrylonitrile-butadiene rubber, and an elastic material obtained by mixing the above substances.
Examples of the conductive agent include an electronically conductive agent and an ion conductive agent. Examples of the electronically conductive agent include powder of carbon black such as furnace black, thermal black, channel black, ketjen black, acetylene black, color black; pyrolytic carbon; graphite; various metals or alloys such as aluminum, copper, nickel, stainless steel; various metal oxides such as a tin oxide, an indium oxide, a titanium oxide, a tin oxide-antimony oxide solid solution, a tin oxide-indium oxide solid solution; a substance subjected to conductive processing on a surface of an insulating material; or the like. Examples of the ion conductive agent include perchlorate or chlorate such as tetraethylammonium, lauryltrimethylammonium, benzyltrialkylammonium; alkali metal or alkali earth metal perchlorate or chlorate such as lithium or magnesium. As the conductive agent, one type thereof may be individually used, or a combination of two or more types thereof may be used.
It is desirable that volume resistivity of the conductive elastic layer is 103 Ωcm to 1014 Ωcm. An electronically conductive agent content in the conductive elastic layer is preferably 1 parts by weight to 30 parts by weight, and more preferably 15 parts by weight to 25 parts by weight, with respect to 100 parts by weight of the elastic material. An ion conductive agent content in the conductive elastic layer is preferably 0.1 parts by weight to 5 parts by weight, and more preferably 0.5 parts by weight to 3 parts by weight, with respect to 100 parts by weight of the elastic material.
Examples of the other compounded additives in the conductive elastic layer include, for example, a softener, a plasticizing agent, a hardener, a vulcanizing agent, a vulcanization accelerator, a vulcanization accelerator aid, an antioxidant, a surfactant, a coupling agent, and a filler.
Examples of the vulcanization accelerator include thiazole series, thiram, sulfenamide, thiourea, dithiocarbamate series, guanidine series, aldehyde-ammonia series, and the like. As the vulcanization accelerator, one type thereof may be individually used, or a combination of two or more types thereof may be used.
A vulcanization accelerator content in the conductive elastic layer is preferably 1 parts by weight to 10 parts by weight, and more preferably 2 parts by weight to 6 parts by weight, with respect to 100 parts by weight of the elastic material.
Examples of the vulcanization accelerator aid include a zinc oxide, stearic acid, and the like. As the vulcanization accelerator aid, one type thereof may be individually used, or a combination of two or more types thereof may be used.
A vulcanization accelerator aid content in the conductive elastic layer is preferably 1 parts by weight to 15 parts by weight, and more preferably 3 parts by weight to 10 parts by weight, with respect to 100 parts by weight of the elastic material.
Examples of the filler contained in the conductive elastic layer include calcium carbonate, silica, clay mineral, and the like. As the filler, one type thereof may be individually used, or a combination of two or more types thereof may be used.
A filler content in the conductive elastic layer is preferably 5 parts by weight to 100 parts by weight, and more preferably 10 parts by weight to 60 parts by weight, with respect to 100 parts by weight of the elastic material.
A granulated substance (the conductive agent such as carbon black, the vulcanization accelerator aid such as a zinc oxide, the filler such as calcium carbonate, or the like) contained in the conductive elastic layer has a particle diameter of preferably at most 10 μm or smaller and a particle diameter of more preferably 2 μm or smaller, and has a particle diameter of preferably at least 20 nm or larger and a particle diameter of more preferably 50 nm or larger. The particle diameter of the granulated substance contained in the conductive elastic layer is obtained by observing a cross section of the conductive elastic layer using an optical microscope.
The layer thickness of the conductive elastic layer is preferably 1 mm to 10 mm, more preferably 2 mm to 8 mm, and still more preferably 3 mm to 6 mm. The layer thickness of the conductive elastic layer is a value obtained by observing a cross section of the charging member cut in a direction orthogonal to the rotating direction using an optical microscope and by measuring random ten points and obtaining an average value.
An example of the adhesive layer interposed between the conductive elastic layer and the support member is a resin layer, specifically, a resin layer formed of a polyolefin, an acrylic resin, an epoxy resin, polyurethane, nitrile rubber, chlorine rubber, a vinyl chloride resin, a vinyl acetate resin, polyester, a phenolic resin, a silicone resin, or the like. The adhesive layer may contain the conductive agent (for example, the electronically conductive agent or the ion conductive agent described above).
Examples of a method of forming the conductive elastic layer on the support member include, for example, a method in which both the bar-shaped support member and a conductive elastic layer forming composition obtained by mixing the elastic material, the conductive agent, and another additive, are extruded from an extruder, a layer of the conductive elastic layer forming composition is formed on the outer circumferential surface of the support member, and then the layer of the conductive elastic layer forming composition is heated to be subjected to cross-linking reaction such that the conductive elastic layer is formed; and a method in which a conductive elastic layer forming composition obtained by mixing the elastic material, the conductive agent, and another additive, is extruded from an extruder to the outer circumferential surface of the support member having an endless belt shape, a layer of the conductive elastic layer forming composition is formed on the outer circumferential surface of the support member, and then the layer of the conductive elastic layer forming composition is heated to be subjected to cross-linking reaction such that the conductive elastic layer is formed. The support member may have an adhesive layer on the outer circumferential surface thereof.
It is desirable that the “irregularities with the cycle of 0.1 mm or longer” (waviness components) which are distributed on the outer circumferential surface of the charging member are the irregularities originating mainly from the conductive elastic layer. When wave undulation is formed on the outer circumferential surface of the charging member and the wave undulation originates from the conductive elastic layer, the wave undulation indicates elasticity when the charging member contacts with the photoreceptor, a nip with the photoreceptor is well formed such that the property of being driven by the photoreceptor is readily achieved, and good high-speed applicability is obtained.
An average height of the “irregularities with the cycle of 0.1 mm or longer” (waviness components) which are distributed on the outer circumferential surface of the conductive elastic layer is preferably 6 μm to 30 μm. In addition, a mean cycle of the waviness components on the outer circumferential surface of the conductive elastic layer is preferably 0.15 mm or longer, more preferably, 0.20 mm or longer, and still more preferably 0.25 mm or longer, and is preferably 0.45 mm or shorter, more preferably, 0.35 mm or shorter, and still more preferably 0.30 mm or shorter.
The height and the cycle of the waviness components on the outer circumferential surface of the conductive elastic layer, and the height and the cycle of the waviness components on the outer circumferential surface of the charging member are controlled, for example, by the following (i) to (iii).
(i) An amount of the vulcanization accelerator or the vulcanization accelerator aid which is contained in the conductive elastic layer forming composition: as the amount of the vulcanization accelerator or the vulcanization accelerator aid is increased, the waviness components tend to be increased.
(ii) A die temperature obtained when the conductive elastic layer forming composition is extruded from the extruder: as the die temperature is increased, the waviness components tend to become decreased. It is preferable that the die temperature is in a range of 40° C. to 95° C.
(iii) The heating temperature and a period of heating time obtained when the conductive elastic layer forming composition is heated to be subjected to the cross-linking reaction: as the heating temperature is increased, the waviness components tend to be decreased. As the period of heating time is increased, the waviness components tend to be decreased. The heating temperature is preferably in a range of 120° C. to 180° C. and the period of heating time is preferably in a range of 20 minutes to 90 minutes.
Surface Layer
For example, the surface layer is provided so as to reduce contamination of the charging member by the toner or the like.
An exemplary embodiment of the surface layer includes a binder resin, particles, and another additive. It is desirable that the particles contained in the surface layer are disposed in the binder resin.
Examples of the binder resin of the surface layer include polyamide, polyimide, polyester, polyethylene, polyurethane, a phenolic resin, a silicone resin, an acrylic resin, a melamine resin, an epoxy resin, polyvinylidene fluoride, a tetrafluoroethylene copolymer, a polyvinyl butyral, ethylene-tetrafluoroethylene copolymer, fluororubber, polycarbonate, polyvinyl alcohol, polyvinylidene chloride, polyvinyl chloride, an ethylene-vinyl acetate copolymer, cellulose, and the like. As the binder resin, one type thereof may be individually used, or a combination of two or more types thereof may be used.
An example of particles contained in the surface layer is a conductive agent. It is desirable that conductive particles having an average particle diameter of 3 μm or smaller and volume resistivity of 109 Ωcm or less as the conductive agent contained in the surface layer. Examples of the conductive particles include a metal oxide such as a tin oxide, a titanium oxide, or a zinc oxide; carbon black; and the like. As the conductive particles, it is preferable to use the tin oxide in terms of reduction in the production of the micro-chromatic line, and it is preferable to use the tin oxide individually, or to use both the tin oxide and the carbon black.
A conductive agent content in the surface layer is preferably 20 parts by weight to 80 parts by weight, and more preferably 50 parts by weight to 60 parts by weight, with respect to 100 parts by weight of the binder resin.
The surface layer may contain particles other than the conductive agent particles in order to control a shape of the surface of the charging member. Examples of the particles include polyamide particles, fluororesin particles, silicone resin particles, and the like, and it is preferable to use polyamide particles in terms of reduction in the production of the micro-chromatic line. As the particles, one type thereof may be individually used, or a combination of two or more types thereof may be used.
A particle content in the surface layer is preferably 3 parts by weight to 30 parts by weight, and more preferably 5 parts by weight to 20 parts by weight, with respect to 100 parts by weight of the binder resin.
A particle diameter of a granulated substance (conductive agent, polyamide particles, or the like) contained in the surface layer is preferably at most 15 μm or smaller and more preferably 10 μm or smaller, and preferably at least 1 μm or larger, and more preferably 3 μm or larger. The particle diameter of the granulated substance contained in the surface layer is obtained by observing a cross section of the surface layer using an optical microscope.
An example of a method of forming the surface layer on the conductive elastic layer is, for example, a method in which a surface layer forming composition obtained by mixing a binder resin, particles, and another additive is applied on the conductive elastic layer, a layer of the surface layer forming composition is formed, and then the layer of the surface layer forming composition is dried. Examples of a method of applying the surface layer forming composition on the conductive elastic layer include, for example, dip coating, roll coating, blade coating, wire bar coating, spraying, bead coating, air knife coating, and curtain coating.
The layer thickness of the surface layer is preferably 3 μm to 20 μm, and more preferably 5 μm to 15 μm. The layer thickness of the surface layer is a value obtained by observing a cross section of the charging member cut in a direction orthogonal to the rotating direction using an optical microscope and by measuring random hundred points and obtaining an average value.
It is desirable that the “irregularities with the cycle of shorter than 0.1 mm” (roughness components) which are distributed on the outer circumferential surface of the charging member are the irregularities originating from the surface layer. The highly uniform roughness components can be distributed in a method in which the “irregularities with the cycle of shorter than 0.1 mm” are formed on the surface layer and, then, the roughness components are distributed on the outer circumferential surface of the charging member, rather than in a method in which the “irregularities with the cycle of shorter than 0.1 mm” are formed on the conductive elastic layer and, then, the roughness components are distributed on the outer circumferential surface of the charging member.
An average height of the “irregularities with the cycle of shorter than 0.1 mm” (roughness components) which are distributed on the outer circumferential surface of the surface layer is preferably 5 μm to 8 μm. In addition, a mean cycle of the roughness components on the outer circumferential surface of the surface layer is preferably 2 μm or longer, more preferably 3 μm or longer, and still more preferably 5 μm or longer, and is preferably 50 μm or shorter, more preferably, 20 μm or shorter, and still more preferably 15 μm or shorter.
The height and the cycle of the roughness components on the outer circumferential surface of the surface layer, and the height and the cycle of the roughness components on the outer circumferential surface of the charging member are controlled, for example, with the particle diameter and the amount of the granulated substance contained in the surface layer forming composition. It is desirable that the irregularities are formed, on the surface of the surface layer, of the granulated substance or an aggregation substance of the granulated substance contained in the surface layer forming composition.
Charging Device, Image Forming Apparatus, and Process Cartridge
A charging device according to the exemplary embodiment is a charging device that includes the charging member according to the exemplary embodiment, and that charges the front surface of the photoreceptor by a contact charging method. The charging device according to the exemplary embodiment is a charging device which applies only the DC voltage to the charging member.
An image forming apparatus according to the exemplary embodiment includes the photoreceptor, the charging device according to the exemplary embodiment, a latent image forming device that forms a latent image on the front surface of the charged photoreceptor, a developing device that develops the latent image formed on the front surface of the photoreceptor by using developer containing toner, and that forms a toner image on the front surface of the photoreceptor, and a transfer device that transfers the toner image formed on the front surface of the photoreceptor to a recording medium. The image forming apparatus according to exemplary embodiment may further include at least one device selected from a fixing device that fixes the toner image to the recording medium; a cleaning device that cleans the front surface of the photoreceptor after the transfer of the toner image and before the charging; or a neutralization device that irradiates the front surface of the photoreceptor with light and neutralizes the charge on the front surface of the photoreceptor after the transfer of the toner image and before the charging.
The image forming apparatus according to the exemplary embodiment may be any one of a direct transfer type apparatus in which the toner image formed on the front surface of the photoreceptor is directly transferred to the recording medium, or an intermediate transfer type apparatus in which the toner image formed on the front surface of the photoreceptor is primarily transferred to a front surface of an intermediate transfer body, and then the toner image transferred to the front surface of the intermediate transfer body is secondarily transferred to a front surface of the recording medium.
A process cartridge according to the exemplary embodiment is a cartridge that is attached to and detached from the image forming apparatus and includes at least the photoreceptor and the charging device according to the exemplary embodiment. The process cartridge according to the exemplary embodiment may further include at least one device selected from the developing device, the cleaning device of the photoreceptor, the neutralization device of the photoreceptor, the transfer device, or the like.
Hereinafter, configurations of the charging device, the image forming apparatus, and the process cartridge according to the exemplary embodiment will be described with reference to the figures.
FIG. 3 is a view schematically showing the direct transfer type image forming apparatus as an example of the image forming apparatus according to the exemplary embodiment. FIG. 4 is a view schematically showing the intermediate transfer type image forming apparatus as an example of the image forming apparatus according to the exemplary embodiment.
An image forming apparatus 200 shown in FIG. 3 includes a photoreceptor 207, a charging device 208A that charges a front surface of the photoreceptor 207, a power supply 209 connected to the charging device 208A, an exposure device 206 that exposes the front surface of the photoreceptor 207 and forms a latent image, a developing device 211 that develops the latent image on the photoreceptor 207 by using developer containing toner, a transfer device 212 that transfers a toner image on the photoreceptor 207 to a recording medium 500, a fixing device 215 that fixes the toner image to the recording medium 500, a cleaning device 213 that removes toner remaining on the photoreceptor 207, and a neutralization device 214 that neutralizes the charge on the front surface of the photoreceptor 207.
An image forming apparatus 210 shown in FIG. 4 includes the photoreceptor 207, the charging device 208A, the power supply 209, the exposure device 206, the developing device 211, a primary transfer member 212a and a secondary transfer member 212b that transfer a toner image on the photoreceptor 207 to the recording medium 500, the fixing device 215, and the cleaning device 213. Similar to the image forming apparatus 200, the image forming apparatus 210 may include the neutralization device.
The charging device 208A is a contact charging type charging device that is configured with a roll-shaped charging member, that contacts with the front surface of the photoreceptor 207, and that charges the front surface of the photoreceptor 207. Only the DC voltage is applied to the charging device 208A from the power supply 209.
An example of the exposure device 206 is an optical system device that includes a light source such as a semiconductor laser, or a light emitting diode (LED).
The developing device 211 is a device that supplies toner to the photoreceptor 207. The developing device 211 causes a roll-shaped developer holding member to come into contact or to approach the photoreceptor 207 and causes the toner to be attached to a latent image on the photoreceptor 207, thereby forming a toner image.
Examples of the transfer device 212 include, for example, a corona discharge generator, and a conductive roll that is pressed to the photoreceptor 207 with the recording medium 500 interposed therebetween.
An example of the primary transfer member 212a is, for example, a conductive roll that contacts with the photoreceptor 207 and rotates. An example of the secondary transfer member 212b is, for example, a conductive roll that is pressed to the primary transfer member 212a with the recording medium 500 interposed therebetween.
An example of the fixing device 215 is a heating-fixing device that includes a heating roll and a pressure roll that is pressed to the heating roll.
An example of the cleaning device 213 is a device that includes a blade, a brush, a roll, or the like, as a cleaning member. Examples of a material of a cleaning blade include urethane rubber, neoprene rubber, silicone rubber, and the like.
The neutralization device 214 is, for example, a device that irradiates the front surface of the photoreceptor 207 with light after the transfer and that neutralizes residual potential of the photoreceptor 207.
FIG. 5 is a view of a schematic configuration showing a tandem type or intermediate transfer type image forming apparatus in which four image forming units are arranged side by side as the image forming apparatus according to the exemplary embodiment.
An image forming apparatus 220 includes, in a housing 400, four image forming units corresponding to respective color toner, an exposure device 403 that has a laser light source, an intermediate transfer belt 409, a secondary transfer roll 413, a fixing device 414, and a cleaning device that has a cleaning blade 416.
Since the four image forming units have the same configuration, the configuration of the image forming unit including a photoreceptor 401a is described as a representative thereof.
A charging roll 402a, a developing device 404a, a primary transfer roll 410a, and a cleaning blade 415a are arranged around the photoreceptor 401a in this order in a rotating direction of the photoreceptor 401a. The primary transfer roll 410a is pressed to the photoreceptor 401a with the intermediate transfer belt 409 interposed therebetween. Toner contained in a toner cartridge 405a is supplied to the developing device 404a. 
The charging roll 402a is the contact charging type charging device that contacts with the front surface of the photoreceptor 401a and charges the front surface of the photoreceptor 401a. Only the DC voltage is applied to the charging roll 402a from a power supply.
The intermediate transfer belt 409 is tensioned by a driving roll 406, a tension roll 407, and a rear roll 408, and travels by rotation of the rolls.
The secondary transfer roll 413 is disposed to be pressed to the rear roll 408 with the intermediate transfer belt 409 interposed therebetween.
The fixing device 414 is, for example, a heating-fixing device that includes a heating roll and a pressure roll.
The cleaning blade 416 is a member that removes toner remaining on the intermediate transfer belt 409. The cleaning blade 416 is disposed downstream of the rear roll 408 and removes the toner remaining on the intermediate transfer belt 409 after the transfer.
A tray 411 that accommodates the recording medium 500 is provided in the housing 400. The recording medium 500 in the tray 411 is transported by a transport roll 412 to a contact portion between the intermediate transfer belt 409 and the secondary transfer roll 413, is further transported to the fixing device 414, and an image is formed on the recording medium 500. The image-formed recording medium 500 is discharged to the outside of the housing 400.
FIG. 6 is a view schematically showing an example of the process cartridge according to the exemplary embodiment. A process cartridge 300 shown in FIG. 6 is attached to and detached from a main body of the image forming apparatus including, for example, the exposure device, the transfer device, and the fixing device.
In the process cartridge 300, the photoreceptor 207, the charging device 208A, the developing device 211, and the cleaning device 213 are integrated by a housing 301. In the housing 301, an attachment rail 302 for attaching and detaching the process cartridge to and from the image forming apparatus, an opening 303 for exposure, and an opening 304 for neutralization exposure are provided.
The charging device 208A that is included in the process cartridge 300 is the contact charging type charging device that is formed by a roll-shaped charging member, that contacts with the front surface of the photoreceptor 207, and that charges the front surface of the photoreceptor 207. When the process cartridge 300 is mounted on the image forming apparatus and an image is formed, only the DC voltage is applied to the charging device 208A from the power supply.
Developer and Toner
There is no particular limitation to the developer that is applied in the image forming apparatus according to the exemplary embodiment. The developer may be one-component developer containing only the toner, or may be two-component developer obtained by mixing toner and carrier.
There is no particular limitation to the toner contained in the developer. The toner contains, for example, a binder resin, a colorant, and a releasing agent. Examples of the binder resin of the toner include polyester and styrene acrylic resin.
An external additive may be externally added to the toner. An example of the external additive of the toner is inorganic particulates such as silica, titanium, or alumina.
Toner particles are produced, then, the external additive is externally added to the toner particles, and thereby the toner is prepared. Examples of a method of producing the toner particles include a kneading and grinding method, an aggregation coalescence method, a suspension polymerization method, a dissolution suspension method, and the like. The toner particles may be toner particles having a single-layer structure, or may be toner particles having a so-called core and shell structure which is configured with a core (core particles) and a coating layer (shell layer) that coats the core.
The volume average particle size (D50v) of the toner particles is preferably 2 μm to 10 μm and more preferably 4 μm to 8 μm.
There is no particular limitation to the carrier contained in the two-component developer. Examples of the carrier include, for example, coated carrier obtained by coating a resin on a front surface of a core formed of magnetic powder; magnetic powder dispersed-type carrier obtained by dispersing and mixing magnetic powder in a matrix resin; and resin impregnated-type carrier obtained by impregnating a resin in porous magnetic powder.
A mixing ratio (ratio by weight) of the toner and carrier in the two-component developer is preferably that toner:carrier is 1:100 to 30:100, and more preferably 3:100 to 20:100.
Example
Hereinafter, the exemplary embodiment of the invention is described in detail with Example; however, the exemplary embodiment of the invention is not limited to the Example at all. In the following description, “parts” and “%” are units based on weight unless noted otherwise.
Preparation of Charging Roll
Example 1
—Forming of Conductive Elastic Layer—
An adhesive (epichlorohydrin rubber, HYDRIN T3106 by Zeon Chemicals L.P.) is applied on an outer circumferential surface of a shaft formed of SUS 303 having a diameter of 8 mm and an adhesive layer is formed. A composition obtained by kneading the following materials on an open roll and the shaft having the adhesive layer are extruded from an extruder (set at a die temperature of 90° C.) including a cross head die, a layer of the composition is formed on the outer circumferential surface of the shaft, and then the layer is heated at 160° C. for 70 minutes, thereby obtaining a conductive elastic layer roll (having an average diameter of 12 mm).

    
    
        Epichlorohydrin rubber (HYDRIN T3106 by Zeon Chemicals L.P) 100 parts
        Carbon black (ASAHI #60 by Asahi Carbon Co., Ltd.) 5 parts
        Ion conductive agent: benzyltrimethylammonium chloride (BTEAC by Lion Specialty Chemicals Co., Ltd.) 1 part
        Vulcanizing agent: 4,4′-dithiodimorpholine (VULNOC R by Ouchi Shinko Chemical Industrial Co., Ltd.) 1.5 parts
        Vulcanization accelerator: di-2-benzothiazolyl disulfide (NOCCELER DM-P by Ouchi Shinko Chemical Industrial Co., Ltd.) 1.5 parts
        Vulcanization accelerator: tetraethylthiuram disulfide (NOCCELER TET-G by Ouchi Shinko Chemical Industrial Co., Ltd.) 1.8 parts
        Vulcanization accelerator aid: stearic acid 3 parts
        Vulcanization accelerator aid: zinc oxide 1 part
        Calcium carbonate (WHITEN SB by Shiraishi CalCium Kaisha Ltd.) 40 parts

—Forming of Surface Layer—

    
    


A dispersion liquid obtained by mixing the following materials and being subjected to dispersion processing in a bead mill is diluted with methanol, is applied on the outer circumferential surface of the conductive elastic layer roll by dip applying, and then is heated at 150° C. for 30 minutes, and thereby a charging roll having a surface layer with an average layer thickness of 9 μm is obtained.

    
    
        N-methoxymethylnylon (F30K by Nagase ChemteX Corporation) 100 parts
        Polyvinyl butyral resin (S-LEC BL-1 by Sekisui Chemical Co., Ltd.) 10 parts
        Tin oxide (S-2000 with an average particle diameter of 15 nm by Mitsubishi Materials Corporation) 30 parts
        Polyamide particles A (POLYAMIDE 12 with an average particle diameter of 5 μm by Arkema Group) 12 parts
        Polyamide particles B (POLYAMIDE 12 with an average particle diameter of 10 μm by Arkema Group) 6 parts
        Catalyst (NACURE 4167 by Kusumoto Chemicals, Ltd.) 1 part
        Methanol 700 parts
        Butanol 200 parts
    
    


Examples 2 to 8
The charging roll is obtained in the same way as in Example 1 except that forming condition of the conductive elastic layer forming compositions and composition of the surface layer forming compositions are changed as shown in Table 1.
Comparative Examples 1 to 4
The charging roll is obtained in the same way as in Example 1 except that forming condition of the conductive elastic layer forming compositions and composition of the surface layer forming compositions are changed as shown in Table 1.
Evaluation
Front Surface Shape of Outer Circumferential Surface
The surface texture of the outer circumferential surface of the charging roll is measured using a confocal laser microscope (VK-8500 with an objective lens magnification of 20 by Keyence Corporation) in conditions of a measurement cycle of 0.05 μm in the X and Y directions, a measurement range of 490 μm by 690 μm in the X and Y directions, and a measurement range of 50 μm in the Z direction. The measurement data is subjected to surface correction with the curvature of the charging roll and noise correction. In a case where, of nine measurement points (three points in the X direction by three points in the Y direction), one point having a specifically high or low value (more than 300% or less than 20% of a median value of the other eight points) is detected, the noise correction is performed by allocating the median value of the other eight points to the specific point. The half-value width of the maximum frequency value of the height distribution, the average height of the roughness components, and the average height of the waviness components are obtained from the corrected data.
Micro-Chromatic Line
In a modified apparatus of DOCUCENTRE-IV C2260 which includes the contact charging type charging device that applies only the DC voltage to the charging roll, the charging roll of each of Examples and Comparative Examples is incorporated, and a halftone image having image density of 30% on an entire surface is printed on 5,000 sheets of A4 paper under a high-temperature and high-humidity environment (28° C. and 85% RH). The last printed image on the paper is visually observed and classification is performed as follows. G0 and G1 are within a range of permission.
G0: No micro-chromatic line is recognized.
G1: One to three micro-chromatic lines are produced.
G2: Four to ten micro-chromatic lines are produced.
G3: 11 to 20 micro-chromatic lines are produced.
G4: 21 micro-chromatic lines or more are produced.
Property of being Driven by Photoreceptor
The photoreceptor is caused to rotate at a speed of 200 mm/s, then, the number of revolutions of the charging roll which is driven to rotate by the photoreceptor is measured for one minute using a non-contact revolution indicator, and the number of revolutions of the charging roll is classified as follows. G0 and G1 are within a range of permission.
G0: 98% or greater of the number of revolutions in theory
G1: 95% or greater and less than 98% of the number of revolutions in theory
G2: 90% or greater and less than 95% of the number of revolutions in theory
G3: 85% or greater and less than 90% of the number of revolutions in theory
G4: Less than 85% of the number of revolutions in theory
























Surface Texture of










Outer Circumferential Surface




























Average
Mean
Average
Mean 

Property 







Surface Layer

Height 
Cycle 
Height 
Cycle 

of


















Conductive Elastic Layer

Amount

of
of
of
of 

Being 






















Vulcanization

of Poly-

Rough-
Rough-
Wav-
Wav-
Micro-
Driven




Die
Condition
Conductive
amide
Half-
ness
ness
iness
iness
Chro-
by





















Molding
Temper-
Temper-

Agent
Particles
Value
Com-
Com-
Com-
Com-
matic
Photo-






















Method
ature
ature
Time
Type
Amount
A
Width
ponents
ponents
ponents
ponents
Line
receptor





Example 1
Extrusion
90° C.
160° C.
70
Tin
30 parts
12 parts
1.7 μm
7.0 μm
12 μm
8.3 μm
0.25 mm
G0
G0



Molding


minutes
Oxide











Example 2
Extrusion
95° C.
160° C.
70
Tin
30 parts
12 parts
1.5 μm
7.1 μm
12 μm
7.2 μm
0.22 mm
G0
G0



Molding


minutes
Oxide











Example 3
Extrusion
80° C.
150° C.
70
Tin
30 parts
 8 parts
2.5 μm
5.2 μm
10 μm
14.1 μm 
0.30 mm
G1
G0



Molding


minutes
Oxide











Example 4
Extrusion
90° C.
160° C.
70
Tin
30 parts
 8 parts
1.1 μm
5.4 μm
10 μm
8.6 μm
0.25 mm
G1
G0



Molding


minutes
Oxide











Example 5
Extrusion
95° C.
170° C.
70
Tin
30 parts
 8 parts
1.2 μm
5.1 μm
10 μm
6.1 μm
0.20 mm
G1
G1



Molding


minutes
Oxide











Example 6
Extrusion
80° C.
150° C.
70
Tin
30 parts
20 parts
2.9 μm
7.9 μm
15 μm
14.7 μm 
0.30 mm
G1
G0



Molding


minutes
Oxide











Example 7
Extrusion
95° C.
160° C.
70
Tin
30 parts
20 parts
1.8 μm
7.8 μm
15 μm
7.0 μm
0.23 mm
G0
G0



Molding


minutes
Oxide











Example 8
Extrusion
95° C.
170° C.
70
Tin
30 parts
20 parts
1.3 μm
7.8 μm
10 μm
6.2 μm
0.18 mm
G1
G1



Molding


minutes
Oxide











Comparative
Extrusion
50° C.
130° C.
70
Tin
30 parts
12 parts
5.0 μm
7.0 μm
12 μm
33.4 μm 
0.44 mm
G3
G2


Example 1
Molding


minutes
Oxide











Comparative
Extrusion
90° C.
160° C.
70
Tin
30 parts
 4 parts
0.6 μm
4.7 μm
 6 μm
8.5 μm
0.25 mm
G3
G0


Example 2
Molding


minutes
Oxide











Comparative
Extrusion
95° C.
180° C.
70
Tin
30 parts
12 parts
0.8 μm
6.9 μm
12 μm
4.7 μm
0.16 mm
G2
G3


Example 3
Molding


minutes
Oxide











Comparative
Extrusion
95° C.
160° C.
70
Tin
30 parts
30 parts
4.5 μm
8.5 μm
10 μm
7.4 μm
0.22 mm
G3
G0


Example 4
Molding


minutes
Oxide









The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.

## Claims

1. A charging member comprising:
a support member;
a conductive elastic layer disposed on the support member; and
a surface layer disposed on the conductive elastic layer,
wherein first irregularities of a first type with a cycle of shorter than 0.1 mm and second irregularities of a second type with a cycle of 0.1 mm or longer are distributed on an entirety of an outer circumferential surface of the charging member, and satisfy the following conditions of (1) and (2):
(1) the first irregularities with the cycle of shorter than 0.1 mm have an average height of 5 μm to 8 μm; and
(2) the second irregularities with the cycle of 0.1 mm or longer have an average height of 6 μm to 30 μm, and
wherein a half-value width of a maximum frequency value of a height distribution on the outer circumferential surface is 1 μm to 3 μm.

2. The charging member according to claim 1,
wherein the first irregularities with the cycle of shorter than 0.1 mm have an average height of 5.5 μm to 7.5 μm.

3. The charging member according to claim 1,
wherein the first irregularities with the cycle of shorter than 0.1 mm have an average height of 6 μm to 7 μm.

4. The charging member according to claim 1,
wherein the second irregularities with the cycle of 0.1 mm or longer have an average height of 8 μm to 25 μm.

5. The charging member according to claim 1,
wherein the second irregularities with the cycle of 0.1 mm or longer have an average height of 10 μm to 20 μm.

6. The charging member according to claim 1,
wherein a mean cycle of the first irregularities with the cycle of shorter than 0.1 mm is 5 μm or longer.

7. The charging member according to claim 1,
wherein a mean cycle of the first irregularities with the cycle of shorter than 0.1 mm is 15 μm or shorter.

8. The charging member according to claim 1,
wherein a mean cycle of the second irregularities with the cycle of 0.1 mm or longer is 0.25 mm or longer.

9. The charging member according to claim 1,
wherein a mean cycle of the second irregularities with the cycle of 0.1 mm or longer is 0.45 mm or shorter.

10. The charging member according to claim 1,
wherein the surface layer contains an electrically conductive agent.

11. The charging member according to claim 10,
wherein the electrically conductive agent is a metal oxide.

12. The charging member according to claim 1,
wherein the surface layer contains tin oxide particles.

13. A process cartridge that is attachable to and detachable from an image forming apparatus, the process cartridge comprising:
an electrophotographic photoreceptor; and
the charging member according to claim 1, wherein the charging member is configured to charge a surface of the electrophotographic photoreceptor.

14. An image forming apparatus comprising:
an electrophotographic photoreceptor;
the charging member according to claim 1, wherein the charging member is configured to charge a surface of the electrophotographic photoreceptor;
a latent image forming device configured to form a latent image on the surface of the charged electrophotographic photoreceptor;
a developing device configured to develop the latent image formed on the surface of the electrophotographic photoreceptor, using developer containing toner, and configured to form a toner image on the surface of the electrophotographic photoreceptor; and
a transfer device configured to transfer the toner image formed on the surface of the electrophotographic photoreceptor to a recording medium.

15. The charging member according to claim 1, wherein the first irregularities of the first type comprise a roughness component of the surface layer, and
wherein the second irregularities of the second type comprise a waviness component of the surface layer.