JP2000242066A - Porous photoreceptor and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize a porous layer with substantially uniform thickness by forming many through-holes at substantially equal intervals at the porous layer of a cylindrical photoreceptor. SOLUTION: This porous photoreceptor is constituted of a supporting body 1, a light-transmissive conductive layer 2, a photoconductive layer 3 and the porous layer 4. The layers 2 and 3 are successively formed on the supporting body 1. The layer 4 is formed on the layer 3. Besides, the layer 4 is provided with the plural very-small holes and an electrode layer 5 is formed on the surface thereof. The plural very-small holes 9 are formed at the substantially equal intervals. Thus, the layer 4 is substantially uniformly formed. When the constitution of the above mentioned porous-layer photoreceptor is realized, high image density is secured and high-quality printing processing is realized.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a photosensitive drum and a method for manufacturing the same in an electrophotographic system.
The present invention relates to a photosensitive drum that achieves high resolution and a high aspect ratio and a method for manufacturing the same.

[0002]

2. Description of the Related Art An electrophotographic process plays an important role as an image forming technique for a copying machine, a printer and the like. Carlson method (xerography) is known as a typical technique of the electrophotographic process.

[0003] In the Carlson method, the printing process is electrification,
It is realized by six steps of exposure, development, transfer, fixing, and cleaning. In each step, a dedicated unit is required. Therefore, it is difficult to avoid upsizing of the entire apparatus.

As a known technique related to the present invention, Japanese Patent Application Laid-Open No. 9-204092 discloses a simplified electrophotographic process (image recording method) instead of the Carlson method.

[0005] In the disclosed technology, the porous insulating layer having an electrode formed on the upper surface is filled with conductive colored particles in the pores of the porous photoconductor laminated on the surface of the photoconductor. Exposure light corresponding to the print information is applied, and the colored particles are selectively fly to the counter electrode via the recording paper.

[0006] The printing step is composed of three steps: a colored particle filling step, an exposure flying step, and a fixing step. The size of the device can be reduced as compared with the conventional system. From the viewpoint of continuous printing, the porous photoreceptor is preferably in the form of a cylinder or an endless sheet.

In the manufacturing process of the porous photoreceptor, holes of the sheet-like porous insulating layer are formed in advance by a laser or a drill. Next, the sheet is brought into close contact with the drum-shaped photoconductor. When this method is adopted, a seam of sheets is inevitably generated. Therefore, the joint portion becomes an image defect, and the image quality is deteriorated.

As a measure against image quality deterioration, after an insulating layer is formed on a drum-shaped photosensitive member, the insulating layer is worked into a porous shape. Suitably, the entire photoconductor is formed as a cylindrical porous photoconductor. In the present disclosure, the technology for forming the porous layer is key.

When a hole is mechanically formed in an insulating layer by a drill or the like, one hole is usually formed by one drilling operation. For example, when a porous layer is formed on a cylindrical photoconductive layer having a length of 210 mm and a diameter of 30 mm corresponding to the A4 size at a resolution of 200 dpi, the number of holes is approximately one million or more. Therefore, the same number of punching operations is required. A method of manufacturing a photoconductor according to this measure is not practical.

In the printing method based on the above-described disclosed technology, the upper limit of the image density is determined by the number of colored particles filling the plurality of formed holes. In order to ensure a certain number of colored particles in the holes, the diameter of the holes must be set to a certain value or more, or the depth of the holes (the thickness of the porous layer) must be set to a certain value or more. The hole diameter is required to be reduced in consideration of the resolution and the high quality image.

Therefore, in order to secure an image density of a certain value or more with a wide dynamic range, it is necessary to set the hole depth (porous layer thickness) to a certain value or more. When a plurality of fine through-holes are formed by the photocurable resin,
The thickness of the photocurable resin is increased and the pore size is further reduced. Therefore, the uncured portion is difficult to be efficiently discharged from the inside of the hole, and it is difficult to form the hole.

An electrophotographic system having a photoreceptor capable of ensuring a high image density is desired. Further, an electrophotographic system including a photoconductor that realizes high-quality printing processing is desired.
Further, it is desired that the electrophotographic system including the present photoreceptor be realized by a simple extension of the conventional structure in consideration of the manufacturing process and cost. Further, it is desired that the above-mentioned photoreceptor is cylindrical and has a lattice-like porous layer as an insulating layer. Further, it is desired that the lattice-like porous layer has a substantially constant thickness. At the same time, it is desired that the lattice-shaped porous layer has a plurality of holes arranged at substantially equal intervals.

[0013]

SUMMARY OF THE INVENTION An object of the present invention is to provide a photoreceptor capable of ensuring a high image density. At the same time, another object is to provide a photoreceptor that realizes high-quality print processing. Another object of the present invention is to provide the above-mentioned photoreceptor by simply expanding the conventional structure in consideration of the manufacturing process and cost. Still another object of the present invention is to provide a porous photoreceptor employing a cylindrical photoreceptor and having a lattice-like porous layer as an insulating layer. Still another object of the present invention is to realize a lattice-like porous layer having a substantially constant thickness. At the same time, the object is to realize a lattice-like porous layer in which a plurality of holes are arranged at substantially equal intervals. Still another object of the present invention is to provide a simple method for producing the porous photoreceptor.

[0014]

In order to achieve the above object, the porous photoreceptor of the present invention (see FIG. 25) comprises a support (1), a light-transmitting conductive layer (2) and a photoconductive layer. (3 (9
1,92)) and the porous layer (4).
The light-transmitting conductive layer and the photoconductive layer are sequentially provided over the support. The porous layer is provided on the photoconductive layer. The porous layer is provided so as to have a plurality of micropores, and an electrode layer (5) is formed on the surface.

In this case, each of the plurality of micro holes (9) is
Preferably, they are provided at substantially equal intervals. The porous layer is
Preferably, it is formed substantially uniformly. The porous layer is
It is preferably formed of a photocurable resin. The photoreceptor formed by the translucent conductive layer and the photoconductive layer sequentially provided on the support has a cylindrical shape, and is preferably an organic photoreceptor.

With the porous photoreceptor having the above configuration, high image density is ensured, and high quality image printing is realized.

Further, the method for producing a porous photoreceptor of the present invention comprises:
The following items (1) to (10) are followed. (1) In the method for producing a porous photoreceptor, the porous layer comprises:
It is formed on an organic photoreceptor in which a light-transmitting conductive layer and a photoconductive layer are sequentially laminated on a light-transmitting support. The electrode layer is formed on the surface of the porous layer. The porous layer has a plurality of substantially equally spaced micropores. The porous layer has an insulating property and is formed to have a substantially constant thickness. In particular, follow the procedure below. As a first step, a convex image type having a plurality of projections formed of a photo-curable liquid resin or a photo-curable dry film, which is paired with each of the plurality of micro holes, is formed. As a second step, a flexible liquid resin layer having a uniform thickness is formed on the photoconductive layer. As a third step, the liquid resin layer is perforated with a convex image type projection. As a fourth step, the liquid resin layer is hardened by the hardening promoting means for the liquid resin layer to such an extent that the perforated protrusion in the liquid resin layer is pulled out. Fifth
As a step, the liquid resin layer is completely cured after the convex image is drawn.

(2) Regarding the method of manufacturing a cylindrical porous photoreceptor, as a first step, a cylindrical convex image having a plurality of projections formed on the inner wall of a cylindrical tube and paired with a plurality of minute holes, respectively. Make a mold. As a second step, a cylindrical photoconductor is inserted into the center of the cylindrical tube. As a third step, a liquid resin having flexibility is injected between the photoconductive layer and the convex image type. As a fourth step, the liquid resin layer is cured by the curing accelerator for the liquid resin layer to such an extent that the protrusions embedded in the resin layer are pulled out. As a fifth step, the liquid resin layer is completely cured after the convex image is drawn.

(3) Regarding the method of manufacturing the cylindrical porous photoreceptor, as a first step, a plurality of minute holes are arranged on the photoconductive layer at substantially the same intervals as the plurality of minute holes. A plurality of protrusions are formed, each having a shape that is paired with each of the holes. As a second step, a liquid resin layer is formed on the photoconductive layer so as to have a substantially uniform thickness. As a third step, the liquid resin layer is cured. As a fourth step, an electrode layer is formed on the cured resin layer. As a fifth step, the protrusion is removed.

(4) Regarding the method for manufacturing a porous photoreceptor described in the item (2), the inner diameter of the cylindrical tube is subjected to precision processing. The cylindrical tube is preferably arranged such that the surface of the photoconductive layer and the surface of the projection tip face each other with a substantially uniform interval.

(5) In the method for manufacturing a porous photoreceptor described in the above items (1) to (3), the height of the projection is substantially higher than the thickness of the liquid resin layer. Is preferred.

(6) With respect to the method for manufacturing a porous photoreceptor described in the item (3), when the projection is removed, only the projection is peeled off. Further, it is preferable to employ a solvent that does not substantially erode the cured liquid resin layer.

(7) With respect to the method for manufacturing a porous photoreceptor described in the above item (1), a process of forming a liquid resin layer on the photoconductive layer, a process of perforating the liquid resin layer, and a process of curing the liquid resin Is preferably performed continuously within one cycle with respect to the rotation of the photoconductor.

(8) In the method of manufacturing a porous photoreceptor described in the above item (1) or (2), after the liquid resin layer is coated on the photoconductive layer, the liquid resin layer is cured. The resin hardness is preferably equal to or less than the hardness when the liquid resin is completely cured.

(9) In the method for producing a porous photoreceptor described in the above items (1) to (8), a solvent that is soluble in the liquid resin is applied in the process of removing the unnecessary resin other than the protrusions. Things are preferred. In this case, the solvent is in the form of a mist, and is put in a high-pressure airflow and is sprayed on the object.

(10) Regarding the method for producing a porous photoreceptor described in the above item (2), the outer diameter of the cylindrical photoreceptor is
It is preferably 70 mm or more.

(11) In the method of manufacturing a porous photoreceptor described in the above items (1) to (3), when a photocurable liquid resin is used as the liquid resin, the photocurable liquid resin is cured. Exposure light is preferably transmitted through the photoreceptor.

It should be noted that the reference numerals given to the above constituent elements are provided to facilitate understanding of the present invention, and should not be taken into consideration when interpreting the scope of the claims.

[0029]

Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In this specification, an insulating layer in which a plurality of holes are formed substantially at regular intervals on the surface is defined as a “porous layer”. Further, a photoconductor in which an insulating layer such as a photocurable resin layer is formed on a photoconductive layer before the porous layer is formed is defined as a “laminated photoconductor”.

Further, before the “porous layer” and the “photocurable resin layer” are formed, the photoconductor on which the photoconductive layer is formed is:
Defined as "photoreceptor". "Photoconductor" generally corresponds to a photoconductor in an electrophotographic process. The final product according to the present invention is a "porous photoreceptor" in which a "porous layer" is formed on a "photoreceptor" and an upper electrode layer is formed on the outermost layer.

FIG. 25 is a schematic view of a porous photoreceptor according to the first embodiment of the present invention. FIG. 25 is schematically shown to facilitate understanding of the present embodiment.

The porous photoreceptor 100 has a translucent conductive layer 2, a photoconductive layer 3, and a porous layer 4 sequentially laminated on a translucent support 1. The upper electrode 5 is formed on the surface of the porous layer 4.

The light-transmitting conductive layer 2 is generally formed by a vapor deposition method, a dip coating method, a spray coating method, or the like. An undercoat layer may be provided between the translucent conductive layer 2 and the photoconductive layer 3.

The photoconductive layer 3 may be made of any of an inorganic material and an organic material. When an organic photoconductive layer is used, the photoconductive layer 3 is usually formed by a method for manufacturing an organic photoconductor drum, for example, a dip coating method.
In this embodiment, a case where an organic photoconductive layer is adopted is described as a premise.

FIG. 26 is a schematic diagram of an image forming process to which the porous photoreceptor 100 according to the present embodiment is applied.

The conductive roller 101 is used for the porous photosensitive member 1.
00 and a gap. Conductive roller 101
Has a conductive particle thin layer 102 thinned by a regulating blade 103.

Further, the recording medium 7 and the counter electrode 8 are disposed downstream of the porous photoreceptor 100 in the rotation direction via a gap. The light source 110 is arranged inside the drum of the porous photoconductor 100.

A voltage is applied between the light transmitting conductive layer 2, the upper electrode 5 and the conductive roller 101. The applied voltage is applied to the light-transmissive conductive layer 2 and the conductive roller 10 at the opposing portion of the porous photoreceptor 100 and the conductive roller 101.
1 and so that an electric field is generated between them.

Due to the generated electric field, the conductive roller 1
The conductive particles 6 on the surface 01 are inductively charged to a negative polarity and are filled in the holes 9 of the porous layer 4. Further, the conductive particles 6 colliding with the upper electrode 5 are positively charged by the generated electric field,
Return to the conductive roller 101 direction.

Only the negatively charged conductive particles 6 are filled in the holes 9 of the porous layer 4. The conductive particles 6 in the holes 9 are filled so as to be equal to the potential of the upper electrode 5,
The electric field at the particle layer surface approaches substantially zero. Therefore, the filled conductive particles 6 are confined in the holes 9 of the porous layer 4.

In the image recording section where the porous photoreceptor 100 and the recording medium 7 face each other, a potential difference is provided so that an electric field is generated from the translucent conductive layer 2 toward the counter electrode 8. When the light corresponding to the image is irradiated on the photoconductive layer 3 by the light source 110, the conductivity of the photoconductive layer 3 in the irradiated portion increases. The charges of the conductive particles 6 in the holes 9 leak through the photoconductive layer 3.

When the charge is leaked, the potential of the conductive particles 6 in the hole 9 approaches the potential of the translucent conductive layer 2. Accordingly, an electric field is generated on the surface of the layer of the conductive particles 6. The conductive particles 6 on the upper electrode 5 side are positively charged and fly from the holes 9. The flying conductive particles adhere to the recording medium 7.
Thus, an image is formed.

The pitch and the diameter of the holes 9 directly affect the image density. Therefore, to ensure a high image density,
The pitch interval is set small. Further, the shape and arrangement of the openings of each hole need to be optimized so that the hole diameter is set large.

Further, since an efficient printing process is executed,
It is preferable to consider the following two points. First, an image is formed on a photoconductive layer that is cylindrical or similar to a cylindrical shape. Second, the printing process is continuously performed with the rotation of the cylindrical shape.

FIG. 27 is an enlarged schematic cross-sectional view of the porous photoreceptor in the present embodiment. Hereinafter, a cylindrical porous photoconductor will be described.

The translucent conductive layer 2 is formed on the translucent support 1. The charge generation layer 91 is formed on the translucent conductive layer 2. The charge transport layer 92 is formed on the charge generation layer 91. The charge transport layer 92 and the charge generation layer 91 are
To form

The porous layer 4 is laminated on the surface of the photoconductive layer 3. The porous layer 4 has an insulating property. In the present embodiment, the porous layer 4 is laminated to a thickness of about 100 μm. The upper electrode layer 5 is formed on the porous layer 4.

The upper electrode 5 has the following three roles. First, a high electric field is formed in the photoconductive layer 3. Second, the conductive colored particles 6 are confined. Third, adhesion of the conductive particles 6 to the surface is prevented.

Incidentally, the method for producing a porous photoreceptor of the present invention comprises
There are two embodiments. The first embodiment relates to a method for manufacturing a porous photoconductor. The hole mold for forming the holes in the porous layer is formed of a photocurable resin. The formed mold is applied as a tool for drilling. The second embodiment relates to the formation of a porous layer. A plurality of pin holes are formed on the cylindrical photoreceptor, and the pins are removed after the formation.

In both of the above-described two embodiments, the holes formed are pin-shaped projections having a positive-negative relationship.
The holes are arranged at intervals corresponding to the holes to be formed. This projection is common in that it is applied as a pore type and a porous layer is produced.

The first embodiment differs from the second embodiment in the following points. In the first embodiment, a hole in which a plurality of pins are embedded is created independently of the photoconductor. The formed mold is subjected to a process of manufacturing a plurality of porous photoconductors. In the second embodiment, the pin formation processing is positioned as an intermediate step of manufacturing a porous photoconductor. The pin protrusion is removed each time the photoconductor production is completed. Hereinafter, a description will be given of the hole formation in the first and second embodiments.

A method for manufacturing a photoconductor having the photoconductive layer 3 will be described. The photoconductive layer 3 is common to the above-described first and second embodiments.

As shown in FIG. 27, the photoconductive layer 3 is formed below the porous layer 4. In the present invention, the thickness of the charge generation layer 91 in the photoconductive layer 3 is about 0.05 to 1
It is formed to about μm. The thickness of the charge transport layer 92 is about 5
It is formed to a thickness of from 30 μm to 30 μm.

In the actual printing process, the photoconductive layer 3 is irradiated with exposure light corresponding to the printing information. At this time, charges corresponding to the exposure amount are generated from the charge generation layer 91. The generated charges are carried to the surface of the photoconductive layer 3. Charge transport layer 92
Causes the generated charge to be neutralized by the counter charge, thereby eliminating the charge. The counter charge is attached to the surface of the photoconductive layer 3 charged to the opposite polarity.

The charge generation layer 91 employs n-type titanyl phthalocyanine and polyvinyl butyral. The charge transport layer 92 will be described. Polycarbonate is dissolved by a solvent such as tetrahydrofuran as a binder resin. The dissolved binder resin is mixed with the charge transport material, and a coating process is performed. The content of the charge transport material is about 20 to 40% by weight.

On the photoconductive layer 3 described above, a porous layer 4 is formed, and a porous photoreceptor 100 is formed. The porous layer 4 (porous photoconductor 100) is common to the first and second embodiments.

The formation of pores in the porous layer 4 in the first embodiment will be described in detail. A first example of the first embodiment will be described below.

FIG. 1 et seq. Show the steps of forming the "groove type". The “hole type” is prepared in advance by embedding a plurality of pins 10 in a line shape. Each of the plurality of pins 10 corresponds to a fine and to-be-formed hole in a positive-negative relationship. The hole forming process is performed on the photoconductor in the main scanning direction a and the sub-scanning direction b using a “hole type” (hereinafter, referred to as a pin type 19).

As shown in FIG. 25, in the cylindrical porous photosensitive member 100 or the laminated photosensitive member 90 before the porous layer 4 is formed, the main scanning direction a is orthogonal to the recording paper conveyance direction. Direction. Therefore, the main scanning direction a indicates the photoconductor axis direction (longitudinal direction). The sub-scanning direction b is a direction perpendicular to the main scanning direction a. Therefore, the photoconductor 1
00 indicates the direction of rotation.

Referring to FIG. 2, ultraviolet rays and the like are irradiated onto translucent flat plate support 1 having excellent flatness, and polymerization / crosslinking of monomers in the components is started. A curable negative type photocurable resin 12 is adhered or applied. After the photocurable liquid resin 12 is dropped by a dropper 13 or the like in an appropriate amount, it is uniformly spread on the support base 11.

As the photo-curable resin, a solid material such as a dry film or a syrup-like liquid resin is employed. Dry films are easy to handle and provide a uniform thickness. Liquid type resins generally have high resolution and excellent resin strength after curing. In this embodiment, a liquid resin is used. Any material can be used as long as it provides a hardness that meets the specifications after curing.

In order to make the thickness of the resin uniform, a spacer having a predetermined thickness is inserted between the release film 17 and the resin 12 in a method of bringing a mask 16 into contact with the resin 12 layer, which will be described later. You. At the time of non-contact, a bar coder coating method is adopted. A bar provided with an appropriate gap is swept, and a resin coating process is performed.

In order to cure a desired portion of the resin 12 layer,
Light of a specific wavelength is irradiated and exposed. In the present embodiment, two methods can be applied to the exposure processing. The first exposure method is a method in which a large area is collectively irradiated using a mask or the like on which a pattern to be cured is printed. In this method, a mask on which a pattern to be formed as a hole is drawn is laminated on the resin 12 layer.

The second exposure method is a method of sequentially irradiating a pattern with a laser or the like and performing scanning exposure. In this method, in response to turning on / off the laser,
A pattern is formed on the resin. Therefore, no mask is required. Further, in consideration of image distortion, irradiation light having excellent parallelism is required.

As shown in FIG. 3, when a dry film is applied, for example, a mask 1 based on a laminating method or the like is used.
6 is pressed so as to pass between the heated one or two pressure rollers 15.

When a liquid resin is applied, there is a possibility that the mask and the resin are stuck after the resin is cured, and the mask does not peel off.
As a countermeasure, as shown in FIG. 4, between the mask 16 and the photocurable liquid resin 12 layer, a release film 17 such as a thin fluorine-based sheet excellent in light transmission and release properties is applied. Also, as shown in FIG. 5, a spacer (not shown) is applied to keep a slight gap 18.

In this embodiment, the hole depth is required to be formed uniformly for each hole. The height of the formed pin tip is required to be uniform. Therefore, the thickness of the resin needs to be strictly controlled. In the present embodiment, the first
Is adopted. The pin height uniformity substantially falls within a range of about ± 2 μm when the total resin thickness is about 100 μm.

FIG. 6 shows a mask 16 applied to this embodiment.
Is shown. The light that has passed through the light transmitting section 20 reaches the photocurable liquid resin 12. In response to the transmitted light, curing proceeds only in the lower layer of the photocurable liquid resin 12.

In this embodiment, a positive photosensitive resin can be used. In this case, the mask pattern has a pattern in which the transmitting part and the shielding part are reversed from those of the type shown in FIG.

The photocurable resin 12 may be, for example, an azide compound, a naphthoquinonediazide, a dichromic acid, a polyvinylcinnamic acid, a nylon resin, an acrylate, an epoxy resin, an ene thiol, an unsaturated polyester. , Unsaturated polyurethane-based, silicone resin-based and the like are applied.

The photo-curable resin used in the present embodiment is an epoxy resin-based curable resin in consideration of the fact that the hardness dynamic range before and after curing is wide, the shrinkage after solidification is small, and the like. In this embodiment, the photocurable resin is not limited to the epoxy resin-based curable resin.

The resin has a property of starting curing with light having a specific wavelength near 365 nm. Therefore, an ultra-high pressure mercury lamp is used as an exposure source. After the exposure, if necessary, the mask 16 and the release film 17 are removed, and a developing process is performed to remove the resin in the uncured portion.

In the developing step, a wet process is simple and suitable. In the wet process, only the insoluble portion present in the cured portion of the photocurable resin and further only the uncured portion are dissolved by the solvent.

Ultrasonic vibration, spray development, air brush development, and the like can be used as a developing method for efficiently removing the uncured resin from the resin layer immersed in the container filled with the solvent. . In the spray development method,
The developer is compressed by a compressor or the like, and is ejected from a nozzle. In the airbrush development method, a mist of a developer is sprayed with compressed air or the like.

The above-described developing method was tried under various conditions in the present embodiment, and it was found that the air brush developing method was the most suitable developing method in the following points. First
This is the point where the image does not fall the most. Second, high-resolution development is possible. Third, the consumption of the developer is the smallest. Furthermore, isopropyl alcohol (IP
By spraying A) on the liquid resin exposed for 2 minutes,
The image is visualized. Further, when an alcohol such as methanol or ethanol, or a ketone such as methyl ethyl ketone (MEK) or methyl isobutyl ketone (MIBK) is used as a developer, good results can be obtained by adjusting the developing time.

After the development processing is completed, storage and drying are performed in a thermostat at 80 ° C. for about 10 minutes so that the developer adhered to the surface of the image is removed.

Image collapse is confirmed by magnifying observation of the microscope. Thereafter, the light source described above irradiates the entire surface with light sufficient to complete the curing process of the liquid resin. Finally, the strength of the cured liquid resin is ensured.

As described above, the pins are formed so as to have a substantially uniform height and a substantially uniform diameter. In the pin hole die 19 for boring, a plurality of pins are arranged on the line at substantially uniform intervals.

When the pin length is sufficiently longer than the thickness of the porous layer 4, the bottom of the pin 10 shown in FIG. 1 does not need to be divided for each pin. In this case, connection at the bottom is allowed. Therefore, when light having more short wavelength components and hardly permeating the resin is irradiated from the bottom side of the support 11 before the development after the exposure, only the vicinity of the support 11 is cured. The adhesion between the support 11 and the pin 10 is strengthened.

FIG. 7 is a conceptual diagram of a concave image forming process and a convex image forming process during development. Concave image formation and convex image formation processing
This is a main step for determining the resolution of the porous photoconductor.

FIG. 7A shows a method of forming a concave image. In the method of forming a concave image, the uncured resin 30 in the hole is used.
Is removed by a development process. In the method of forming a concave image, development efficiency is an important factor. The development efficiency refers to the physical properties of the uncured resin 30 such as the resin viscosity and solubility in the developer, the structural area of the pores, the depth of the pores, and the adhesion to the pore walls. It is defined as the efficiency with which the cured resin 30 is removed from the pores.

Accordingly, since a high quality printing process is realized, it is extremely difficult to increase the hole depth of the porous layer in the porous photosensitive member, and to further reduce the hole pitch. This is mainly based on the structural factors mentioned above.

As a feature of the present invention, in forming an image using a photocurable resin, the pinhole type 1 of the convex image shown in FIG.
9 is formed. The convex image is formed of a photocurable resin. Thereafter, a hole is formed based on the pin hole mold 19.

As shown in FIGS. 7A and 7B, in the formation of a convex image according to the present invention, the uncured resin 30 to be removed is not covered and shielded by the cured resin 31. Therefore, unnecessary portions are easily removed by development, and high resolution and a high aspect ratio are easily realized.

Further, the opening ratio of the holes in the porous layer in the present printing method is usually set to 60% or more. This porosity is
This is based on the fact that the conductive coloring particles are not filled (the hole wall portion that does not contribute to printing is reduced as much as possible).

As shown in FIG. 6 and FIG.
The area of 1 occupies a wider ratio than the area of the uncured resin 30. Therefore, the development efficiency is improved. Through the steps shown in FIGS. 1 to 7, the pin hole mold 19 is formed.

Next, the laminated photosensitive member 9 using the pin hole type 19
A hole drilling method of 0 is described. First, a photo-curable liquid resin 1 having a uniform thickness is placed on the above-mentioned cylindrical photoreceptor.
Two layers are formed, and the laminated photoconductor 90 is formed.

FIG. 8 shows the steps of a method for forming a photocurable liquid resin layer. In the present embodiment, a blade coating method is adopted as a forming method. A roll coating method or a dip coating method is also applicable.

After application, the laminated photoreceptor 90 has a thickness of about 2 mm / s.
It is rotated at a peripheral speed of ec to 50 mm / sec, and the process is shifted from the liquid resin layer forming process to the next process. At the time of shifting to the next step, attention must be paid to the occurrence of dripping due to gravity and unevenness in coating thickness. These factors vary with the resin viscosity and the temperature that affects the viscosity.

Next, holes 9 are provided in the formed 12 layers of the photocurable liquid resin by using a pin hole mold 19. FIG.
FIG. 2 is a schematic diagram showing the formation of holes in the laminated photoreceptor. The axis 4 of the laminated photoreceptor 90 in which the 12 resin layers are formed on the outermost layer
2 is fixed to a bearing (not shown). Pin hole type 19
Is fixed to a Z-axis stage 43 whose precision position can be controlled by a motor (not shown).

The stage 43 can be lowered so that the tip of the pin 10 of the hole mold 19 fixed on the stage 43 does not come into contact with the photocurable liquid resin 12 layer. Next, the stage 43 is raised, and the light-curable liquid resin 12
The layer is pierced. When the tip of the pin 10 reaches the photoconductive layer 3, the stage 43 is stopped by a control device connected to a sensor (not shown).

With the pins 10 pierced by the photocurable liquid resin 12 layer, the back surface of the pin hole mold 19 is exposed, and the photocurable liquid resin 12 is cured. The exposure light 45 substantially passing through the slit 44 opened by the pitch in the sub-scanning direction b partially solidifies the resin below the slit width (cured resin 31).

When the curing of the resin has completely progressed, the photocurable liquid resin 12 and the pins 10 are solidified, and the pins 10 cannot be pulled out. It is necessary to adjust the integrated exposure amount, which is the product of the illuminance and the irradiation time, and irradiate the resin based on the optimum exposure amount so that the resin is in a semi-cured state.

FIG. 10 shows the resin hardness of the photocurable resin with respect to the exposure amount. In general, the degree of progress of curing (for example, the hardness of the resin) with respect to the exposure amount of the photocurable resin starts to cure in response to the irradiation of the exposure amount which is a certain value or more. Thereafter, a fully cured state is reached based on an appropriate inclination. In this embodiment, a preliminary experiment is provided. The amount of exposure that remains in a semi-cured state is determined in advance by a preliminary experiment.

Thereafter, the stage 43 is lowered again. In this case, the pin 10 is pulled out, and the laminated photosensitive member 90 is rotated by the pitch in the sub-scanning direction b in the direction of the arrow. In the case of the present photocurable resin 12, the irradiation exposure amount is about 50 mJ / c.
Exposure amounts of m ^{2 to} 200 mJ / cm ² are preferred. Further, at about 80 mJ / cm ^{2 to} 140 mJ / cm ² , more preferable resin strength can be obtained. When the holes are formed, no burrs occur when the pins are pulled out.

In the pin hole mold 19 shown in FIG. 1, the pins 10 are shown in a line in a line. In the mask 16 shown in FIG. 6, the patterns are shown in a line in a line. The present invention is not limited to these. FIG.
Like the hole pattern formed by the pattern shown in FIG. 1, a hole may be formed by a pin hole pattern in which a plurality of rows of pins are arranged in the sub-scanning direction b.

FIG. 12 is a schematic diagram showing the application of a photocurable liquid resin to a photoreceptor and the formation of holes. The coating of the photocurable resin layer 12 and the hole forming process may be continuously performed while the laminated photoconductor 90 is rotating.

Bath 4 filled with photocurable liquid resin 12
6 is moved downward and away by an electric stage (not shown). The downward separating process is performed immediately before the laminated photoconductor 90 rotates in the direction of the arrow so that the perforated hole 9 is not filled with the resin, and the curing start end reenters the resin liquid level. .

FIG. 13 is a schematic sectional view showing an exposure method from the inside of the laminated photoreceptor. When the exposure light 45 passes through the respective layers of the translucent support 1, the translucent conductive layer 2, and the photoconductive layer 3 with sufficient strength to cure the photocurable liquid resin, May be applied.

In this case, a straight tube lamp 47 integrated with the photoreceptor shaft and a mask 16 having a slit 44 are arranged inside the laminated photoreceptor 90. The slit 44 is attached to the inner wall of the translucent support 1 so that it can be peeled off later. When the above-mentioned internal exposure method is adopted, it is preferable that the coating of the resin layer and the hole forming process are continuously performed.

FIG. 14 is a schematic diagram relating to post-exposure for curing the photocurable resin after forming the holes. After the perforation processing of the entire circumference in the sub-scanning direction b is completed, the entire surface of the resin layer is irradiated with light again by the straight tube lamp 47 while the porous photoconductor 100 is rotating before the upper electrode is formed, and the hole wall is formed. Is completely cured.

When the porous photoconductor 100 does not rotate, a structure in which the straight tube lamp 47 is arranged in a circle around the photoconductor 100 may be provided. After the resin is cured, the surface of the laminated photoreceptor is lightly polished to remove burrs at the edge of the hole, and then an electrode layer is formed.

The upper electrode 5 layer is formed on the porous layer 4 by vacuum aluminum deposition so as to have a thickness of about 250 °,
A porous photoconductor 100 is obtained. The upper electrode 5 is formed of a metal such as gold, bismuth, or the like, in addition to aluminum, by evaporation using ITO,
Further, the surface layer may be coated with an adhesion by electroless plating or the like, and further, a conductive polymer or the like. As described above, the porous photoconductor based on the first example of the present embodiment is manufactured.

Next, a second example according to this embodiment will be described. In the present embodiment, a hole having a plurality of pins arranged in the main and sub-scanning directions is formed on the inner wall of the light-transmitting cylinder. The hole forming process is performed on the resin layer by the pin hole type.

FIG. 15 is a schematic view of a pin hole type according to the present embodiment. The cavity is shown from the axial direction. Pin 10 having a substantially uniform height and a substantially uniform diameter
Are arranged from the inner wall of the cylinder formed by the translucent glass tube 50 and the translucent support film 51 toward the center. The circumferential interval between the pins corresponds to the hole pitch in the sub-scanning direction b of the porous photoconductor to be manufactured.

Similarly, pins (not shown) are arranged at intervals corresponding to the hole pitch in the main scanning direction a in the axial direction (the direction from the near side to the far side in the figure). The pin hole mold 19 is formed from a plurality of pins 10, a light transmitting glass tube 50, and a light transmitting support film 51.

The pins 10 are formed by applying the photo-curable liquid resin 12 or the dry film 14 in the same manner as in the above-described embodiment (see FIGS. 2 and 3). Each pin 10 is formed on a translucent support film 51. The translucent support film 51 has flexibility.

The support film 51 is formed into a cylindrical shape by forming a pin, which will be described later, such that the start end and the end are connected so that there is no step. The cylindrical support film 51
Is temporarily fixed to the inner wall of the translucent glass tube 50 by an adhesive. The light-transmitting support film 51 is considered to have light-transmitting properties and furthermore to be adhered to a pin-forming resin described later. In this embodiment, a polycarbonate having a thickness of about 200 μm is employed for the translucent support film 51.

FIG. 16 is a schematic diagram showing the positional relationship between the tip of the pin-hole type pin and the photoconductor photoconductive layer. When the laminated photoreceptor is introduced at the center, the transparent glass tube 50
Is determined with strict precision. The inner diameter of the translucent glass tube 50 is determined so that the tip of the pin 10 finally contacts the photoconductive layer 3 on the surface of the laminated photoreceptor.

The arrangement of the plurality of pins 10 with respect to the translucent support film 51 is not limited to that the pin hole mold 19 described in the first embodiment (see FIG. 1) is not limited to one line but a plurality of pins in the sub-scanning direction b. The rows are arranged side by side based on the same interval as the hole pitch in the sub-scanning direction b.

In this case, the mask pattern applied is
As shown in FIG. 11, the pattern shown in FIG. 6 is arranged in the horizontal direction corresponding to the sub-scanning direction b up to the circumferential length of the translucent glass tube 50.

The center of the axis of the laminated photosensitive member coincides with the center of the cylinder. The laminated photoconductor 90 is inserted into a cylinder, and one end is fixed by a flange. A resin is injected between the translucent support film and the translucent glass tube. The other end is likewise sealed by a flange. As the injection resin to be the porous layer 4, an insulating photo-curable resin or thermosetting resin is employed.
The thermosetting resin is a resin having a function of being cured by heat.

FIG. 17 is a schematic diagram relating to batch exposure from inside the photosensitive member. In order to accelerate the curing, for example, when a photocurable resin is applied to the porous layer, the shaft embedded with the straight tube lamp 47 (see FIG. 13) is diverted, and the entire surface is exposed from inside the photoconductor. Be executed. In this case, no slit is required.

This embodiment is different from the above-described first embodiment in the following points. Photocurable resins are not solidified sequentially and locally. The entire surface of the photocurable resin is cured to the same extent.

In the case of a thermosetting resin which is cured by heating, the curing temperature is kept at a constant atmospheric condition for curing to proceed. This is because the laminated photoreceptor 90 on which the pin hole mold 19 is set is placed in a thermostat. Therefore, it is applied to the present embodiment. In any of the examples, the curing progress is stopped by the semi-cured state. This is the pin hole type 19
Is removed.

Next, the laminated photoreceptor 90 and the translucent support film 51 are removed from the translucent glass tube 50. Further, the laminated photoconductor 90 is peeled off from the translucent support film 51. Thereafter, when a photocurable resin is adopted, a post-exposure process is executed. When a thermosetting resin is adopted, a heating process and a solidification process are executed after the post-exposure process. For the solidification treatment, the conditions under which the resin strength is generally used are considered.

Finally, an electrode layer is formed on the surface of the porous layer, and a porous photoreceptor is formed. This step is the same as in the first embodiment described above.

FIG. 18 is a schematic diagram showing film overlap at the edge of the translucent support film. When a porous photoreceptor is manufactured based on the above-described method, a flat pinhole type end is joined to form a cylindrical shape.

With respect to the circumference of the inner wall of the translucent glass tube 50,
If the entire length of the translucent support film 51 of the pin hole mold 19 is long, there is a possibility that a film overlapping portion 52 occurs.
The gap between the support film and the photoconductive layer is narrowed by the thickness of the translucent support film 51, and the hole-shaped pin falls. Therefore, it is necessary that the entire length of the hole mold is substantially the same as or slightly shorter than the circumference of the inner wall of the translucent glass tube 50.

In the actual mass production process, when the film is cut to a fixed length, a certain margin is required. Further, it is necessary to consider that the length does not become the same as the circumference of the cylinder due to elongation at the time of sticking.

FIG. 19 is a schematic view showing a film gap at an end portion of the translucent support film. As described above, the film gap 53 is provided between the ends of the translucent support film 51 of the pin hole mold 19.

In the porous photoreceptor based on the above, at the time of normal character printing, and further, when a solid black printing process is executed, a part of the circumferential direction is blank due to the resin layer entering the gap. Will be recognized as

The line width of about 0.1 mm is recognized by human eyes. This must be taken into account so that it is not reflected in the printing process. As a countermeasure, it is necessary that the position detection processing of the film overlapping portion of the porous photoreceptor is always executed, and that the printing process is not executed on the joining portion during the printing operation on the recording paper.

The recording paper to be printed is 210 mm wide × 2 vertical.
In the case of the A4 size of 97 mm, if the circumferential length of the porous photoreceptor is at least (210 mm in width of A4 recording paper + the width of the connecting portion), image defects do not occur on this recording paper. Printed. Therefore, the outer diameter of the porous photoconductor is required to be about 70 mm or more (210 mm).
/ Pi = ６６66.8 mm).

According to the present embodiment, once the pinhole type is formed, the pinhole type formed for manufacturing a plurality of porous photoconductors is applied. Excellent mass productivity compared to the first embodiment,
Suitable for producing large-diameter porous photoconductors.

Next, a porous photoreceptor according to a second embodiment of the present invention will be described. FIG. 20 shows a schematic view of pin formation on the surface of the photoconductor.

The plurality of pin-shaped holes 19 are formed on the photoconductive layer 3 of the cylindrical photoreceptor 93. Multiple pins 1
The 0-shaped hole is formed in the circumferential direction and the axial direction of the photoconductor 93. The plurality of pin-shaped holes are arranged at a uniform pitch toward the outside.

After the hole mold 19 is formed, a resin layer for a porous layer and an electrode layer are sequentially formed on the photoconductive layer 3 of the photoconductor 93. Finally, the pin hole mold 19 is removed, and a porous photoreceptor is formed.

The manufacturing difference from the above-described first embodiment is that a pin 10 serving as a hole is formed on the photosensitive member 93 in an intermediate step. In the last step, this pin is removed.

First, a photocurable liquid resin layer serving as a pin material is formed on a photoreceptor. The photo-curable liquid resin is hereinafter defined as the A resin 60 in consideration of the distinction between the resin which is a porous layer material described later and the photo-curable liquid resin layer.

FIGS. 21A to 21E are schematic sectional views showing a procedure for forming pins on the surface of the photosensitive member. In FIG. 21A, the A resin 60 is thicker than a resin thickness of a B resin described later.

In the present embodiment, the A resin 60 is
It is coated based on a blade coating method (see FIG. 8) so as to have a uniform thickness of about 100 μm or more. As described above, a dip coating method or a dip coating method may be adopted instead of the blade coating method.

In this embodiment, a negative type photoresist (manufactured by Tokyo Ohka Kogyo Co., Ltd.) is used as the A resin 60. The A resin 60 does not limit the present invention. A positive resin in which the relationship between light transmission and shielding of the mask pattern is reversed may be employed. In consideration of the binding property with the A resin 60, a primer layer such as a nylon resin layer is preferably provided on the photoconductive layer 3.

The exposure processing for the A resin 60 layer is performed by a sequential exposure processing using a laser or a batch exposure processing using a mask. FIG. 22 shows a schematic view of the exposure step.

When the batch exposure process is performed by using the mask, a pattern arranged in one or several rows in the main scanning direction a is adopted as the mask (FIG. 22 shows a case of two rows). The mask is arranged with a minute gap 18 between the mask and the A resin 60 layer. After the portion other than the irradiation portion is shielded through the slit 44, the portion is exposed by a light source (not shown).

When the exposure processing for the pattern width is completed,
The laminated photoreceptor 90 is rotated by a small angle corresponding to the pattern width, for example, in the direction of arrow B, and the exposure process is sequentially repeated. When the exposure processing for the exposed portion on the laminated photoreceptor 90 makes one round, the exposure processing ends.

The case where the exposure light 45 having a wavelength range in which the A resin 60 cures passes through the respective layers of the translucent support 1, the translucent conductive layer 2, and the photoconductive layer 3 (see FIG. 13). You. FIG. 23 shows a schematic view of an exposure method from inside the photoconductor. In this case, a straight tube lamp 4 integrated with the photoreceptor shaft
Seven light sources are arranged. Translucent support 1 of laminated photoreceptor 90
Is provided with a cylindrical seamless mask 16 in which a pattern is only partially drawn. Finally, the exposure processing is performed by exposing a pattern from inside the laminated photoreceptor 90.

The mask 16 is independent of the rotation of the photosensitive member. In FIG. 23, the mask 16 is always fixed so as to face downward. As in the exposure method shown in FIG. 22, the exposure processing is performed sequentially. Alternatively, when the laminated photoconductor 90 is fixed as another exposure process, the laminated photoconductor 9
A cylindrical mask having a pattern drawn on the entire surface is provided inside the light-transmitting support 1. Finally, the exposure processing is performed such that the entire inner surface of the photoconductor 90 is exposed collectively.

The exposed laminated photoreceptor 90 is visualized by the air brush developing method described above. Finally, the pin hole mold 19 is formed on the photoconductor 93. Pin hole type 19
Is formed of the A resin 60. In the pin hole mold 19, a plurality of pins 10 having a height of about 110 μm are arranged (see FIGS. 20 and 21B).

In the present embodiment, the density of the formed pin hole molds 19 directly determines the resolution of the porous layer 4. Therefore, it is particularly required that a mold in which the pitch of each pin is fine is formed.

In the process of forming the pin hole mold 19 according to the present embodiment, the developing process is easier than that of the concave image. Further, a convex shape capable of forming an image with high definition and high density is formed. Finally, a porous layer is formed that corresponds one-to-one with the convex resolution. The above features are common to the above-described first embodiment. The resolution of the finally manufactured porous photoconductor 100 is substantially determined in the main development step.

As shown in FIG. 21C, the uncured liquid resin (B resin 61) which becomes the porous layer 4 after solidification is formed on the photoconductor photoconductive layer 3 based on the dip coating method described above. To be coated.

In the present embodiment, the thickness of B resin 61 is about 100 μm. This thickness is taken into consideration that the total thickness up to the upper electrode 5 formed on the B resin 61 is not more than the height of the pin 10 (FIGS. 21C and 21D). )). The upper electrode 5 will be described later. This means that, in the present embodiment, the perforation process is performed by the B resin 61.
And the upper electrode 5 is executed at once.

As will be described later, the pins 10 formed on the photoreceptor 93 are removed by a solvent. Therefore, the B resin 61 is required to have chemical resistance after curing. In the present embodiment, as a solvent for removing the A resin 60, an alkaline exclusive release agent is employed. As the B resin 61, a urethane resin photosensitive resin (manufactured by Asahi Kasei Corporation) is employed. The B resin 61 is considered for its resistance to an alkaline exclusive release agent and its insulation after solidification.

As described in the second embodiment of the first embodiment, the material of the porous layer 4 is not limited to the photocurable liquid resin, but may be a thermosetting liquid having the properties of a porous layer. Resin is applied. In this embodiment, the exposure light 4 based on the exposure method described in the first embodiment (see FIG. 14) is used.
5 is applied to the entire surface of the resin. The B resin 61 is completely cured.

As shown in FIG. 21D, the A resin 60
A conductive paste is imprinted on the surface of the B resin 61 layer one step lower than the layer. Further, by the heating treatment at 80 ° C., the organic solvent contained in the conductive paste is volatilized, and the upper electrode 5
Is formed.

The upper electrode 5 may be formed by vacuum aluminum vapor deposition, metal such as gold or bismuth, ITO, or electroless plating. This is the same as in the first embodiment described above.

In a state where the B resin 61 and the upper electrode 5 are solidified, the pins 10 are removed (FIG. 21E).
In the process of removing the pins 10, the laminated photoconductor 90 is immersed in an alkaline resist stripper. In this state, ultrasonic vibration treatment is performed for 2 minutes, and the solidified A resin 60 is swelled and peeled. In the removal processing of the pins 10, the peeling of the upper electrode 5 and the deterioration of the cured resin 31 do not substantially occur.

The release agent remaining on the surface is removed through a rinsing treatment with pure water. 1 in an environment of about 80 ° C
After drying treatment for 0 minutes, flange (not shown)
Is press-fitted from both ends in the axial direction, and the porous photoconductor 100 is formed.

In the present embodiment, in addition to the features common to the first embodiment, the resin in the hole (pin-hole type resin, A resin) is different from the resin (B resin) outside the hole. Different materials can be applied. The resin outside the hole is a resin that forms the hole wall.

In the present embodiment, when selecting the resin inside the hole and the resin outside the hole, attention is paid only to the difference in solubility between the two types of resin. A release agent dedicated to resin A is selected so that resin B is not attacked.

In the above, in the case where the hardness contrast between the cured and uncured B resin is wide, the exposure intensity is appropriately adjusted, and the hardness after curing of the B resin is maintained in a semi-cured state, the first embodiment Thus, a porous photoreceptor is formed.

The B resin is suitable for the porous layer from the viewpoints of film formability, ease of application, insulation, electrode adhesion, toner adhesion to the pore wall, and the like. FIG. 24 shows the resin hardness with respect to the exposure amount of the photocurable resin.

In the case where the hardness contrast between the cured and uncured state is steep, further, as applied in the first embodiment,
When the exposure amount or curing conditions in the semi-cured state cannot be controlled, the method for manufacturing a porous photoconductor according to the present embodiment is applied. In the present embodiment, the upper electrode 5 layer is applied continuously to the process of forming the porous layer 4. Therefore, productivity is improved.

When the electrode forming process by vacuum evaporation is adopted, the amount of metal particles in the hole wall becomes excessive depending on the control of the film thickness. In this case, when the charged conductive coloring particles are filled in the holes (see FIG. 26), a charge leak phenomenon from the conductive coloring particles occurs. The manufacturing method according to the present embodiment can cope with the charge leak phenomenon.

[0156]

The method for producing a porous photoreceptor according to the present invention has the following effects. A high development efficiency, high resolution, and a high aspect ratio convex image are formed. The convex image is transferred, and a porous layer is formed. This point is common to the first and second embodiments.

In addition, according to the first embodiment, once the convex hole type is formed, it is used for manufacturing a plurality of porous photoconductors. Therefore, productivity is improved. In the second embodiment, a resin having excellent curing properties is applied, and the porous layer forming process and the upper electrode layer forming process are continuously performed. Therefore, it is excellent in mass productivity and prevents charge leakage due to metal adhesion to the hole wall.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a pin hole mold manufactured according to the present invention.

FIG. 2 is a diagram showing a state in which a photocurable liquid resin is dropped on a support base;
It is the schematic which shows expansion | deployment.

FIG. 3 is a schematic view showing thermocompression bonding of a mask used in the present invention to a dry film.

FIG. 4 is a schematic diagram showing a configuration at the time of exposure using a curable liquid resin.

FIG. 5 is a diagram showing an exposure using a photocurable liquid resin.
It is the schematic which showed the structure of a mask non-contact.

FIG. 6 is a schematic view showing a mask used in the present invention.

FIG. 7 is a schematic diagram showing a difference between a concave image and a convex image in the present invention.

FIG. 8 is a schematic view showing a method of applying a photocurable liquid resin according to the present invention.

FIG. 9 is a schematic diagram showing the formation of holes in the laminated photoreceptor according to the present invention.

FIG. 10 is a diagram showing the resin hardness of the photocurable resin with respect to the exposure amount.

FIG. 11 is a schematic view showing a mask used in the present invention.

FIG. 12 is a schematic view showing the application of a photocurable liquid resin to a photoreceptor and the formation of continuous holes.

FIG. 13 is a schematic cross-sectional view showing an exposure method from the inside of the laminated photoconductor according to the present invention.

FIG. 14 is a schematic view showing post-exposure for curing the photocurable resin after forming the holes.

FIG. 15 is a schematic diagram showing a pin hole die manufactured and used according to the present invention.

FIG. 16 is a schematic view showing a positional relationship between a pin tip of a pin hole type and a photoconductor photoconductive layer.

FIG. 17 is a schematic view showing batch exposure from the inside of the photoconductor in the present invention.

FIG. 18 is a schematic diagram showing film overlap at the edge of the translucent support film in the present invention.

FIG. 19 is a schematic view showing a film gap at an end portion of the translucent support film in the present invention.

FIG. 20 is a schematic view showing the formation of pins on the surface of a photoreceptor in the present invention.

FIG. 21 is a schematic cross-sectional view illustrating a procedure for forming pins on the surface of a photoreceptor according to the present invention.

FIG. 22 is a schematic view showing an exposure step for forming a pin hole type on a photoreceptor according to the present invention.

FIG. 23 is a schematic view showing a method of exposing the inside of the photoconductor according to the present invention.

FIG. 24 is a diagram showing the resin hardness of the photocurable resin with respect to the exposure amount.

FIG. 25 is a schematic diagram showing the entire configuration of a porous photoreceptor.

FIG. 26 is a schematic view showing an image forming process using a porous photoreceptor according to the present invention.

FIG. 27 is an enlarged schematic cross-sectional view of a porous photoreceptor produced according to the present invention.

[Explanation of symbols]

 1: translucent support 2: translucent conductive layer 3: photoconductive layer 4: porous layer 5: upper electrode 6: conductive particles 7: recording medium 8: counter electrode 9: hole 10: pin 11: support Table 12: Photocurable liquid resin 13: Dropper 14: Dry film 15: Roller 16: Mask 17: Peeling film 18: Gap 19: Pin hole type 20: Light transmitting part 21: Light shielding part 30: Uncured resin 31: Cured resin 40: regulating blade 41: regulating gap 42: axis 43: stage 44: slit 45: exposure light 46: bathtub 47: straight tube lamp 48: flange 50: translucent glass tube 51: translucent support film 52: Film overlapping portion 53: Film gap 60: A resin 61: B resin 90: Laminated photoconductor 91: Charge generation layer 92: Charge transport layer 93: Photosensitivity 100: porous photoreceptor 101: conductive roller 102: conductive particle thin layer 103: regulating blade 110: light source a: a main scanning direction b: the sub-scanning direction

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Tomoyuki Yoshii 5-7-1 Shiba, Minato-ku, Tokyo Inside NEC Corporation (72) Inventor ▲ Ship ▼ Yasuhiro Yamashi 5-7-1 Shiba, Minato-ku, Tokyo No. 1 F-term in NEC Corporation (reference) 2H029 DB00 DB01 2H035 CA07 CB02 CB03 2H068 AA03 AA09 AA54 BB59 FC06 GA14

Claims (22)

[Claims] 1. A support, a light-transmitting conductive layer and a photoconductive layer sequentially provided on the support, and a porous material provided on the photoconductive layer and provided with a plurality of micropores. A porous layer, and an electrode layer formed on the surface of the porous layer. 2. The porous photoconductor according to claim 1, wherein the plurality of micropores are provided at substantially equal intervals. 3. The porous photoconductor according to claim 1, wherein said porous layer is formed substantially uniformly. 4. The porous photoconductor according to claim 1, wherein said porous layer is formed of a photocurable resin. 5. The porous photoconductor according to claim 1, wherein the photoconductor formed by the light-transmitting conductive layer and the photoconductive layer sequentially provided on the support has a cylindrical shape. 6. The porous photoreceptor according to claim 1, wherein the photoreceptor formed by the light-transmitting conductive layer and the photoconductive layer sequentially provided on the support is an organic photoreceptor. . 7. An electrode layer is formed on a surface of a photoconductor in which a light-transmitting conductive layer and a photoconductive layer are sequentially laminated on a light-transmitting support, and each of a plurality of micropores is substantially formed. A method for producing a cylindrical porous photoconductor in which porous layers arranged at equal intervals are formed so as to have a substantially constant thickness, wherein each of the plurality of micropores has a shape. A first step of forming a convex image having a plurality of protrusions; and a second step of forming a liquid resin layer having flexibility on the photoconductive layer so as to have a substantially uniform thickness. A third step of perforating the liquid resin layer with the protrusions of the convex image type; and a means for accelerating the curing of the liquid resin layer so that the protrusion perforated in the liquid resin layer is pulled out. A fourth step of curing the layer; and after the convex mold has been drawn, the liquid Method for producing a porous shaped photosensitive body, wherein a fifth step of completely curing the resin layer, that consists. 8. An electrode layer is formed on a surface of a photoconductor in which a light-transmitting conductive layer and a photoconductive layer are sequentially laminated on a light-transmitting support, and each of the plurality of micropores is substantially formed. A method for producing a cylindrical porous photoreceptor in which porous layers arranged at equal intervals are formed so as to have a substantially constant thickness, wherein each of the plurality of micropores is formed on an inner wall of a cylindrical tube. Forming a cylindrical convex image having a plurality of projections in a pair shape;
A second step of inserting the cylindrical photoreceptor into the center of the cylindrical tube; a third step of injecting a liquid resin having flexibility between the photoconductive layer and the convex image type; A fourth step of curing the liquid resin layer so that the protrusions embedded in the liquid resin layer are pulled out by the curing accelerating means for the liquid resin layer; and 5. A method for manufacturing a porous photoreceptor, comprising: a fifth step of completely curing a resin layer. 9. An electrode layer is formed on a surface of a photoconductor in which a light-transmitting conductive layer and a photoconductive layer are sequentially laminated on a light-transmitting support, and each of a plurality of micropores is substantially formed. A method for producing a cylindrical porous photoconductor in which porous layers arranged at equal intervals are formed so as to have a substantially constant thickness, wherein the plurality of micropores are formed on the photoconductive layer. A first step of forming a plurality of protrusions, each of which is arranged at substantially the same interval as each of the plurality of micropores, and has a shape on the photoconductive layer; A second step of forming the liquid resin layer to have a substantially uniform thickness, a third step of curing the liquid resin layer, and a fourth step of forming an electrode layer on the cured liquid resin layer And a fifth step of removing the protrusions. Method. 10. The method according to claim 7, wherein the protrusion is formed of a photocurable liquid resin. 11. The method according to claim 7, wherein said projections are formed of a photocurable dry film. 12. The cylindrical tube has its inner diameter subjected to precision processing, and the surfaces of the photoconductive layer and the tip of the projection are opposed to each other at a substantially uniform interval. 9. The method for producing a porous photoreceptor according to claim 8, wherein the photoreceptor is used in such a manner as to be used. 13. The method according to claim 7, wherein the height of the projection is substantially higher than the thickness of the resin. 14. The porous photosensitive material according to claim 9, wherein when the protrusions are removed, only the protrusions are peeled off, and a solvent that does not substantially erode the liquid resin layer after curing is used. How to make the body. 15. The method according to claim 7, wherein the liquid resin is a photocurable liquid resin. 16. The method according to claim 8, wherein the liquid resin is a thermosetting liquid resin. 17. A process for forming said liquid resin layer on said photoconductive layer, a perforating process for said liquid resin layer, and a curing process for said liquid resin are continuously performed within one cycle with respect to rotation of said photoconductor. 8. The method for producing a porous photoreceptor according to claim 7, wherein: 18. When the liquid resin layer is applied on the photoconductive layer, when the liquid resin is cured, the resin hardness of the cured liquid resin is such that the liquid resin is completely cured. The method for producing a porous photoreceptor according to any one of claims 7, 8, 15, and 16, wherein the hardness is less than or equal to the hardness at the time. 19. The method according to claim 7, wherein the photoconductor is an organic photoconductor. 20. In the process of removing unnecessary resin other than the protrusions, a solvent soluble in the liquid resin is applied, and the solvent is put in a mist-like high-pressure air flow and is sprayed on an object. The method for producing a porous photoreceptor according to any one of claims 10, 11 and 14, wherein: 21. An outer diameter of the cylindrical photosensitive member is 70 mm.
9. The method for producing a porous photoreceptor according to claim 8, wherein: 22. The method according to claim 15, wherein the exposure light for curing the photocurable liquid resin is transmitted through the photoconductor.