Photoreceptor having polycarbonate layers and process for the preparation thereof

Abstract

A photoreceptor comprising a photosensitive layer and a support, wherein said photosensitive layer contains a polycarbonate compound binder selected from the group consisting of Formula A and B, ##STR1## wherein R 1 and R 2 are independently hydrogen, substituted or unsubstituted aliphatic, or a substituted or unsubstituted hydrocarbon ring, provided that at least one of R 1 and R 2 has at least 3 carbon atoms, Z represents a group of atoms necessary to constitute a substituted or unsubstituted carbon ring or a substituted or unsubstituted heterocylic ring, R 3 to R 10 in Formulas A and B are independently hydrogen, halogen, substituted or unsubstituted aliphatic, or a substituted or unsubstituted hydrocarbon ring, and n is a number from 10 to 1000.

What is claimed is: .[.1. A photoreceptor comprising a photosensitive layer and a support wherein said photosensitive layer comprises a carrier generation layer and a carrier transport layer wherein said carrier generation layer and/or said carrier transport layer contains a polycarbonate compound represented by the following Formula (A) or (B) as a binder.]. ##STR34## .[.wherein R 1  and R 2  are independently hydrogen atom, substituted or unsubstituted aliphatic group, or substituted or unsubstituted hydrocarbon ring provided that at least one of R 1  and R 2  has at least 3 carbon atoms, Z represents a group of atoms necessary for constituting a substituted or unsubstituted carbon ring or a substituted or unsubstituted heterocyclic ring, R 3  to R 10  in Formulas (A) and (B) are independently a hydrogen atom, a halogen atom, a substituted or unsubstituted aliphatic group or a substituted or unsubstituted hydrocarbon ring, and n is a number from 10 to 1000..]. 
     
        .[. .  The photoreceptor of claim 1, wherein said carrier generation layer contains a carrier generating material and said carrier transport layer 
     
     
        contains a carrier transporting material..].  3. The photoreceptor of claim .[.2,.]. .Iadd.33, .Iaddend.wherein said carrier generation layer contains said polycarbonate compound at least 15 wt % by weight of the 
     
     
        total amount of the binder contained therein. 4. The photoreceptor of claim 3, wherein said carrier generation layer contains said polycarbonate compound at least 30 wt % by weight of the total amount of the binder 
     
     
        contained therein. 5. The photoreceptor of claim 3, wherein the ratio by weight of said carrier generating material against said total binder in 
     
     
        said carrier generation layer is from 1:0.1 to 1:100. 6. The photoreceptor of claim 5, wherein the ratio by weight of said carrier generating material against said total binder in said carrier generation layer is 
     
     
        from 1:0.1 to 1:10. 7. The photoreceptor of claim .[.2,.]. .Iadd.33, .Iaddend.wherein said carrier generating material is selected from the 
     
     
        group consisting of bisazo compounds and polycyclic quinone compounds. 8. The photoreceptor of claim .[.2,.]. .Iadd.33, .Iaddend.wherein said carrier transport layer contains said polycarbonate compound at least 15 
     
     
        wt % by weight of the total amount of the binder contained therein. 9. The photoreceptor of claim 8, wherein said carrier transport layer contains said polycarbonate compound at least 30 wt % by weight of the total amount 
     
     
        of the binder contained therein. 10. The photoreceptor of claim 8, wherein the ratio by weight of said carrier transporting material against said total binder in said carrier transporting layer is from 1:0.1 to 1:100. 
     
     
            The photoreceptor of claim 10, wherein the ratio by weight of said carrier transporting material against said total binder in said carrier 
     
     
        transporting layer is from 1:0.1 to 1:10. 12. The photoreceptor of claim .[.2,.]. .Iadd.33, .Iaddend.wherein said carrier transporting material is selected from the group consisting of hydrazone derivatives, carbazol derivatives, pyrazoline derivatives, styryl derivatives and amine derivatives. .[.13. The photoreceptor of claim 1, wherein said photosensitive layer is a single layer in which the carrier generating material and carrier transporting material are dispersed..]. .[.14. The photoreceptor of claim 13, wherein said photosensitive layer contains said polycarbonate compound at least 15 wt % by weight of the total amount of the binder contained therein..]. .[.15. The photoreceptor of claim 14, wherein said photosensitive layer contains said polycarbonate compound at least 30 wt % by weight of the total amount of the binder contained therein..]. .[.16. The photoreceptor of claim 1, wherein at least one of said R 1  and R 2  is selected from the group consisting of.]. ##STR35## .[.wherein, R 11  is a hydrogen atom, an alkyl group, or an alkyl ester group represented by --CH 2 ) m  COOR' in which R' is an alkyl group, and m is equal to or more than 1,.]. ##STR36## .[.(3) An alkyl group represented by --C m  H 2m+1  in which m is equal to or more than 4, and (4) An alkyl ester group represented by --CH 2 ) m  COOR 12  in which R 12  is an alkyl group, and m is equal to or more than 2..].   
     
     
        .[. 7.  The photoreceptor of claim 1, wherein said R 3  to R 10  are independently a hydrogen atom, a halogen atom, an alkyl group or a saturated hydrocarbon ring..]. .[.18. The photoreceptor of claim 1, wherein said Z represents a group necessary for constituting a cyclopentyl ring or a cyclohexyl ring, said ring may have an acetyl group or acetylamido group..]. .[.19. The photoreceptor of claim 2, wherein said carrier generation layer has the thickness within the range of from 0.005 μm to 20 μm..]. .[.20. The photoreceptor of claim 2, wherein said carrier transport layer has the thickness within the range of from 2 μm to 100 μm..]. .[.21. The photoreceptor of claim 2, wherein said photoreceptor has a intermediate layer between said photosensitive layer and said support..]. .[.22. The photoreceptor of claim 2, wherein said support is composed of a sheet of metal such as aluminum, nickel, copper, zinc, palladium, silver, indium, tin, platinum, gold, stainless steel and brass..]. .[.23. The photoreceptor of claim 2, wherein said support consists of isolated substrate and conductive layer provided thereon..]. .[.24. A process for preparing a photoreceptor which comprises forming a photosensitive layer by coating a solution containing a semiconductor material and a binder on a support, wherein said solution contains a polycarbonate compound represented by the following formula [A] or [B] as said binder and the content of said binder is in the range of from 5% to 30% by weight of a solvent.]. ##STR37## 
     
     
        .[.25.  The process of claim 24, wherein said semiconductor material is 
     
     
        carrier generating material or carrier transporting material..]. 26. The .[.process.]. .Iadd.method .Iaddend.of claim .[.24,.]. .Iadd.85, .Iaddend.wherein the content of said polycarbonate is at least 15% by weight of the total amount of said binder contained in said solution. .[.27. The process of claim 25, wherein the content of said polycarbonate is at least 30% by weight of the total amount of said binder contained in 
     
     
        said solution..]. 28. The process of claim .[.26,.]. .Iadd.85, .Iaddend.wherein the viscosity of said solution is in the range of from 
     
     
        0.5 cp to 1000 cp. 29. The process of claim 28, wherein the viscosity of 
     
     
        said solution is in the range of from 3 cp to 300 cp. .[.30.  The photoreceptor of claim 13, wherein said photoreceptor has a intermediate layer between said photosensitive layer and said support..]. .[.31. The photoreceptor of claim 13, wherein said support is composed of a sheet of metal such as aluminum, nickel, copper, zinc, palladium, silver, indium, tin, platinum, gold, stainless steel and brass..]. .[.32. The photoreceptor of claim 13, wherein said support consists of isolated 
     
     
        substrate and conductive layer provided thereon..]. .Iadd.33.  A photoreceptor comprising a photosensitive layer on a support, said photosensitive layer comprising a carrier generation layer and a carrier transport layer, said carrier generation layer containing a carrier generating material and a first binder, said carrier transport layer being formed by immersion coating and said carrier transport layer containing a carrier transporting material and a second binder which is a polycarbonate compound of at least one of the formulas ##STR38##.Iaddend. wherein R 1  and R 2  are each independently a hydrogen atom, a substituted or unsubstituted aliphatic group, or a substituted or unsubstituted hydrocarbon ring provided that at least one of R 1  and R 2  has at least 3 carbon atoms; wherein Z represents a group of atoms necessary to form a substituted or unsubstituted carbon ring or a substituted or unsubstituted heterocyclic ring, R 3  to R 10  are each independently a hydrogen atom, a halogen atom, a substituted or unsubstituted aliphatic group, or a substituted or unsubstituted hydrocarbon ring, and n is a number from 10   
     
     
        to 1000.  .Iadd.34.  The method of claim 44 wherein said support is first coated with a charge generating layer. .Iaddend. .Iadd.35. The method of claim 44, wherein said support is a drum. .Iaddend. .Iadd.36. The method of claim 44 wherein said support is a drum vertically movably arranged inside a coating container containing a coating solution. .Iaddend. .Iadd.37. The method of claim 44 wherein immersion coating comprises immersing said support in a container containing said solution and then extracting said support therefrom. .Iaddend. .Iadd.38. The method of claim 44 wherein immersion coating comprises raising a container containing said support to immerse said support therein and then lowering said container to remove said support therefrom. .Iaddend. .Iadd.39. The method of claim 38 wherein a direction of said raising is vertical. .Iaddend. .Iadd.40. The method of claim 37 wherein said container has a cylindrical cover member. .Iaddend. .Iadd.41. The method of claim 38 wherein said container has a cylindrical cover member. .Iaddend. .Iadd.42. The method of claim 40 wherein said cover member has pierced holes in the side wall thereof. .Iaddend. .Iadd.43. The method of claim 41 wherein said cover member has 
     
     
        pierced holes in the side wall thereof. .Iaddend. .Iadd.44.  A method for preparing a photoreceptor which comprises a photosensitive layer on an endless support, said photosensitive layer comprising a carrier generation layer containing a first binder and a carrier transport layer, said method comprising immersion coating a solution forming said carrier transport layer containing a carrier transporting material and a second binder on said support, and said solution contains as said second binder a polycarbonate compound represented by ##STR39##.Iaddend.  wherein R 1  and R 2  are independently a hydrogen atom, a substituted or unsubstituted aliphatic group, or a substituted or unsubstituted hydrocarbon ring provided that at least one of R 1  and R 2  has at least 3 carbon atoms, Z represents a group of atoms necessary for constituting a substituted or unsubstituted carbon ring or a substituent or unsubstituted heterocyclic ring, R 3  to R 10  in Formula [A] and [B] are independently a hydrogen atom, a halogen atom, a substituted or unsubstituted aliphatic group or a substituted or unsubstituted hydrocarbon ring, and n is a number from 10 to 1000. 
     
     
        .Iadd. 5.  The method of claim 44 wherein said Z represents a cyclohexyl ring. .Iaddend. .Iadd.46. The method of claim 44 wherein said solution containing said binder which is in the range of from 5% to 30% by weight 
     
     
        of a solvent. .Iaddend. .Iadd.47.  The photoreceptor of claim 33 wherein said polycarbonate compound is of the formula ##STR40## 
     
     
         .Iadd.48.  The photoreceptor of claim 47 wherein said carrier generation layer contains said polycarbonate compound at least 15 weight % by weight of the total amount of the binder contained therein. .Iaddend. .Iadd.49. The photoreceptor of claim 48 wherein said carrier generation layer contains said polycarbonate compound at least 30% by weight of the total amount of the binder contained therein. .Iaddend. .Iadd.50. The photoreceptor of claim 48 wherein the ratio by weight of said carrier generating material against said total binder in said carrier generation 
     
     
        layer is from 1:01 to 1:100. .Iaddend. .Iadd.51.  The photoreceptor of claim 50 wherein the ratio by weight of said carrier generating material against said total binder in said carrier generation layer is from 1:0.1 to 1:10. .Iaddend. .Iadd.52. The photoreceptor of claim 47 wherein said carrier generating material is selected from the group consisting of bisazo compounds and polycyclic quinone compounds. .Iaddend. .Iadd.53. The photoreceptor of claim 47 wherein said carrier transport layer contains said polycarbonate compound at least 15% weight % by weight of the total amount of the binder contained therein. .Iaddend. .Iadd.54. The photoreceptor of claim 53, wherein said carrier transport layer contains said polycarbonate compound at least 30 weight % by weight of the total amount of the binder contained therein. .Iaddend. .Iadd.55. The photoreceptor of claim 53, wherein the ratio by weight of said carrier transporting material against said total binder in said carrier transporting layer is from 1:0.1 to 1:100. .Iaddend. .Iadd.56. The photoreceptor of claim 55, wherein the ratio by weight of said carrier transporting material against said total binder in said carrier 
     
     
        transporting layer is from 1:0.1 to 1:10. .Iaddend. .Iadd.57.  The photoreceptor of claim 47, wherein said carrier transporting material is selected from the group consisting of hydrazone derivatives, carbazol derivatives, pyrazoline derivatives, styryl derivatives and amine derivatives. .Iaddend. .Iadd.58. The photoreceptor of claim 33 wherein said carrier generation layer and said carrier transport layer are formed on said support in this order outwardly from said support. .Iaddend. .Iadd.59. The photoreceptor of claim 47 wherein said carrier generation layer and said carrier transport layer are formed on said support in this order outwardly from said support. .Iaddend. .Iadd.60. The method of claim 44 wherein said carrier generation layer and said carrier transport layer are formed in this order from said support. .Iaddend. .Iadd.61. The photoreceptor of claim 33 wherein at least one of said R 1  and R 2  is selected from the group consisting of ##STR41## wherein, R 11  is a hydrogen atom, an alkyl group, or an alkyl ester group represented by CH 2 ) m  COOR' in which R 1  is an alkyl group, and m is equal to or more than 1, ##STR42## (3) an alkyl group represented by --C m  H 2m  -1 in which m is equal to or more than 4, and (4) an alkyl ester group represented by --CH 2 ) m  COOR 12  in which R 12  is an alkyl group, and m is equal to or more than 2.   
     
     
        .Iaddend. .Iadd.62.  The photoreceptor of claim 33 wherein said R 3  to R 10  are independently a hydrogen atom, a halogen atom, an alkyl group 
     
     
        or a saturated hydrocarbon ring. .Iaddend. .Iadd.63.  The photoreceptor of claim 33 wherein said Z represent a group necessary for constituting a cyclopentyl ring or a cyclohexyl ring, said ring may have an acetyl group or acetylamido group. .Iaddend. .Iadd.64. The photoreceptor of claim 33 wherein said carrier generation layer has the thickness within the range of from 0.005 μm to 20 μm. .Iaddend. .Iadd.65. The photoreceptor of claim 33 wherein said carrier transport layer has the thickness within the range of from 2 μm to 100 μm. .Iadd.66. The photoreceptor of claim 33 wherein said photoreceptor has a intermediate layer between said photosensitive layer and said support. .Iaddend. .Iadd.67. The photoreceptor of claim 33 wherein said support is composed of a sheet of metal such as aluminum, nickel copper, zinc, palladium, silver, indium, tin, platinum, gold, stainless steel and brass. .Iaddend. .Iadd.68. The photoreceptor of claim 33 wherein said support consists of isolated substrate and conductive layer provided thereon. .Iaddend. .Iadd.69. The photoreceptor of claim 47 wherein said carrier generation layer has the thickness within the range of from 0.005 μm to 20 μm. .Iaddend. 
     
     
        .Iadd.70.  The photoreceptor of claim 47 wherein said carrier transport layer has the thickness within the range of from 2 μm to 100 μm. .Iaddend. .Iadd.71. The photoreceptor of claim 47 wherein said photoreceptor has a intermediate layer between said photosensitive layer and said support. .Iaddend. .Iadd.72. The photoreceptor of claim 47 wherein said support is composed of a sheet of metal such as aluminum, nickel copper, zinc, palladium, silver, indium, tin, platinum, gold, stainless steel and brass. .Iaddend. .Iadd.73. The photoreceptor of claim 47 wherein said support consists of isolated substrate and conductive layer provided thereon. .Iaddend. .Iadd.74. The method of claim 44 wherein at least one of R 1  and R 2  is selected from the group consisting of ##STR43## wherein R 11  is hydrogen, alkyl, or an alkyl ester of the formula (CH 2 ) m  COOR' in which R 1  is alkyl and m is more than one; ##STR44## an alkyl group of formula (C m  H 2m-1 ) wherein m is at least 4; and an alkyl ester group of the formula (CH 2 ) m  COOR 12  wherein   
     
     
        R 12  is alkyl and m is at least 2. .Iaddend. .Iadd.75.  The method of claim 44 wherein said R 3  to R 10  are independently a hydrogen atom, a halogen atom, an alkyl group or a saturated hydrocarbon ring. .Iaddend. .Iadd.76. The method of claim 44 wherein said Z represents a group necessary for constituting a cyclopentyl ring or a cyclohexyl ring, said ring may have an acetyl group or acetylamido group. .Iaddend. .Iadd.77. The method of claim 44 wherein said carrier generation layer has the thickness within the range of from 0.005 μm to 20 μm. .Iadd.78. The method of claim 44 wherein said carrier transport layer has the thickness within the range of from 2 μm to 100 μm. .Iaddend. 
     
     
        .Iadd.  .  The method of claim 44 wherein said photoreceptor has a intermediate layer between said photosensitive layer and said support. .Iaddend. .Iadd.80. The method of claim 44 wherein said support is composed of a sheet of metal such as aluminum, nickel copper, zinc, palladium, silver, indium, tin, platinum, gold, stainless steel and brass. .Iaddend. .Iadd.81. The method of claim 44 wherein said support consists of isolated substrate and conductive layer provided thereon. .Iaddend.