CN1641486A - 一种制造循环的图象形成介质的方法 - Google Patents

一种制造循环的图象形成介质的方法 Download PDF

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CN1641486A
CN1641486A CNA2005100059148A CN200510005914A CN1641486A CN 1641486 A CN1641486 A CN 1641486A CN A2005100059148 A CNA2005100059148 A CN A2005100059148A CN 200510005914 A CN200510005914 A CN 200510005914A CN 1641486 A CN1641486 A CN 1641486A
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supporting mass
visual
cylinder
glass transition
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M·米德马
R·H·维林加
R·N·J·贾科布斯
R·林克
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Canon Production Printing Netherlands BV
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Abstract

本发明涉及一种制造循环的图象形成介质的方法，介质用半结晶的支承材料带制造，该带延伸于第一和第二端部之间。该方法包括使两个端部连到一起，熔化连接到一起的部分，形成循环的支承体，使熔化部分重结晶，并施加图象形成层到支承体，其中在施加图象形成层之前，包括熔化部分的至少一部分支承体进行拉伸，支承体的拉伸部分加热到超过支承材料的玻璃化转变温度。

Description

一种制造循环的图象形成介质的方法
技术领域
本发明涉及一种制造循环的图象形成介质的方法，所述介质用半结晶支承材料带制造，该带在第一和第二端之间延伸。所述方法包括使端部连到一起，熔化连接到一起的部分，形成循环的支承体，使熔化部分再结晶，和施加图象形成介质层到支承体。
背景技术
国际专利申请WO 03/028982公开了这种方法，如该申请所作介绍，该方法可用于形成打印机的光电导体。在这种已知的方法中，半结晶支承材料带作为原材料，即材料的一部分是结晶的，一部分是非晶的，如所述申请介绍的，是半结晶的聚酯。在这个方法中，支承材料带的端部的前边施加到另一端。两个端部然后进行熔化形成焊接连接。在已知的方法中，利用在要求焊接位置的辐射热，使带加热到形成带的材料的熔点以上的温度。结果带的端部熔化到一起。但是，熔化后的支承材料显著地非晶化，形成薄弱的焊缝。此外在循环的支承体上形成拉力。为了使焊缝结实和减少所述拉力问题，对焊缝进行处理，使非晶材料至少部分再结晶。对于这一点，没有必要实现与原始材料的结晶度相同程度或形式的结晶。在一个实施例中，为此对焊缝加热到一定温度，在该温度下材料不熔化，但受热材料的分子具有足够的移动自由度，能够与相关的分子形成取向，使得支承材料重结晶，在焊接位置得到较高的结晶度。在另一实施例中，两个端部熔化后马上使焊缝缓慢冷却，使得熔化的非晶材料有机会再结晶。
如果图象形成材料层施加到以这种方式得到的循环支承体，可得到循环的图象形成介质，该介质于焊接位置不会损失图象功能。其优点是图象形成过程中不必考虑焊缝位置。
已知工艺的重大缺点是效率较低。尽管得到的图象形成介质可以在熔化部分位置(下面称作焊缝)具有与带的其他位置相同的功能，发现大部分的图象介质，大约为70％，在这个位置出现偏差。该偏差具有的形式为，例如，在对应焊缝的位置图象上出现条纹。尽管对于此现象的原因不是完全清楚，很明显与焊接位置的的图象形成层的缺陷有关。
发明内容
本发明的目的是提供具有更高效率的方法。为此，本发明提出了一种制造循环图象形成介质的方法，所述介质用半结晶支承材料带制造，所述带延伸于第一和第二端部之间，所述方法包括：使两个端部连到一起；熔化连接到一起的部分，形成循环的支承体；使熔化部分进行重结晶；施加图象形成层到所述支承体；其特征在于，施加图象形成层之前，包括熔化部分的至少一部分支承体进行拉伸，支承体的拉伸部分加热到超过支承材料的玻璃化转变温度。
已经令人惊奇地发现对循环的支承体进行热处理，其中至少一部分围绕所述焊缝的带受到拉伸，使得该方法的效率明显地提高。通过应用这个方法，发现可以减少损耗至20％或更低。还发现对支承体的热处理应当在实际施加图象形成层到所述支承体之前进行。实现本发明的功能，所述支承体的处理和施加图象形成层之间的间隔时间长短或者其间是否进行另外的工艺步骤并不重要。
此外，本发明的有效作用不是因为重结晶过程导致焊缝产生的拉伸消失。另一方面，上面提到的国际申请说明，产生的拉伸可通过所述重结晶精确地得到消除。
另一方面，根据本发明的方法，显示出循环的支承体接受的后处理的温度要在原始支承材料的玻璃化转变温度以上的重要性。如果焊缝中存在拉伸，可以准确地估计出温度超过重结晶的焊接材料的玻璃化转变温度的焊缝有足够拉伸，该温度一般低于原始支承材料的玻璃化转变温度5到10℃。另外，支承材料的玻璃化转变温度，例如，可通过“Thermal Analysis”手册中的已有方法来确定，该手册由Bernhard Wunderlich于1990年出版，见101页。根据本发明，术语“玻璃化转变温度”不是指单个温度，而是玻璃化转变区间的所有温度(参考Bernhard Wunderlich手册101页18行的“玻璃化转变区间”)。本发明可在超过开始转变温度(Wunderlich用Tb表示)时进行。玻璃化转变的区间可在不同的冷却(或加热)速度下进行确定。最好采用非常慢的速度，例如，1℃/min，尤其是使用微分扫描量热器(DSC)。
还应当注意到需要施加的拉伸量很小。已经发现，如果循环的支承体在拉伸下有不等于零的延伸，本发明就可以成功实施。还应当注意到本发明不限于光(电)导层，如图象形成层。原理上，本发明可成功用于得到对可形成图象的任何层的支承体。本发明不限于通过热源来熔化两个端部的焊缝。原理上，任何导致相近结果的技术都可用于本发明。
此外，从美国专利5 885 512和6 068 722已经知道通过加热来处理带有焊缝的循环的光电导体，光电导体保持一定拉伸。这些专利公开的后处理的目的不是得到更高比例的，在焊缝位置原始具有很好的图象形成能力的光电导体，而是使焊缝位置的光电导体可承受机械时效。因此该专利的工艺是为了使光电导体作为包括图象形成层的整体来承受后热处理。后处理的目的在于清除由于施加不同层形成的内部拉伸。本工艺的发明人已经认识到已知的方法不能提供所要求的生产效率的提高。
从美国专利6 232 028还知道一种方法，其中光电导体的至少一部分受到拉伸，同时温度暂时增加。该专利说明书说明最好选择后处理的温度，使其低于支承体的玻璃化转变温度。
在本发明的一个实施例中，在加热超过玻璃化转变温度之后和在施加图象形成层之前，支承材料冷却到支承材料的玻璃化转变温度之下。其结果是，得到的新状态是凝固的，对循环的支承体可进行机械处理，对生产工艺不产生负面影响。带来的结果是使生产工艺有很大的自由度。因此，支承体可在图象形成层实际施加前暂时保存。
在另一实施例中，整个支承体受到拉伸。该实施例的优点是所要求的拉伸可容易的得到，例如通过使支承体在一个或多个滚筒上进行延伸。这样可避免需要把持支承体的表面来进行伸展。否则将造成所述表面污染或损坏，进一步影响所得到的图象形成介质的功能。还有，除了如上所述的减少支承体的损坏或污染的发生，利用本实施例还可以进一步提高生产效率。其原因尚未完全清楚。
在另一实施例中，所述支承体在滚筒上伸展，滚筒的半径稍大于带的长度L被2π除得的长度。在这个实施例中，支承体只在一个滚筒上伸展，其周长稍大于循环的支承体的长度，一般为1％，在一实施例中，可超过0.15％。其结果是，支承体在滚筒上自己进行伸展。这是一种简化的方法，使得生产缺陷减少。
在另一实施例中，通过放置带有支承体的滚筒到炉中，将支承体加热到超过玻璃化转变温度。该方法一方面的优点是加热可非常简单地进行。另一方面的优点是滚筒膨胀的结果使支承体的伸展增加。这样当支承体施加到滚筒时可使初始拉伸保持最小。这种方式的优点是施加支承体到滚筒可以最简单的方式进行，施加支承体时尤其在焊缝位置出现撕裂危险，应用受到很大限制。
在一个实施例中，所述图象形成层以溶液形式施加，然后使溶剂蒸发。已经准确地发现，在这个实施例中，可实现生产效率的最大提高。其中的原因仍不清楚。
在一个实施例中，图象形成层包括施加到循环的支承体表面的金属层。对于这种形式的图象形成层，采用现有技术已有的方法在焊缝位置可得到有偏差的图象形成功能。通过施加根据本发明的方法，这种情况可极大地避免。
在一个实施例中，聚酯用作支承材料。这种材料的优点是可明显地防止水分和有机溶剂蒸发。也非常适合用于本发明。
在另一实施例中，聚酯薄膜用作支承材料。聚酯薄膜为Dpont/Teijin生产的双向拉伸的聚酯(聚对苯二甲酸乙二醇酯)膜。这种膜非常适合于根据本发明的方法。
附图说明。
下面通过进一步参考示例，对本发明进行说明，附图中：
图1是图象形成装置的示意图；
图2示意性地显示了焊接支承材料带的机构；
图3显示了处理循环的支承体的机构；
图4是显示图象形成介质的结构的示意图。
具体实施方式
图1显示的图象形成装置带有循环的图象形成介质1，在本示例中是具有光电导性质的可带电的带，该材料带通过各驱动和导向滚轮2，3和4以均匀速度前进。介质1通过电晕装置10带有静电后，初始位于窗口5的图象通过闪光灯6和7，透镜8和反射镜9投射到介质1。因此介质1上形成电荷潜像。在另一实施例中，电荷图象的形成是通过使用扫描光源，例如，已知的光栅输出扫描器(raster outputscanner)或液晶显示杆式印刷机。后一种光源是数码印刷机经常使用的。曝光后形成的电荷潜像通过磁性刷装置11进行显影，使用调色粉形成色粉图象，色粉图象然后在压力下与循环的中间介质带12在第一转移区接触，所述带12设有软弹性和耐热材料顶层，比如硅橡胶，如欧洲专利0 349 072所公开的。色粉图象通过附着力从介质1转移到带12。通过这种方式图象在所述中间介质上形成。图象转移后，通过清理装置13对介质1上的任何图象残留进行清除，这时光电导的介质1就可以再次使用。
中间介质带12设置在驱动和导向滚筒14，15上，中间介质带12加热到调色粉软化温度以上，例如可通过设置在滚筒14内的红外辐射源17进行。随着带有色粉图象的带12的前进，色粉图象由于加热变成粘性的。然后在第二转移区，粘性的色粉图象通过具有设置在滚筒23、24的带22形式的压力机构在压力下转移并同时固定到接收材料片上，接收材料片来自容器18并通过滚筒19，20。最后，通过这种方式得到的拷贝通过设置在滚筒23和24上的带22沉积在传送盘25中。
图2是焊接如国际申请WO 03/028982公开的支承材料带的示意图，该专利说明书的第5页4行到13页的21行给出了介绍。其中对工艺的细节进行了详细介绍。对已知工艺的简单介绍将在下面给出。图中显示了聚酯薄膜带100，其设置在将所述带的两端焊接到一起的机构中。所述带的两个相对端部的前沿设置在区域45。两个端部及其周围区域被封闭在两个玻璃板46，47之间。这些板通过压力机构48，49压到薄膜上，使板之间的距离总是等于薄膜的厚度。
在这个实施例中，带100的端部用激光焊接到一起，激光通过激光引导线50，51输送到机构。为了在位置45熔化薄膜材料，激光束通过光学系统40，41聚焦到两个端部自己的过渡区。吸收激光的涂层可根据需要施加到表面60，61，向薄膜提供适当的热量。
带100的端部熔化以后互相流入，形成非晶的焊缝。对焊缝要进行处理使得支承材料在所述焊缝位置结晶。为此，已经冷却的非晶焊缝可进行加热到某温度，在该温度下薄膜的分子具有足够的活动度进行重结晶，但活动度尚未达到使材料重新熔化。一般地，选择温度比材料的熔化温度低几度。焊缝加热到这个温度可使用来自激光源50，51的激光进行，如上所述。通过上面介绍的方式，可以得到循环的支承体，适合形成循环的图象形成介质。在本发明的特定实施例中，初始的非晶焊缝的端部，即焊缝与形成的带的边沿重合的部分，未处理成为结晶的。而是，这些端部仍保留非晶状态。很明显通过这种方式，局部抵抗焊缝机械损坏的能力有明显提高。
图3显示了通过使用参考图2介绍的焊接工艺得到的循环的支承体100。该支承体用厚度为150微米、宽度为35厘米和长度为1200毫米的聚酯薄膜带形成。因此，在根据此实施例的焊接工艺中，带的端部的前沿连到另一个端部前沿，循环的支承体100具有相同的长度。所用聚酯薄膜的玻璃化转变发生在温度80℃。
为了在施加图象形成层以前处理循环的支承体，将支承体设置到滚筒200上。该滚筒的铝侧壁201的厚度为15毫米，形成圆形的周边。滚筒的直径是382.00毫米，长度为50厘米。直径的选择使得支承体100可以很小的延伸张力安装到滚筒200。为了使带施加到滚筒简单方便，滚筒的一端有一定的锥度。通过这种方式，带能够容易地沿图中显示的方向F推到滚筒的端部上。为了对推动支承体到滚筒作进一步简化，使用泵(未显示)通过孔202吹入空气。通过吹气的方式，支承体延伸大约数十毫米，使得其内部直径稍大于382.0毫米。通过这种方式支承体可容易地推到滚筒上。当支承体完全推到滚筒上时，关闭泵，使支承体收缩并包围滚筒。然后对支承体进行清洗，如通过溶剂进行清洗。清洗后，将滚筒置于炉中，温度保持在85℃。炉子设有风扇使空气循环。加热的结果是，滚筒壁201的膨胀超过支承体100，这样，将进一步增加支承体的延伸张力。滚筒和支承体共同达到这个温度，将这个状态保持15分钟。然后从炉中取出滚筒，在无外力的情况下冷却到室温。整个过程在低尘的条件下进行，以尽可能避免支承体污染。
图4是显示图象形成介质1的结构的示意图。该图显示了这种介质的部分截面图。由亚层301到305构成的图象形成层300施加到支承体100上。亚层301是50纳米厚的钛层，其可通过溅射工艺施加到支承体。100纳米厚的粘性层通过喷涂工艺施加到该金属层。在所显示的示例中，粘性层包括Dynapol，这是一种从市场可得到的聚酯。该层通过用空气吹净杂质进行清洁。生成层303施加到该粘性层，其含有可吸收光同时释放自由电荷载流子的色料(pigment)。这种色料可从现有技术充分了解，例如，美国专利说明书4 587 189。在这个示例中，生成层的厚度为500纳米。施加生成层后，施加传输层304。这种层及其应用可从现有技术充分了解，例如，如上面提到的美国专利说明书4 587 189中的示例III所作的介绍。该工艺的其他细节也在该专利说明书中介绍。最后，施加保护层305，在这个示例中，是厚度为150纳米的无定形碳层。该层在用于图1所示的工艺时可减少图象形成介质的机械磨损。
上面介绍的实施例只是作为示例给出，对于所属领域的技术人员，很明显会认识到在本发明的范围内可以进行修改，本发明的范围由所附权利要求确定。

Claims (9)

1.一种制造循环的图象形成介质的方法，所述介质用半结晶支承材料带制造，所述带延伸于第一和第二端部之间，所述方法包括：
使两个端部连到一起；
熔化连接到一起的部分，形成循环的支承体；
使熔化部分进行重结晶；
施加图象形成层到所述支承体；
其特征在于，在施加所述图象形成层之前，包括熔化部分的至少一部分支承体受到拉伸，所述支承体的拉伸部分加热到超过支承材料的玻璃化转变温度。
2.根据权利要求1所述的方法，其特征在于，加热到超过玻璃化转变温度后和施加图象形成层之前，将所述支承材料冷却到低于所述支承材料的玻璃化转变温度。
3.根据权利要求1或2所述的方法，其特征在于，整个所述支承体受到拉伸。
4.根据权利要求3所述的方法，其特征在于，所述支承体在滚筒上拉伸，所述滚筒的半径稍大于所述带的长度L被2π除得的长度。
5.根据权利要求4所述的方法，其特征在于，通过放置带有所述支承体的滚筒到炉中，将所述支承体加热到超过玻璃化转变温度。
6.根据前面权利要求中任一项所述的方法，其特征在于，所述图象形成层包括绝缘层，其以溶液形式施加，然后使溶剂蒸发。
7.根据前面权利要求中任一项所述的方法，其特征在于，所述图象形成层包括施加到循环的支承体表面的金属层。
8.根据前面权利要求中任一项所述的方法，其特征在于，聚酯用作支承材料。
9.根据权利要求8所述的方法，其特征在于，聚酯薄膜用作支承材料。
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