Polycarbonate, and molding and electrophotographic photoreceptor prepared therefrom

• US 6,136,521 A
• Filed: 10/20/1998
• Issued: 10/24/2000
• Est. Priority Date: 02/20/1997
• Status: Expired due to Term

• Current Assignee: Dow Corning Toray Company Limited (Dow, Inc.), Idemitsu Kosan Company Limited
• Original Assignee: Dow Corning Toray Company Limited (Dow, Inc.), Idemitsu Kosan Company Limited
• Inventors: Manzoji, Ryuko, Horikawa, Yasuaki, Morita, Yoshitsugu, Ueki, Hiroshi, Furukawa, Haruhiko, Hikosaka, Takaaki, Okawa, Tadashi, Sakamoto, Shuji
• Primary Examiner(s): Dawson, Robert
• Assistant Examiner(s): Robertson, Jeffrey B.
• Application Number:
  US09/171,484
• Time in Patent Office: 735 Days
• Field of Search: 430/61, 430/69, 430/905, 430/908, 430/533, 528/26, 428/412
• US Class Current: 430/533
• CPC Class Codes: C08G 64/085 containing silicon
• CPC Class Codes: C08G 64/186 containing polysiloxane sequences
• CPC Class Codes: C08G 77/448 containing polycarbonate sequences
• CPC Class Codes: G03G 5/0564 Polycarbonates
• CPC Class Codes: G03G 5/0578 Polycondensates comprising silicon atoms in the main chain
• CPC Class Codes: G03G 5/0589 Macromolecular compounds characterised by specific side-chain substituents or end groups
• CPC Class Codes: G03G 5/0592 Macromolecular compounds characterised by their structure or by their chemical properties, e.g. block polymers, reticulated polymers, molecular weight, acidity
• CPC Class Codes: G03G 5/0596 Macromolecular compounds characterised by their physical properties
• CPC Class Codes: G03G 5/14756 Polycarbonates
• CPC Class Codes: G03G 5/14773 Polycondensates comprising silicon atoms in the main chain
• CPC Class Codes: G03G 5/14786 Macromolecular compounds characterised by specific side-chain substituents or end groups
• CPC Class Codes: G03G 5/14791 Macromolecular compounds characterised by their structure, e.g. block polymers, reticulated polymers, or by their chemical properties, e.g. by molecular weight or acidity
• CPC Class Codes: G03G 5/14795 Macromolecular compounds characterised by their physical properties
• CPC Class Codes: Y10S 430/106 Binder containing
• CPC Class Codes: Y10S 430/109 Polyester
• CPC Class Codes: Y10T 428/31507 Of polycarbonate

Abstract

A polycarbonate containing repeating units (1) represented by the general formula (1), a polycarbonate molding produced by molding the polycarbonate, and an electrophotographic photoreceptor having a photosensitive layer which has a surface layer containing the polycarbonate: ##STR1## wherein R is an aliphatic unsaturation-free monovalent hydrocarbon group, R¹ is a halogen atom, an alkyl group, an alkoxy group or an aryl group, X is an alkylene group or an alkyleneoxyalkylene group, X'"'"' is an alkylene group of 2 or more carbon atoms, an alkyleneoxyalkylene group or oxygen atom, a is an integer of 0 to 4, na is 0 or 1, nb is 1 or 2, nc is 1 or 2, provided na+nb+nc=3, n1, n2, n3 and n4 are 0 or an integer of 1 or more, provided n1+n2+n3+n4 is an integer of 0 to 450.

Claims

1. A polycarbonate containing repeating units (1) represented by the following general formula (1):

##STR103## wherein each R is independently an aliphatic unsaturation-free monovalent hydrocarbon group, the R groups being identical with or different from each other, each R¹ is independently a halogen atom, a substituted or non-substituted alkyl group of 1 to 6 carbon atoms, a substituted or non-substituted alkoxy group of 1 to 6 carbon atoms or a substituted or non-substituted aryl group of 6 to 12 carbon atoms, each X is independently an alkylene group of 2 or more carbon atoms or an alkyleneoxyalkylene group of 2 or more carbon atoms, each X'"'"' is independently an alkylene group of 2 or more carbon atoms, an alkyleneoxyalkylene group of 2 or more carbon atoms or oxygen atom, each a is independently an integer of 0 to 4, na is 0 or 1, nb is 1 or 2, nc is 1 or 2, provided na+nb+nc=3, n1, n2, n3 and n4 are each independently 0 or an integer of 1 or more, provided n1+n2+n3+n4 is an integer of 0 to 450.

2. The polycarbonate of claim 1, which has a reduced viscosity of 0.1 to 10.0 dl/g as measured at a concentration of 0.5 g/dl in methylene chloride.

3. The polycarbonate of claim 1, which comprises the repeating units (1) and repeating units (2) represented by the following general formula (2):

##STR104## wherein each R² is independently a halogen atom, vinyl, allyl, a substituted or non-substituted alkyl group of 1 to 10 carbon atoms, a substituted or non-substituted aryl group of 6 to 12 carbon atoms, a substituted or non-substituted cycloalkyl group of 3 to 12 carbon atoms, a substituted or non-substituted alkoxy group of 1 to 6 carbon atoms, a substituted or non-substituted aryloxy group of 6 to 12 carbon atoms, each a is independently an integer of 0 to 4, Y is single bond, --O--, --CO--, --S--, --SO--, --SO₂ --, --CR³ R⁴ --, a substituted or non-substituted cycloalkylidene group of 5 to 11 carbon atoms, a substituted or non-substituted α

,ω

-alkylene group of 2 to 12 carbon atoms, 9,9-fluorenylidene, 1,8-menthanediyl, 2,8-menthanediyl, a substituted or non-substituted pyrazinylidene group or a substituted or non-substituted arylene group of 6 to 24 carbon atoms, R³ and R⁴ are each independently hydrogen atom, a substituted or non-substituted alkyl group of 1 to 10 carbon atoms or a substituted or non-substituted aryl group of 6 to 12 carbon atoms.

4. The polycarbonate of claim 3, wherein the molar ratio of the repeating units (1) to a total of the repeating units (1) and the repeating units (2), (1)/[(1)+(2)], is 0.001 to 1.

5. The polycarbonate of claim 3, wherein the repeating units (1) are the repeating units (A) shown in the following:

##STR105## wherein each R is independently an aliphatic unsaturation-free monovalent hydrocarbon group, the R groups being identical with or different from each other, each R^x is independently an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms or a halogen atom, each X is independently an alkylene group of 2 or more carbon atoms or an alkyleneoxyalkylene group of 2 or more carbon atoms, n is an integer of 1 to 400, and each a is independently an integer of 0 to 4.

6. The polycarbonate of claim 3, wherein the repeating units (1) are repeating units selected from the group consisting of the following repeating units:

##STR106## and the repeating units (2) are repeating units selected from the group consisting of the following repeating units;

##STR107##

7. The polycarbonate of claim 1, wherein the repeating units (1) are repeating units (A) represented by the following general formula (A), and the polycarbonate contains 0.01 to 100 mol % of the repeating units (A):

wherein each R is independently an aliphatic unsaturation-free monovalent hydrocarbon group, the R groups being identical with or different from each other, each R^x is independently an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms or a halogen atom, each X is independently an alkylene group of 2 or more carbon atoms or an alkyleneoxyalkylene group of 2 or more carbon atoms, n is an integer of 1 to 400, and each a is independently an integer of 0 to 4.

8. The polycarbonate of claim 1, wherein the repeating units (1) are repeating units (A) represented by the following general formula (A), and the polycarbonate comprises 0.01 to 100 mol % of the repeating units (A) and 99.99 to 0 mol % of repeating units (B) represented by the following general formula (B):

General formula (A) ##STR108## wherein each R is independently an aliphatic unsaturation-free monovalent hydrocarbon group, the R groups being identical with or different from each other, each R^x is independently an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms or a halogen atom, each X is independently an alkylene group of 2 or more carbon atoms or an alkyleneoxyalkylene group of 2 or more carbon atoms, n is an integer of 1 to 400, and each a is independently an integer of 0 to 4,

General formula (B) ##STR109## wherein each R^y is independently a halogen atom or a monovalent hydrocarbon group of 1 to 4 carbon atoms, Z is selected from the group consisting of an alkylidene group of 1 to 10 carbon atoms, an aryl-substituted alkylidene group, an alkylene group, an arylene group, --O--, --S--, --CO-- and --SO₂ --, and a is an integer of 0 to 4.

9. The polycarbonate of claim 1, wherein the repeating units (1) are selected from the group consisting of the following repeating units:

##STR110##10.

17. A polycarbonate molding which is produced by molding the polycarbonate of any one of claims 1-9.

10. An electrophotographic photoreceptor comprising a conductive substrate and a photosensitive layer that is disposed on the conductive substrate, the photosensitive layer having a surface layer which contains a polycarbonate containing repeating units (1) represented by the following general formula (1):

wherein each R is independently an aliphatic unsaturation-free monovalent hydrocarbon group, the R groups being identical with or different from each other, each R¹ is independently a halogen atom, a substituted or non-substituted alkyl group of 1 to 6 carbon atoms, a substituted or non-substituted alkoxy group of 1 to 6 carbon atoms or a substituted or non-substituted aryl group of 6 to 12 carbon atoms, each X is independently an alkylene group of 2 or more carbon atoms or an alkyleneoxyalkylene group of 2 or more carbon atoms, each X'"'"' is independently an alkylene group of 2 or more carbon atoms, an alkyleneoxyalkylene group of 2 or more carbon atoms or oxygen atom, each a is independently an integer of 0 to 4, na is 0 or 1, nb is 1 or 2, nc is 1 or 2, provided na+nb+nc=3, n1, n2, n3 and n4 are each independently 0 or an integer of 1 or more, provided n1+n2+n3+n4 is an integer of 0 to 450.

11. The electrophotographic photoreceptor of claim 10, wherein the repeating units (1) are selected from the group consisting of the following repeating units:

##STR111##

12. The electrophotographic photoreceptor of claim 10, wherein the polycarbonate has a reduced viscosity of 0.1 to 10.0 dl/g as measured at a concentration of 0.5 g/dl in methylene chloride.

13. The electrophotographic photoreceptor of claim 10, wherein the photosensitive layer comprises a charge-generating layer containing a charge-generating substance and the surface layer, the surface layer being a charge-transfer layer containing a charge-transfer substance and a binder resin which contains the polycarbonate.

14. The electrophotographic photoreceptor of claim 10, wherein the polycarbonate comprises the repeating units (1) and repeating units (2) represented by the following general formula (2):

wherein each R² is independently a halogen atom, vinyl, allyl, a substituted or non-substituted alkyl group of 1 to 10 carbon atoms, a substituted or non-substituted aryl group of 6 to 12 carbon atoms, a substituted or non-substituted cycloalkyl group of 3 to 12 carbon atoms, a substituted or non-substituted alkoxy group of 1 to 6 carbon atoms, a substituted or non-substituted aryloxy group of 6 to 12 carbon atoms, each a is independently an integer of 0 to 4, Y is single bond, --O--, --CO--, --S--, --SO--, --SO₂ --, --CR³ R⁴ --, a substituted or non-substituted cycloalkylidene group of 5 to 11 carbon atoms, a substituted or non-substituted α

,ω

-alkylene group of 2 to 12 carbon atoms, 9,9-fluorenylidene, 1,8-menthanediyl, 2,8-menthanediyl, a substituted or non-substituted pyrazinylidene group or a substituted or non-substituted arylene group of 6 to 24 carbon atoms, R³ and R⁴ are each independently hydrogen atom, a substituted or non-substituted alkyl group of 1 to 10 carbon atoms or a substituted or non-substituted aryl group of 6 to 12 carbon atoms.

15. The electrophotographic photoreceptor of claim 14, wherein the molar ratio of the repeating units (1) to a total of the repeating units (1) and the repeating units (2), (1)/[(1)+(2)], is 0.001 to 1 in the polycarbonate.

16. The electrophotographic photoreceptor of claim 14, wherein the repeating units (1) are repeating units selected from the group consisting of the following repeating units:

##STR112## and the repeating units (2) are repeating units selected from the group consisting of the following repeating units;

##STR113##