JP2006065149A - Method and apparatus for manufacturing electrophotographic photoreceptor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide parts for an electrophotographic apparatus (such as a drum-shaped or belt-like OPC) having no coating defects and free of deterioration or change of electrical properties required as parts for an electrophotographic apparatus when parts of an electrophotographic apparatus are manufactured by spray coating. <P>SOLUTION: There is provided an apparatus for manufacturing an electrophotographic photoreceptor in which a body to be coated is put in a spray coating booth and spray coating is carried out with a spray gun while rotating the body to be coated to form a coating film on a surface of the body to be coated. The apparatus has a dust removing means having a function to remove dust from the surface of the body to be coated in the coating booth and also has an exhaust system for exhausting the air in the coating booth, wherein the dust removing means is a spray gun or an air nozzle having a function to remove dust from the surface of the rotating body to be coated immediately before coating. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a spray coating method on an electrophotographic substrate, a spray coating method of an electrophotographic photosensitive member, and a manufacturing method of an electrophotographic photosensitive member, and more particularly, a manufacturing method and manufacturing of an electrophotographic photosensitive member by spray coating. The present invention relates to an apparatus and an electrophotographic photosensitive member. Furthermore, the present invention relates to an electrophotographic apparatus, a process cartridge, and an electrophotographic method using such an electrophotographic photosensitive member.

An electrophotographic apparatus has been widely put into practical use as a copying machine, a printer, and the like, but in recent years, its resolution and full color have been advanced. As for higher resolution, a resolution of 1200 dpi or more, which has been 600 dpi in the past, is now required. In addition, the color is full color, and full color approaching silver salt is required.
In these high-resolution or full-color electrophotographic apparatuses, parts directly related to image formation are also required to have higher quality than before. For example, an electrophotographic photosensitive member is an important part that forms an electrostatic latent image and then attaches toner to form an image with toner, but this defect directly affects the electrostatic latent image and the toner image. Therefore, it is required to be uniform and free from defects.

  Electrophotographic photoreceptors include inorganic photoreceptors using amorphous silicon and the like, and organic photoreceptors (hereinafter abbreviated as OPC) using organic optical semiconductors. Organic photoreceptors can be manufactured by coating, and are widely used because their properties can be controlled by the composition of the coating film and the components and thickness of each coating film. By coating, a functional film is formed on a sheet substrate or drum substrate as an electrophotographic photosensitive member. As a method for producing this functional film, dip coating and spray coating are generally used. In dip coating, a method of coating the substrate by a balloon chuck or a mechanical chucking method is often used. Dip coating has the advantage that many substrates can be coated at once, but there is a problem that a large amount of liquid must be used. In addition, when the types of substrates and the layer configuration increase, many equipment modifications and setup changes occur in order to cope with them. Furthermore, it is very unsuitable when applying a small variety of products.

In addition to the belt, spray coating is used for coating a drum-shaped photoreceptor substrate. In Patent Document 1, a cylindrical tube 3 on which a cylindrical conductive substrate can be mounted on the outer peripheral surface is used as a spray coating booth 1. It is supported in the horizontal direction and can be rotated by the rotation drive unit 4. A cylindrical tube is provided with a heating / forced cooling device, and a spray nozzle 2 is provided so as to be capable of scanning in the axial direction of the cylindrical tube. When manufacturing the photoreceptor, the substrate is mounted on the cylindrical tube, and after a predetermined coating process is performed by the spray nozzle 2, the substrate is mounted on the cylindrical tube, and then heated and dried by a heating / forced cooling device, and then forced. It proposes to improve productivity by cooling.
As described in Patent Document 2, spray coating is performed by placing an object to be coated in a coating booth and rotating it while spraying a coating liquid from a coating gun. It is a method of forming a coating film by attaching it to the surface.

OPC is prepared by coating on a conductive substrate. As a coating method, so-called dip coating and spray coating disclosed in Patent Document 2 are used.
In some OPCs, an undercoat layer, a charge generation layer, and a charge transport layer are formed on a conductive substrate by dip coating, and a protective layer is formed thereon by spray coating.
Spray coating is used in the manufacture of OPC in this way, but it is also used in the manufacture of other parts of electrophotographic devices such as transfer rollers, transfer belts, fixing rollers, fixing belts, etc. Since a coating film can be formed with a small amount of coating liquid compared to coating, it has been widely used in recent years.

In Patent Document 3, a rod-shaped halogen lamp that emits infrared rays when energized is provided inside a substrate, and this is used as a heater, so that the time for preliminary drying after coating can be increased by rotating around a predetermined time after spraying. Propose to shorten and increase productivity.
Further, in Patent Document 4, a non-uniform coating film is obtained by providing a pre-drying time between an oscillate and an oscillate in a method for producing an electrophotographic photosensitive member formed by spray coating at least twice per oslate per layer coating. It has been proposed that productivity is improved without sagging of the coating film and generation of bubbles.
Also, in Patent Document 5, as a countermeasure against the adhesion of the spray gun tip that is the cause of the coating film defect, after the spray gun is formed, the spray gun is moved to the outside of the formation region, a cap is applied to the tip of the spray gun, and the cleaning liquid is discharged from the nozzle. A method of cleaning the nozzle tip through an air ejection hole has been proposed.

Here, in spray coating, the object to be coated is placed in the spray booth, but the spray booth is equipped with an air supply / exhaust port, and it is applied by supplying air filtered with a HEPA or ULPA filter. The booth is replaced with clean air.
After the spray mist flow ejected from the spray gun hits the object to be coated and forms a coating film, the mist that has not adhered is discharged along the flow of airflow from the air supply port to the exhaust port. This discharge port is usually provided in or below the spraying direction of the spray gun. Therefore, it is desirable that the inside of the booth be shaped so that the airflow is rectified.
The outside of the spray booth is also a clean room, but the level of cleanliness is lowered due to the operator carrying the workpiece, and the surface of the object to be coated easily becomes dusty and dusty.
From the above, it is conceivable to prevent dust and dust from adhering to the surface of the object to be coated by connecting the spraying process with a spray booth and transporting the machine. A transport mechanism is provided in the spray booth. This disturbs the airflow in the spray booth and is difficult to adopt.
Although the spray booth has such a structure and is considered to be related to the quality of the coating film, there has been no prior art studied as a spray booth for use in the production of an electrophotographic photosensitive member.
However, some studies have been made outside the field of electrophotography. For example, there are Patent Documents 6 to 16 relating to a spray coating booth.

  The present inventor has been investigating the production of OPC that can be used in high resolution and full color by spray coating in recent years. However, the coating defects considered to be caused by dust and fibers adhering inside and outside the coating booth. And satisfactory quality OPC could not be stably obtained. And this coating defect was not able to be solved also by the technique of patent document description.

In our study, before spray coating, the entire spray booth is wiped and washed with a solvent, and after spraying after 30 minutes or more, the first few are free of defects, Alternatively, very few OPCs can be obtained, but after coating 5 or more, the occurrence of defects is recognized at a rate of 1 per several. Here, even if wiping and cleaning is performed using a solvent, coating defects still occur immediately after that, and the coating booth must be left still.
However, this method cannot stably obtain an OPC having a good coating film quality, which is a serious problem.

There are many examples of spray coating other than parts for electrophotographic devices, and we investigated the technology that can be used, but there are many inventions related to the method of collecting spray mist, but there are many coating defects that the inventors have a problem with. There was no examination of a spray booth aimed at eradication.
In this application, the thickness of the coating film is several μm to 20 μm in OPC, and the coating defect of several μm in size is a problem, but in the field where spray coating is generally used, the coating film is several times thicker. It is possible that there is no problem.
In addition, OPC requires electrical characteristics as an electrophotographic photosensitive member in the coating film. However, when spray coating is used in other fields, the appearance is mainly important, and electrical characteristics and the like are questioned. It is possible that nothing will happen.

Further, in these spray coating methods, the spray gun is not operated during heating, drying and cooling, resulting in a decrease in productivity. Further, since the spray does not discharge the liquid during heating, drying, and cooling, the liquid applied before is solidified and the lump is removed at the next application and falls on the electrophotographic photosensitive member, resulting in a coating film defect. On the other hand, since heating is performed without sufficient preliminary drying, bubbles are generated in the film, resulting in coating film defects, and the film surface is rough, resulting in unevenness in the image.
The improvement in productivity by providing a pre-drying time between the oscillate and the oscillate has not been achieved due to a sufficient equipment operation rate because the coating booth and the coating tact have not been sufficiently studied. The nozzle tip cleaning method for coating film defect countermeasures is complicated and the productivity is very poor. From the above, it can be said that there are three problems: (1) reduction in productivity, (2) increase in coating film defects due to spray gun tip contamination, and (3) occurrence of image unevenness due to deterioration in surface properties. These three points can be regarded as a subject of the present invention as they are.

Japanese Patent Laid-Open No. 8-15876 Japanese Patent No. 3286707 Japanese Patent Laid-Open No. 1-231056 JP 2003-91082 A JP 2003-2111064 A JP 59-10269 A JP 59-10270 A JP 59-23870 A No. 01-43191 No. 03-1085 Japanese Utility Model Publication No. 05-18669 Japanese Utility Model Publication No. 06-39152 JP 2000-225361 A JP 2001-205155 A JP 2001-239194 A JP 2001-300370 A

  Accordingly, an object of the present invention is to provide an electronic device that is free from coating defects and has no deterioration or change in electrical characteristics required as a component for an electrophotographic apparatus when a part of an electrophotographic apparatus such as OPC is manufactured by spray coating. It is to provide parts for photographic devices (drum-like or belt-like OPC electrophotographic photoreceptors, etc.). Further, the object to be coated in the present invention is an OPC drum, an OPC belt, a transfer belt, a transfer roller, a fixing roller, and a transfer belt. Another object of the present invention is to improve the productivity of these electrophotographic photosensitive members (OPC drums, OPC belts), transfer belts, transfer rollers, fixing rollers, and transfer belts, and to reduce coating film defects and image quality. An object is to provide an electrophotographic photosensitive member coating apparatus, a manufacturing method, and an electrophotographic photosensitive member by spray coating in which unevenness does not occur. Furthermore, another object is to provide an electrophotographic method and an electrophotographic apparatus using such an electrophotographic photosensitive member.

Although these problems are solved by the present invention, the present invention can be divided into a first group of inventions and a second group of inventions for convenience of understanding.

[First Group of the Invention]
The inventor investigates the cause of the occurrence of coating defects in the above-mentioned spray coating, and when installing the article to be coated in the coating booth as the cause of the coating defect, Even if the surface of the object to be coated is wiped off with a solvent, or the surface of the object to be coated is wiped for about 20 seconds with a compressed air of 0.5 Mpa, and the dust is removed, it is applied to the object to be coated from the person or the surrounding atmosphere when handling the operator. Adhesive fibers and dust are brought into the spray booth, and foreign objects such as fibers and dust floating in the atmosphere outside the coating booth are brought into the coating booth. It was confirmed that it adhered to the work or once adhered to the inner wall of the spray booth and then peeled off and adhered to the object to be coated.
And the inventor examined the countermeasure and reached the present invention.

That is, the above-mentioned problem is the first group of the present invention (1) “Place the object to be coated in the spray coating booth, and perform the spray coating with a spray gun while rotating this to the surface of the object to be coated. An apparatus for producing an electrophotographic photosensitive member for forming a coating film, comprising: dust removing means having a function of removing dust from the surface of an object to be coated in the coating booth; and exhaust means for exhausting air in the coating booth. And the dust removing means is a spray gun or an air nozzle, and has a function of removing dust on the surface of the object to be rotated immediately before application of the object to be coated. An electrophotographic photoreceptor manufacturing apparatus "
(2) “The spray gun in the coating booth is an air spray gun, and air pressure switching means capable of switching the air pressure of the atomizing air discharge port before and during coating is disposed. The apparatus for producing an electrophotographic photosensitive member according to item (1), characterized in that;
(3) “Air jetting means is disposed adjacent to the spray gun in the coating booth, and the air jetting means also operates as a drive system for spraying the coating liquid of the spray gun. The apparatus for producing an electrophotographic photosensitive member according to item (1), characterized in that it exists;
(4) “The air spraying to the coated object is completed within 30 seconds before the start of coating, and the rotation of the coated object is not stopped between the air spraying and the coating start. The electrophotographic photosensitive member manufacturing apparatus according to item (1) above;
(5) “Manufacture of electrophotographic photosensitive member according to (1) above, wherein the direction of the air blowing means is arranged to blow toward the center of rotation of the workpiece. apparatus";
(6) The first (1) characterized in that the air blowing means of the spray gun or the air blowing direction of the air nozzle is arranged in parallel with the air supply direction of ventilation air to the coating booth. Electrophotographic photosensitive member manufacturing apparatus according to item):
(7) The electrophotographic photosensitive member according to (1), wherein the spraying means or the air nozzle of the spray gun is scanned along the rotation axis direction of the object to be coated. Manufacturing equipment";
(8) The item (7), wherein the air spraying means or the air nozzle of the spray gun is arranged perpendicular to the scanning direction of the air spraying means or the air nozzle of the spray gun. The electrophotographic photosensitive member manufacturing apparatus described in “:”
(9) The electrophotographic photosensitive member according to (1) above, wherein the distance between the tip of the air spraying means of the spray gun or the tip of the air nozzle and the object to be coated is 100 mm or less. Manufacturing equipment";
(10) "Electrophotographic photosensitive member manufacturing apparatus according to item (1) above, wherein an air blowing speed to an object to be coated is at least 200 m / s or less";
(11) “The apparatus for producing an electrophotographic photosensitive member according to (1) above, wherein an air blowing amount is 1% or less of a coating boot ventilation air flow”;
(12) The electrophotography according to item (1), wherein at least one set of exhaust ports of the coating booth is arranged parallel to and / or in a direction perpendicular to the blowing air direction. This is achieved by the “photoconductor manufacturing apparatus”.

Further, the above-mentioned problem is the first group of the present invention (13) “Places the object to be coated in the spray coating booth and performs spray coating with a spray gun while rotating the object to be coated. A method for producing an electrophotographic photosensitive member for forming a coating film on a surface, wherein at least a surface of an object to be coated disposed in the coating booth is removed, and a step of exhausting air in the coating booth The dust removal step is performed by spraying air onto the surface of the object to be coated by a spray gun or an air nozzle, and rotating the surface of the object to be coated immediately before coating the object to be coated. A process for producing an electrophotographic photosensitive member, characterized in that it removes dust from
(14) The item (13), wherein the spray gun in the coating booth is an air spray gun, and the air pressure of the atomizing air discharge port can be switched between before coating and during coating. A process for producing the electrophotographic photoreceptor according to 1);
(15) “Air jetting means is disposed adjacent to the spray gun in the coating booth, and the air jetting means also operates as a drive system for spraying the coating liquid of the spray gun. The method for producing an electrophotographic photosensitive member according to item (13), characterized in that it exists;
(16) “Completion of air spraying on the object to be coated is within 30 seconds before the start of coating, and the rotation of the object to be coated is not stopped from the time of air spraying to the start of coating. The method for producing an electrophotographic photosensitive member according to (13) above;
(17) The production of the electrophotographic photosensitive member according to (13), wherein the direction of the air blowing means is arranged to blow toward the rotation center of the article to be coated. Method";
(18) The above-mentioned (13), wherein the air blowing means of the spray gun or the air blowing direction of the air nozzle is arranged in parallel with the air supply direction of the ventilation air to the coating booth. The production method of the electrophotographic photosensitive member according to the item);
(19) The electrophotographic photosensitive member as described in (13) above, wherein the air jetting means or the air nozzle of the spray gun is scanned along the rotation axis direction of the object to be coated. Production method";
(20) The item (19), wherein the air ejection means or the air nozzle of the spray gun is arranged perpendicular to the scanning direction of the air ejection means or the air nozzle of the spray gun. A process for producing the electrophotographic photoreceptor according to 1);
(21) The electrophotographic photosensitive member according to item (13), wherein the distance between the tip of air spraying means of the spray gun or the tip of the air nozzle and the object to be coated is 100 mm or less. Production method";
(22) "The method for producing an electrophotographic photosensitive member according to item (13) above, wherein an air blowing speed to an object to be coated is at least 200 m / s or less";
(23) "The method for producing an electrophotographic photosensitive member according to item (13) above, wherein the amount of air blown is 1% or less of the air flow rate of coating boot ventilation";
(24) The electrophotography described in (13) above, wherein at least one set of exhaust ports of the coating booth is arranged in parallel and / or perpendicular to the blowing air direction. This is achieved by the “photoconductor production method”.

[Second Group of the Invention]
In addition, the above-mentioned problem is (25) of the second group of the present invention, “a coating method of an electrophotographic photosensitive member in which a coating layer having a thickness of 20 μm or more is formed on a substrate by spray coating, When the number of booths is A, the coating tact is B (seconds), the preliminary drying time is C (seconds), and the number of spray guns is 1, 0.95 ≦ B / (C / (A-1)) ≦ 1 .05, an electrophotographic photosensitive member coating method characterized by the relationship
(26) “It is a coating method of an electrophotographic photosensitive member in which two or more coating layers are formed on a substrate by spray coating, and at least one layer is 20 μm or more, and the number of coating booths is A, When the total coating tact for coating two or more layers is B (seconds), the total preliminary drying time for two or more layers is C (seconds), and the number of spray guns is one for each layer, 0.95 ≦ B / (C /(A-1))≦1.05, “Coating method of electrophotographic photosensitive member,”
(27) “A method for applying an electrophotographic photosensitive member according to (25) or (26) above, wherein the rotational speed during the preliminary drying is 60 to 130 rpm”. .

Further, the above-mentioned problem is a coating apparatus for an electrophotographic photosensitive member for forming a coating layer having a thickness of 20 μm or more on a substrate by spray coating (28) of the second group of the present invention. When the number of booths is A, the coating tact is B (seconds), the preliminary drying time is C (seconds), and the number of spray guns is 1, 0.95 ≦ B / (C / (A-1)) ≦ 1 .05, an electrophotographic photosensitive member coating apparatus characterized by having a relationship of “05”;
(29) “An electrophotographic photosensitive member coating apparatus in which two or more coating layers are formed on a substrate by spray coating, and at least one layer is 20 μm or more, and the number of coating booths is A, When the total coating tact for coating two or more layers is B (seconds), the total preliminary drying time for two or more layers is C (seconds), and the number of spray guns is one for each layer, 0.95 ≦ B / (C /(A-1))≦1.05 relationship, electrophotographic photosensitive member coating apparatus ”;
(30) “A coating apparatus for an electrophotographic photosensitive member according to the item (28) or (29), wherein the rotational speed during the preliminary drying is 60 to 130 rpm”. .

[Invention common to the first and second groups]
Furthermore, the present invention provides the following inventions as preferred embodiments thereof.
(31) “The electrophotographic photoreceptor manufacturing apparatus according to any one of (1) to (12)” or the electrophotography according to any of (28) to (30). A process for producing an electrophotographic photosensitive member, characterized by using a coating device for the photosensitive member;
(32) "A method for producing an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member coating method according to any one of (25) to (27)" is used;
(33) "Electrophotographic photosensitive member produced by the method according to item (31) or (32)";
(34) “An electrophotographic apparatus comprising at least a charging step, an image exposure step, a development step, a transfer step, a cleaning step, a charge removal step, and an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the above (33). An electrophotographic photosensitive member according to the item);
(35) “A process cartridge for an electrophotographic apparatus comprising at least an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the electrophotographic photosensitive member according to item (33). Process cartridge ";
(36) “An electrophotographic apparatus comprising at least a charging means, an image exposing means, a developing means, a transferring means, a cleaning means, a static eliminating means, and an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the above (33). An electrophotographic photosensitive member according to the item);
(37) “A process cartridge for an electrophotographic apparatus comprising at least an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the electrophotographic photosensitive member according to item (33). Process cartridge ";
(38) “An electrophotographic method in which at least a charging step, an image exposure step, a development step, a transfer step, a cleaning step, and a static elimination step are performed on the electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is described in the above (33). An electrophotographic method comprising the electrophotographic photosensitive member according to the description.

The first group of the present invention relates to a manufacturing method and a manufacturing apparatus for forming a coating film of a part for an electrophotographic apparatus by spray coating, and air spraying on the surface of an object to be coated immediately before spray coating, The basic content is to prevent the occurrence of coating defects by removing dust by exhausting dust and mist accompanying air, and coating is performed immediately before spray coating (for example, preferably within 30 seconds before spray coating). Fibers attached to the surface of the object to be coated by blowing appropriate compressed air (preferably 0.2 Mpa or more) in an appropriate mode (preferably a mode as described in each claim), It has an extremely excellent effect that it can exfoliate foreign objects and can quickly evacuate, and can prevent coating defects caused by coating defects and image defects caused by coating roughness. To.
In the second group of the present invention, the number of coating booths is A, the coating tact time is B, and the preliminary drying time is set in the step of producing an electrophotographic photosensitive member having a film thickness of 20 μm or more by spray coating on a substrate. When C is set to satisfy the relationship of 0.95 ≦ B / (C / (A-1)) ≦ 1.05, the productivity is improved and the coating film defect is caused by the contamination of the spray gun. And, there is an extremely excellent effect that image defects due to the roughness of the coating film can be reduced.

Hereinafter, the present invention will be described in detail with reference to the drawings.
[First Group of the Invention]
FIG. 1 shows an outline of an example of a photoconductor manufacturing apparatus of the first group of the present invention. In the apparatus of FIG. 1, an object to be coated (1), which is an electrophotographic photosensitive substrate placed in a spray coating booth (100), is an object rotating means (2) for holding and rotating the object. An example of a manufacturing apparatus for an electrophotographic photosensitive member, in which a coating is formed on the surface of an object to be coated by spray coating with a spray gun (3) while rotating. The spray gun (3) in this apparatus example includes The adjoining air ejection means (7) (dust removal nozzle) is provided, but the spray gun (3) can be an air spray gun, and the air pressure can be switched between before coating and during coating. It is preferable to arrange an air pressure switching means. Further, when the spray gun (3) cannot inject only air, an air nozzle (not shown) can be provided adjacent to or near the spray gun (3), or the spray gun An air nozzle that moves in synchronization with (3) can be provided at a remote location. The spray gun (3) is scanned by the moving means (4) along the rotation axis direction of the coated object (1).

  A supply pipe (5) is connected to the spray gun (3), and compressed air is supplied to the spray gun (3) via the supply pipe (5). The source of the supply pipe (5) In the direction, air pressure switching means (not shown) for adjusting the pressure of supplied air is provided. The air pressure switching means switches the air pressure at the discharge port between before coating and during coating between the coating mode of the spray gun (3) (for example, the dust removal mode before coating) and the non-coating mode. be able to. The supply pipe (5) may preferably have a dual structure part that can supply the coating liquid and air separately.

  At the bottom of the coating booth (100), there is an exhaust port (6) directed in the direction parallel to the direction of the blowing air by the air supply means (9) (not shown, shown in FIG. 3), and at the side, Two exhaust ports (8) oriented in the direction perpendicular to the attached air direction are provided, but it is preferable that at least one of these exhaust ports (6) and (8) is provided.

  FIG. 2 explains an example of the direction of the air ejection means and the air nozzle (7) in the present invention. As shown in FIG. 2, in the present invention, it is preferable that the air jetting means and the air nozzle (7) are arranged so as to blow toward the rotation center of the article to be coated (1). The number of air nozzles (7) is not limited to one. The air blowing direction of the spray gun (3) or the air nozzle (7) is as described above, and the air supply direction of the ventilation air to the coating booth (100) by the air supply means (9) is as described above. Are preferably arranged in parallel. Moreover, it is preferable that the air ejection means or the air nozzle (7) of the spray gun (3) is arranged perpendicular to the scanning direction of the air ejection means or the air nozzle (7) of the spray gun (3). .

In the present invention, the distance between the tip of the air jetting means of the spray gun (3) or the tip of the air nozzle (7) and the article to be coated (1) is preferably 100 mm or less. The air blowing speed to 1) is preferably at least 200 m / s.
Furthermore, the air blowing amount is preferably 1% or less of the coating boot ventilation air flow. Further, in the present invention, it is preferable that the completion of air spraying on the article to be coated (1) is within 30 seconds before the start of coating, and further, during the period from air spraying to the start of coating, It is preferable not to stop the rotation of the workpiece.

In the method of the present invention, a part for an electrophotographic apparatus in which a coating object is placed in a spray coating booth and a coating is formed on the surface of the coating object by performing spray coating with a spray gun while rotating the coating object. In the manufacturing method, by blowing compressed air of 0.2 Mpa or more on the surface of the object to be coated within 30 seconds before the spray coating, the fibers and dust particles adhering to the surface of the object to be peeled are peeled off quickly. Can be made.
The removal effect can be easily confirmed by marking the periphery of the fibers and dust particles adhering to the surface of the object to be coated, peeling them off, observing them with black light irradiation, and collecting the foreign materials with an adhesive tape.
As in the present invention (see FIG. 1), by removing dust on the surface of the object to be coated just before the coating, it is possible to prevent a defect from being created by spray coating with a foreign object on the surface of the object to be coated. Can do. If dust is not removed immediately before, there is a problem that fibers and dust cannot be prevented from adhering to the object to be coated before coating, resulting in coating defects.

In the present invention (see FIG. 1), in the method for manufacturing a part for an electrophotographic apparatus, an air spray gun (3) is used as a gun for spray coating, and the coating liquid is a constituent part of the air spray gun. The compressed air discharge port for atomizing the air can be used as air for dust removal by controlling the pressure.
This combination does not increase the number of extra structures inside the coating booth, so the inside of the coating booth can be simplified.
If the structure in the coating booth is complicated, the airflow from the air supply port to the exhaust port becomes turbulent, and the fibers, dust, and exhaust mist are not exhausted quickly due to stagnation and accumulation on the structure, causing defects. The problem which becomes a cause of a foreign material, or induces the drying nonuniformity of the coating film after coating, and inhibits uniform coating-film formation generate | occur | produces.

  Further, in the method for producing a part for an electrophotographic apparatus of the present invention, when the spray gun is not air spray, the coating liquid residue adheres to the gun tip due to the liquid property of the coating liquid and the shape of the spray gun. As dust removal air according to (7), it is effective when there is a risk of wiping off liquid residue adhering to the object to be coated when atomized air is used. By using the drive system also as a spray gun, the structure can be simplified.

  As described above, the period from the completion of air dust removal of the workpiece to the start of coating within 30 seconds, and further, the rotation of the workpiece is not stopped until the coating starts, so that the foreign matter after dust removal can be recovered. There is an effect to suppress adhesion, and when air dust removal is performed on the object to be coated (see FIG. 2), by arranging the air blowing nozzle to spray toward the center of rotation of the object to be coated, It is possible to efficiently remove dust and foreign fibers.

  The direction of spraying air to remove dust (see Fig. 3) can maintain cleanliness in the booth by arranging the flow direction of clean air supplied to the spray coating booth and the flow direction of dust removal air in parallel. It is possible to efficiently remove dust and fiber foreign matter by scanning the air blowing nozzle for removing dust in the axial direction (see FIG. 4) and rotating the object to be coated.

  The installation position of the air outlet nozzle for dust removal (see FIG. 4) is arranged in a direction perpendicular to the nozzle scanning direction, so that foreign matters can be efficiently removed in the exhaust direction, and as described above. The distance from the air nozzle for dust removal to the object to be coated is 100 mm or less for good dust removal efficiency (see FIG. 5).

  The blowing speed of the dust removing air has a good dust removal efficiency of 200 m / s or less, and preferably 30 m / s to 150 m / s. When the speed is 200 m / s or more, there is a large amount of foreign matter adhering to the object to be coated, which causes a reduction in the yield rate.

  The amount of air to be removed is preferably less than 5% with respect to the amount of air supplied to the booth. If the amount of air is 5% or more, there is a problem that foreign matter adheres to the object to be coated. Further, as shown in FIG. 6, the spray mist exhaust port in the coating booth is arranged such that the exhaust direction is downward and perpendicular to the air supply direction, and mist generated during spray coating is generated. Is efficiently removed.

  As described above, the apparatus of the present invention can eliminate the adhesion of foreign matters by removing air dust from an object to be coated. Furthermore, in the present invention, in order to prevent adhesion of mist generated at the time of spraying, the mist can be quickly discharged out of the booth by installing a mist exhaust port, and the occurrence of coating film defects can be suppressed.

As coating in the present invention, coating of a part of the layer may be formed by a coating method other than spray coating. For example, dip coating or ring coating can be used.
In the present invention, two-fluid spray coating is suitable as the spray coating, but one-fluid spray coating can also be used.

As an object to be coated according to the present invention, a part for an electrophotographic apparatus other than an electrophotographic photosensitive member can be used. For example, a transfer roller or a coating film formed by spray coating at the time of manufacturing a transfer belt, or a fixing roller Alternatively, even in the formation of a coating film by spray coating in the production of a fixing belt, coating film defects can be suppressed, and a uniform and excellent quality coating film can be formed.
In particular, it is suitable for spray coating of electrophotographic apparatus parts used in recent high-resolution electrophotographic apparatuses of 1200 dpi or higher, and electrophotographic apparatuses capable of full color output.
Here, for example, a fixing belt is prepared by spraying a primer on a polyimide fillet belt and further applying a silicone resin thereon by spray coating. Sometimes the first group of the present invention can be applied as it is.

[Second Group of the Invention]
(Coating equipment)
FIG. 7 is a view showing a coating portion of an example of an apparatus for performing spray coating on the outer surface of a belt according to the second group of the present invention. In the figure, (1) is a substrate as a workpiece, which is attached to a substrate holding jig (22). And (23) is a ball screw, (3) is a spray gun, (5) is piping (tube) which supplies a coating liquid and a sprayer to a spray gun (3). The coating liquid is pumped from a coating tank (not shown). In some cases, the coating liquid is fed by applying pressure to the coating liquid storage tank with compressed air or the like. Although not shown, a filter, a flow meter, and a viscometer for filtering the coating liquid may be attached to the liquid supply piping system connected to the tube (5).
In this coating apparatus, a partitioned booth (not shown) is installed, ventilation (air supply, exhaust) is performed, and spray mist is not scattered around. In the figure, the substrate (1) is mounted horizontally, but it may be mounted vertically. Further, the positions of the spray gun (3) and the substrate (1) may be set in view of the finished film.

The coating booth in the second group of the present invention is a place where the substrate (1) shown in FIG. 7 can be charged, and the number of coating booths can be charged the substrate (1) in one coating facility. It is a number. The coating tact in the second group of the present invention is from the introduction of the substrate (1) shown in FIG. 7 until the spray gun (3) finishes coating and the spray gun (3) moves to another booth. Time (minutes). The pre-drying time is the time (minutes) from the end of coating with the spray gun (3) until the substrate is taken out.
In the second group of the present invention, the operating rate of the spray gun 1 and the operating rate of the coating booth are influenced by the relationship between the coating booth number A, the coating tact B, and the preliminary drying time C, respectively. . In the second group of the present invention, when the operation rate of the spray gun and the coating booth becomes the highest, the equation 0.95 ≦ B / (C / (A-1)) ≦ 1.05 holds. .
For example, when B / (C / (A-1)) is smaller than 0.95, in other words, when the preliminary drying time is long, it indicates that the time during which the spray gun is stopped is long. On the contrary, when B / (C / (A-1)) is larger than 1.05, in other words, when the coating tact is long, the substrate is stopped in the coating booth and the operation rate as the coating booth is low. It shows that it has become. In the second group of the present invention, ideally, when the above formula is 1, both the spray gun and the coating booth have an operation rate of 100%.

As a specific example, assuming that the coating booth number A = 3, the coating tact B = 10 minutes, and the preliminary drying time C = 20 minutes, B / (C / (A-1)) = 1. In this case, coating is performed at the first coating booth, then coating is performed at the second coating booth, and coating is performed at the third coating booth. Since the coating tact time is 10 minutes and the preliminary drying time is 20 minutes, the second and third electrophotographic photosensitive members coated at the same time as the first coating have completed the preliminary drying time and the fourth electronic The photoconductor can be applied at the first coating booth. By repeating this, it can be seen that the operating rate is 100% in both the coating booth and the spray gun.
Ideally, the above equation should be 1, but a range of 0.95 to 1.05 is sufficiently effective.

  Similarly, in the process of producing two or more layers of electrophotographic photoreceptors with the same coating equipment, the number of coating booths is set to A, two or more layers as the case where the operation rate of the spray gun and the coating booth is the highest. When the total coating tact of B is B, the total preliminary drying time of two or more layers is C, and the number of spray guns is one per layer, 0.95 ≦ B / (C / (A-1)) ≦ 1.05 This is when the formula holds.

  However, in order to make a coating film having a film thickness of 20 μm or more uniform, it is necessary to take a sufficient pre-drying time to volatilize the coating solvent, but the number of coating booths is large from the above relational expression. The equipment becomes larger. Therefore, it is desirable that the coating booth is about 2 to 4.

On the other hand, in order to shorten the preliminary drying time, it is advantageous to increase the rotational speed during preliminary drying and volatilize the solvent by centrifugal force. However, if the rotational speed is increased too much, the surface property of the electrophotographic photosensitive member surface is increased. It has been confirmed that it worsens and Rmax increases. Rmax is preferably 0.5 μm or less. If it exceeds 0.5 μm, unevenness tends to occur in a halftone image.
If the rotational speed is too small, the preliminary drying time becomes long and the purpose of improving productivity cannot be achieved.
Therefore, it is desirable that the rotation speed during preliminary drying is 60 to 130 rpm.
Also, if the balance between the coating tact time and the pre-drying time is poor, if the spray gun liquid spray interval is long, the paint will dry on the tip of the spray gun, and a lump of paint will adhere to the substrate during the next coating. Adhering coating film defects occur.
Therefore, 0.95 ≦ B / (C / (A-1)) ≦ 1.05 is required to reduce the coating film defects of the coating lump. With this method, the apparatus is not complicated.

[Electrophotographic photoconductor]
FIG. 8 shows an overall view of the electrophotographic photoreceptors (belt (example)) of the first and second groups of the present invention. In the figure, (31) is a photoconductor surface, and (32) is a surface opposite to the photoconductor surface.
FIG. 9 is a cross-sectional view of the electrophotographic photoreceptors (belt (example)) of the first and second groups of the present invention.
As shown in B and C, the photosensitive layer (33) provided on the base (11) of the electrophotographic photosensitive member in the present invention includes, for example, an undercoat layer (12), a charge generation layer (13), and a charge transport layer. (14) (Fig. B), or further comprising a protective layer (15) (Fig. C), or a single function that is not functionally separated into the charge generation layer (13) and the charge transport layer (14). An intermediate layer (not shown) may be provided between the undercoat layer (12) and the charge generation layer (13), or between the charge transport layer (14) and the protective layer (15). Therefore, the constituent layers in the second group of the present invention include these undercoat layer (12), charge generation layer (13), charge transport layer (14), protective layer (15 ), An intermediate layer not shown. The electrophotographic photoreceptors of the first and second groups of the present invention have good surface properties and achieve Rmax of 0.5 μm or less. In addition, there is an advantage that the occurrence of uneven coating during coating is small. Although not shown in the drawing, rib-shaped guides that stop the belt may be provided on both sides of the belt.

  FIG. 9 shows a cross-sectional view of another example of the electrophotographic photosensitive member of the first and second groups of the present invention. In the figure, (31) is a photoreceptor surface, (32) is a surface opposite to the photoreceptor surface, (33) is a photoreceptor layer, and (34) is a nickel layer. Here, the photoreceptor layer (33) may be a single layer or a laminate, but at least one layer has a thickness of 20 μm or more. As an example of lamination, the charge generation layer is composed of a charge generation material or a charge generation material and a binder resin, and the film thickness is preferably in the range of 0.05 to 3 μm.

  Examples of the charge generating substance include C.I. Pigment Blue 25 (Color Index CI 21180), C.I. Pigment Red 41 (CI 21200), C.I.C. Red 52 (CI 45100), C.I. Basic Red 3 (CI 45210), and azo having a carbazole skeleton. Pigments, azo pigments having a distyrylbenzene skeleton, azo pigments having a triphenylamine skeleton, azo pigments having a dibenzothiophene skeleton, azo pigments having an oxadiazole skeleton, azo pigments having a fluorenone skeleton, azo having a bistilbene skeleton Azo pigments such as pigments, azo pigments having a distyryl oxadiazole skeleton, azo pigments having a distyryl carbazole skeleton; for example, pigments such as CI Pigment Blue 16 (CI 74100) Tarocyanine pigments; for example, Indigo pigments such as C-Ibat Brown (CI 73410) and C-Ibat Die (CI 73030); Perylene pigments such as Argol Scarlet 5 (manufactured by Bayer), Indusence Scarlet R (manufactured by Bayer), Examples include squaric dyes and hexagonal Se powders.

  These charge generation materials are pulverized and dispersed together with a solvent such as tetrahydrofuran, cyclohexanone, dioxane, or dichloroethane by a method such as a ball mill, an attritor, or a sand mill. At this time, for example, polyamide, polyurethane, polyester, epoxy resin, polyketone, polycarbonate, silicone resin, acrylic resin, polyvinyl butyral, polyvinyl formal, polyvinyl ketone, polystyrene, poly-N-vinylcarbazole, polyacrylamide, etc. are bound. It may be added as an agent.

  Examples of the charge transport material include polycyclic aromatic compounds such as anthracene, pyrene, phenanthrene and coronene in the main chain or side chain, or indole, carbazole, oxazole, isoxazole, thiazole, imidazole, pyrazole, oxadiazole, pyrazoline, thiadiazole, A compound having a nitrogen-containing cyclic compound such as triazole, a triphenylamine compound, a hydrazone compound, an α-phenylstilbene compound, or the like is used. These charge transport materials are made of polystyrene, styrene-acrylonitrile copolymer, styrene-butadiene copolymer, styrene-maleic anhydride copolymer, polyester, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, polyvinyl acetate, Vinylidene chloride, polyarylate resin, phenoxy resin, polycarbonate, cellulose acetate resin, ethyl cellulose resin, polyvinyl butyral, polyvinyl formal, polyvinyl toluene, poly-N-vinylcarbazole, acrylic resin, silicone resin, epoxy resin, melamine resin, urethane resin, Prepare a charge transport layer forming solution by dissolving it in a solvent such as tetrahydrofuran, cyclohexanone, dioxane, dichloroethane, etc. together with a thermoplastic or thermosetting resin such as phenol resin or alkyd resin. , Spray coating, to form a charge transport layer and the drying after a preliminary drying.

  So far, the electrophotographic photosensitive layer has been described as a layered type of a charge generation layer and a charge transport layer, but as described above, the electrophotographic photosensitive layer in the present invention may be a single layer as a matter of course. Good. If necessary, an undercoat layer and an intermediate layer may be provided between the conductive support and the charge transport layer or charge generation layer adjacent thereto. In that case, a material selected from the resins listed as the binder resin for the charge generation layer can be used, and further, a white pigment such as titanium oxide, an anion such as sulfonic acid or an alkali metal salt of sulfonic acid, and an ammonium salt. A conductive polymer can also be added. At this time, it is preferable to select a material that does not dissolve in the solvent used in the liquid for forming the layer laminated on the undercoat layer.

[Process cartridge for electrophotography]
FIG. 10 is an example of a process cartridge for electrophotography suitable for carrying out the first and second groups of the present invention. In the figure, (51) is an electrophotographic photosensitive member, (52) is a developing mechanism, (53) is a transfer mechanism, (54) is a cleaning mechanism, (55) is a charging mechanism, (56) is a fixing mechanism, (57) is exposure light, and (58) is a case of a process cartridge.

[Electrophotographic equipment]
FIG. 11 shows an example of an electrophotographic apparatus suitable for carrying out the present invention. In the figure, (51) is an electrophotographic photosensitive member, (52) is a developing mechanism, (53) is a transfer mechanism, and (54). Is a cleaning mechanism, (55) is a charging mechanism, (56) is a fixing mechanism, and (57) is exposure light.

[First Group of the Invention]
Hereinafter, the first group of the present invention will be described with reference to examples and comparative examples, but the present invention is not limited to the following examples.
Sample preparation was performed by the following method.
15 parts by weight of alkyd resin (Beckosol 1307-60-EL (Dainippon Ink Chemical Co., Ltd.)) and 10 parts by weight of melamine resin (Super Becamine G-821-60 (Dainippon Ink Chemical Co., Ltd.)) It melt | dissolved in the weight part, 90 weight part of titanium oxide powders (Typer CR-EL (made by Ishihara Sangyo Co., Ltd.)) were added to this, and it disperse | distributed for 12 hours with the ball mill. This was taken out into a container and diluted with cyclohexanone so that the solid content was 25% by weight to prepare a coating solution for an undercoat layer.
This was applied to a nickel seamless belt having a diameter of 92 mm, a length of 410 mm, a thickness of 30 μm, and a maximum surface roughness of 0.05 μm by the spray coating method under the conditions shown in Table 1.
The spray gun used was a two-fluid spray manufactured by Mesak Co., Ltd.
After spray coating, the film was dried at 130 ° C. for 20 minutes to form an undercoat layer having a film thickness of 6.5 μm and a maximum film thickness difference of 0.9 μm in the effective image area.
Next, 4 parts by weight of polyvinyl butyral resin (S-LEC HL-S (manufactured by Sekisui Chemical Co., Ltd.)) was dissolved in 150 parts by weight of cyclohexanone, and 10 parts by weight of the trisazo pigment shown below was added and dispersed for 48 hours with a ball mill. Further, 210 parts by weight of cyclohexanone was added and dispersed for 3 hours.

This was taken out into a container and diluted with cyclohexanone so that the solid content was 1.5% by weight.
The coating solution for charge generation layer thus obtained was applied on the intermediate layer by the spray coating method under the conditions shown in Table 1, dried at 145 ° C. for 30 minutes, and an effective image with a transmittance of 4% at a wavelength of 690 nm. A charge generation layer having a maximum transmittance difference of 0.8% in the region was formed.
As the spray gun, a two-fluid spray manufactured by Meiji Machinery Co., Ltd. was used.

  Next, 10 parts of bisphenol A polycarbonate resin and 0.002 part of silicon oil (KF-50 (manufactured by Shin-Etsu Chemical Co., Ltd.)) are dissolved in 83 parts of tetrahydrofuran, and 8 parts of a charge transport material having the following structural formula are dissolved therein. In addition, it was dissolved and diluted with cyclohexanone so that the solid content was 8% by weight to prepare a charge transport layer coating solution.

The charge transport layer coating solution thus obtained was applied onto the charge generation layer by the spray coating method under the conditions shown in Table 1.
As the spray gun, a two-fluid spray manufactured by Meiji Machinery Co., Ltd. was used.
After spray coating, the film was dried at 155 ° C. for 30 minutes to form a charge transport layer having a film thickness of 25 μm and a maximum film thickness difference of 1.2 μm in the effective image area. Thereafter, both ends were cut so that the length of the endless belt-like photoconductor was 367 mm.
As described above, the electrophotographic photoreceptors of Examples 1 to 4 were spray-coated under the conditions shown in Tables 1 to 4 to produce 10 each.
The difference in film thickness between the undercoat layer and the charge transport layer obtained in Examples 1 to 4 was obtained by providing a single film on the support, and using an eddy current film thickness meter (manufactured by Fischer). ) To measure the film thickness at 80 arbitrary measurement points, and set the difference between the maximum value and the minimum value. The difference in the transmittance of the charge generation layer was similarly provided as a single film on the transparent PET fillet, and the transmittance at 690 nm was measured at 60 arbitrary measurement points by spectrophotometry, and the difference between the maximum value and the minimum value was determined. .
The film thickness of the undercoat layer was 6.4 μm, and the maximum film thickness difference in the effective image area was 0.9 μm.
Further, when the amount of the charge transport layer attached was indicated by the transmittance at a wavelength of 690 nm, the transmittance was 4% and the maximum transmittance difference in the effective image area was 0.8%.
The film thickness of the charge transport layer was 25 μm, and the maximum film thickness difference in the effective image area was 1.2 μm.

△：塗膜欠陥による外観検査で白ポチを発見
○：外観に異常なし
エアー拭き付けから塗工開始までの時間が３０ｓｅｃを境に短いほうが効果があった。
スプレーブース内の排気は被塗工物回りで０．４ｍ／ｓの風速があることとした。

Δ: White spot was found by appearance inspection due to coating film defect ○: No abnormality in appearance Appearance was more effective when the time from air wiping to the start of coating was shorter than 30 sec.
The exhaust in the spray booth is assumed to have a wind speed of 0.4 m / s around the object to be coated.

△：塗膜欠陥による外観検査で白ポチを発見
○：外観に異常なし
スプレー塗工ブース内の排気を０．４ｍ／ｓｅｃ以上することで、異物付着による塗膜欠陥を無くすことができた。

Δ: A white spot was found by appearance inspection due to coating film defects. ○: No abnormality in appearance. By exhausting the spray coating booth at 0.4 m / sec or more, coating film defects due to adhesion of foreign substances could be eliminated.

△：塗膜欠陥による外観検査で白ポチを発見
○：外観に異常なし
エアー速度を１５０ｍ／ｓ以下にすることで、異物付着による塗膜欠陥を無くすことができ、良好な結果が得られた。

Δ: A white spot was found by appearance inspection due to coating film defects. ○: No abnormality in appearance. By setting the air speed to 150 m / s or less, coating film defects due to adhesion of foreign substances could be eliminated, and good results were obtained. .

×：塗膜欠陥による画像白ポチが発生
○：画像に異常なし
ミスト排気方法を下方向＋横方向にすることで、異物付着による塗膜欠陥を無くすことができ、良好な結果が得られた。

×: Image white spots due to coating film defects ○: No abnormality in the image By making the mist exhaust method downward + horizontal direction, coating film defects due to foreign matter adhesion can be eliminated, and good results were obtained .

(Evaluation of Examples)
The photoreceptors of Examples 1 to 4 obtained as described above were converted into a full color laser printer IPSIO Color 5000 manufactured by Ricoh Co., Ltd. (λ = 655 nm, 1200 dpi, beam spot 2.7 × 10 ⁻³ mm ²⁾ . The image quality was visually determined using image modification.
The halftone image is a 2 × 2 dot image.
The image evaluation results are shown in Tables 5-8.

[Second Group of the Invention]
Example 5
1. Adjustment of undercoat layer coating solution The following materials were placed in a ball mill, milled, and diluted to prepare an undercoat layer coating solution.
Polyamide resin 10 parts Titanium oxide 40 parts Cyclohexanone 50 parts Methyl ethyl ketone 50 parts Coating of Undercoat Layer A nickel belt having a thickness of 30 μm was prepared as a nickel belt, and this was attached to a substrate holding jig. Next, coating was performed with a spray coating apparatus shown in FIG. 7, and this was dried to form an undercoat layer having a thickness of 3 μm.
(Spray coating conditions)
Nozzle: JFS made by Meiji Machine
Distance between nozzle substrates: 75mm
3. Adjustment of charge generation layer coating solution The following materials were placed in a ball mill, milled, and diluted to prepare a charge generation layer coating solution.
Titanyl phthalocyanine 3 parts Polyvinyl butyral resin 1 part Cyclohexanone 250 parts Methyl ethyl ketone 250 parts (spray coating conditions)
Nozzle: A100 manufactured by Meiji Machine
Distance between nozzle substrates: 60mm
4). Formation of Charge Generation Layer A 0.08 μm thick charge generation layer was formed using a spray coating apparatus similar to that used for forming the undercoat layer except for the spray gun.
5. Preparation of charge transport layer coating solution The following materials were dissolved and filtered to prepare a charge transport layer coating solution.
Polycarbonate resin 10 parts Silicone oil 0.02 parts Tetrahydrofuran 60 parts Cyclohexanone 60 parts Charge transport material of the following structural formula 7 parts

（スプレー塗工条件）
ノズル：明治機械製 ＪＦＳ
ノズル基体間距離：６０ｍｍ
６．電荷輸送層の形成
スプレー塗工装置を使用して厚さ２５μｍの電荷輸送層を形成した。
その時の塗工装置条件を示す。
塗工ブース数Ａ：３，塗工タクトＢ：９．７分，予備乾燥時間Ｃ：２０分，予備乾燥中の回転数：１５０ｒｐｍとすると、
Ｂ／（Ｃ／（Ａ−１））＝０．９７
１本塗工当たりのスプレーガン停止時間０．３分／塗工ブース稼動停止時間０分
７．塗膜評価
このようにして作製した感光体の表面粗さＲｍａｘ及び塗膜欠陥を評価した。
この時Ｒｍａｘ＝０．６５μｍ、塗膜欠陥は無かった。
８．画像評価
作製した電子写真感光体を図１０で示した電子写真感光体を搭載した電子写真装置にて画像評価を行なった。画像評価は、７％文字パターン、中間調画像、白画像を各５枚出力した。
画像ムラ評価は５段階評価した結果、ランク４であった。

(Spray coating conditions)
Nozzle: JFS made by Meiji Machine
Distance between nozzle substrates: 60mm
6). Formation of Charge Transport Layer A 25 μm thick charge transport layer was formed using a spray coating apparatus.
The coating apparatus conditions at that time are shown.
When the coating booth number A is 3, the coating tact B is 9.7 minutes, the preliminary drying time C is 20 minutes, and the rotational speed during preliminary drying is 150 rpm.
B / (C / (A-1)) = 0.97
6. Spray gun stoppage time per coating 0.3 minutes / coating booth stoppage time 0 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.65 μm and there were no coating film defects.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 4 as a result of 5-level evaluation.

Example 6
1 to 5 are the same as in the fifth embodiment.
6). Formation of Charge Transport Layer A 25 μm thick charge transport layer was formed using a spray coating apparatus.
The coating apparatus conditions at that time are shown.
When the coating booth number A is 3, the coating tact B is 9.7 minutes, the preliminary drying time C is 20 minutes, and the rotational speed during preliminary drying is 100 rpm.
B / (C / (A-1)) = 0.97
6. Spray gun stoppage time per coating 0.3 minutes / coating booth stoppage time 0 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.41 μm and there were no coating film defects.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 5 as a result of 5-level evaluation.

Example 7
3 and 5 are the same as in Example 5.
6 '. The charge generation layer and the charge transport layer are formed in the same coating booth.
Using a spray coating apparatus, a charge generation layer of 0.08 μm and a charge transport layer of 25 μm were formed.
The coating apparatus conditions at that time are shown.
Coating booth number A: 3, coating tact B: 117 minutes, pre-drying time C: 22 minutes, rotation speed during pre-drying: 130 rpm,
B / (C / (A-1)) = 1
6. Spray gun stoppage time per coating 0.3 minutes / coating booth stoppage time 0 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.57 μm and there were no coating film defects.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 4 as a result of 5-level evaluation.

Example 8
The steps up to 6 ′ are the same as in Example 7.
6 '. The charge generation layer and the charge transport layer are formed in the same coating booth.
Using a spray coating apparatus, a charge generation layer of 0.08 μm and a charge transport layer of 25 μm were formed.
The coating apparatus conditions at that time are shown.
Coating booth number A: 3, coating tact B: 117 minutes, pre-drying time C: 22 minutes, rotation speed during pre-drying: 100 rpm,
B / (C / (A-1)) = 1
6. Spray gun stop time per coating 0 minutes / coating booth stop time 0 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.38 μm, and there were no coating film defects.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 5 as a result of 5-level evaluation.

Comparative Example 1
1 to 5 are the same as in the fifth embodiment.
6). Formation of Charge Transport Layer A 25 μm thick charge transport layer was formed using a spray coating apparatus.
The coating apparatus conditions at that time are shown.
Coating booth number A: 3, coating tact B: 8.5 minutes, pre-drying time C: 20 minutes, rotation speed during pre-drying: 150 rpm,
B / (C / (A-1)) = 0.85
6. Spray gun stoppage time per coating 1.5 minutes / coating booth stoppage time 0 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.57 μm, and 5 (pieces / piece) coating film defects occurred.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 4 as a result of 5-level evaluation.

Comparative Example 2
1 to 5 are the same as in the fifth embodiment.
6). Formation of Charge Transport Layer A 25 μm thick charge transport layer was formed using a spray coating apparatus.
The coating apparatus conditions at that time are shown.
When the coating booth number A is 3, the coating tact B is 10 minutes, the preliminary drying time C is 16 minutes, and the rotational speed during preliminary drying is 150 rpm.
B / (C / (A-1)) = 1.25
6. Spray gun stop time per coating 0 minute / coating booth stoppage time 2 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.85 μm and there were no coating film defects.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 3 as a result of 5-level evaluation.

Comparative Example 3
1 to 5 are the same as in the fifth embodiment.
6). Formation of Charge Transport Layer A 25 μm thick charge transport layer was formed using a spray coating apparatus.
The coating apparatus conditions at that time are shown.
Coating booth number A: 3, coating tact B: 8.5 minutes, predrying time C: 20 minutes, rotation speed during predrying: 100 rpm,
B / (C / (A-1)) = 0.85
6. Spray gun stoppage time per coating 1.5 minutes / coating booth stoppage time 0 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.38 μm, and 5 (pieces / piece) coating film defects occurred.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 5 as a result of 5-level evaluation.

Comparative Example 4
1 to 5 are the same as in the fifth embodiment.
6). Formation of Charge Transport Layer A 25 μm thick charge transport layer was formed using a spray coating apparatus.
The coating apparatus conditions at that time are shown.
When the coating booth number A is 3, the coating tact B is 10 minutes, the preliminary drying time C is 16 minutes, and the rotational speed during preliminary drying is 130 rpm.
B / (C / (A-1)) = 1.25
6. Spray gun stop time per coating 0 minute / coating booth stoppage time 2 minutes Coating Film Evaluation The surface roughness Rmax and coating film defects of the photoreceptors thus produced were evaluated.
At this time, Rmax = 0.49 μm and there were no coating film defects.
8). Image Evaluation The produced electrophotographic photosensitive member was subjected to image evaluation using an electrophotographic apparatus equipped with the electrophotographic photosensitive member shown in FIG. For image evaluation, 5% of 7% character patterns, halftone images, and white images were output.
The image unevenness evaluation was ranked 4 as a result of 5-level evaluation.
The above results are summarized in the following table.

It is a figure which shows the structural example of the spray coating apparatus suitable for implementing this invention. It is a figure which shows the structural example of the spray dust removal nozzle position suitable for implementing this invention. It is a figure which shows the structural example of the spray dust removal nozzle position suitable for implementing this invention. It is a figure which shows the structural example of the spray dust removal scanning direction suitable for implementing this invention. It is a figure which shows the structural example of the spray dust removal nozzle position suitable for implementing this invention. It is a figure which shows the structural example of the exhaust port position of the spray coating apparatus suitable for implementing this invention. It is a block diagram of the apparatus of this invention which performs spray coating to the outer surface of a belt. It is a figure which shows the belt photoreceptor of this invention. It is a figure of the structural example of the photoreceptor of this invention. It is a figure which shows an example of the process cartridge for electrophotography which mounts an electrophotographic photoreceptor. It is a figure which shows an example of the electrophotographic apparatus carrying an electrophotographic photoreceptor.

Explanation of symbols

1 Object (base)
2 Mechanism for holding and rotating the workpiece 3 Spray gun 4 Spray gun reciprocating means 5 Coating liquid and compressed air piping (tube)
6 Exhaust port on the lower side of the object to be coated 7 Dust removal nozzle 8 Exhaust port on the side of the object to be coated 9 Air supply means 11 Substrate (workpiece)
DESCRIPTION OF SYMBOLS 12 Undercoat layer 13 Charge generation layer 14 Charge transport layer 15 Protective layer 22 Base holding jig 23 Ball screw 31 Electrophotographic photosensitive member surface 32 Electrophotographic photosensitive member back surface 33 Electrophotographic photosensitive member cross section 34 Nickel substrate (coating material) )
51 Electrophotographic Photoreceptor 52 Development Mechanism 53 Transfer Mechanism 54 Cleaning Mechanism 55 Charging Mechanism 56 Fixing Mechanism 57 Exposure 58 Process Cartridge Case 100 Coating Booth

Claims (38)

An apparatus for producing an electrophotographic photosensitive member that places an object to be coated in a spray coating booth, performs spray coating with a spray gun while rotating the object, and forms a coating film on the surface of the object to be coated. A dust removing means having a function of removing dust from the surface of the object to be coated in the coating booth, and an exhaust means for exhausting air in the coating booth, wherein the dust removing means is a spray gun or an air nozzle, An electrophotographic photosensitive member manufacturing apparatus having a function of removing dust on the surface of a rotated object to be coated immediately before the object is coated. The spray gun in the coating booth is an air spray gun, and air pressure switching means capable of switching the air pressure of the atomizing air discharge port before and during coating is disposed. Item 2. An apparatus for producing an electrophotographic photosensitive member according to Item 1. Air jetting means is arranged adjacent to the spray gun in the coating booth, and the air jetting means also operates as a drive system for spraying the coating liquid of the spray gun. The apparatus for producing an electrophotographic photosensitive member according to claim 1. The completion of air spraying on the object to be coated is within 30 seconds before the start of coating, and the rotation of the object to be coated is not stopped between the time of air spraying and the start of coating. 2. An apparatus for producing an electrophotographic photosensitive member according to 1. 2. The apparatus for producing an electrophotographic photosensitive member according to claim 1, wherein the air blowing means is arranged so that the air blowing means is blown toward a rotation center of the object to be coated. 2. The electrophotographic apparatus according to claim 1, wherein an air blowing direction of the spray gun or an air blowing direction of the air nozzle is arranged in parallel with a supply direction of ventilation air to the coating booth. Photoconductor manufacturing equipment. 2. The electrophotographic photosensitive member manufacturing apparatus according to claim 1, wherein the spraying means or the air nozzle of the spray gun is scanned along the rotation axis direction of the object to be coated. The electrophotographic photosensitive member according to claim 7, wherein the air blowing means or the air nozzle of the spray gun is arranged perpendicular to the scanning direction of the air blowing means or the air nozzle of the spray gun. Manufacturing equipment. The apparatus for producing an electrophotographic photosensitive member according to claim 1, wherein a distance between the tip of air spraying means of the spray gun or the tip of the air nozzle and the object to be coated is 100 mm or less. The apparatus for producing an electrophotographic photosensitive member according to claim 1, wherein an air blowing speed to the object to be coated is at least 200 m / s or less. 2. The apparatus for producing an electrophotographic photosensitive member according to claim 1, wherein the air blowing amount is 1% or less of the coating boot ventilation air flow. 2. The electrophotographic photosensitive member manufacturing apparatus according to claim 1, wherein at least one set of exhaust ports of the coating booth is arranged parallel to and / or in a direction perpendicular to the blowing air direction. A method for producing an electrophotographic photosensitive member, in which an object to be coated is placed in a spray coating booth, and spray coating is performed with a spray gun while rotating the coating object to form a coating film on the surface of the object to be coated. A step of removing dust from the surface of an object to be coated disposed in the coating booth; and a step of exhausting air in the coating booth, wherein the dust removal step is performed by a spray gun or an air nozzle. A method for producing an electrophotographic photosensitive member, characterized in that dust is removed from the surface of the rotated object to be coated immediately before the object is coated by blowing air onto the surface of the object to be coated. . The electrophotographic photosensitive member according to claim 13, wherein the spray gun in the coating booth is an air spray gun, and the air pressure of the atomizing air discharge port can be switched between before coating and during coating. Manufacturing method. Air jetting means is arranged adjacent to the spray gun in the coating booth, and the air jetting means also operates as a drive system for spraying the coating liquid of the spray gun. The method for producing an electrophotographic photosensitive member according to claim 13. The completion of air spraying on the object to be coated is within 30 seconds before the start of coating, and the rotation of the object to be coated is not stopped between the time of air spraying and the start of coating. 14. A method for producing an electrophotographic photosensitive member according to item 13. 14. The method for producing an electrophotographic photosensitive member according to claim 13, wherein the air blowing means is disposed so as to blow toward the center of rotation of the article to be coated. 14. The electrophotographic apparatus according to claim 13, wherein the air blowing means of the spray gun or the air blowing direction of the air nozzle is arranged in parallel to the air supply direction of ventilation air to the coating booth. A method for producing a photoreceptor. 14. The method of manufacturing an electrophotographic photosensitive member according to claim 13, wherein the air blowing means or the air nozzle of the spray gun is scanned along the rotation axis direction of the object to be coated. 20. The electrophotographic photosensitive member according to claim 19, wherein the air blowing means or the air nozzle of the spray gun is arranged perpendicular to the scanning direction of the air blowing means or the air nozzle of the spray gun. Manufacturing method. 14. The method for producing an electrophotographic photosensitive member according to claim 13, wherein the distance between the tip of air spraying means of the spray gun or the tip of the air nozzle and the object to be coated is 100 mm or less. The method for producing an electrophotographic photosensitive member according to claim 13, wherein an air blowing speed to an object to be coated is at least 200 m / s or less. 14. The method for producing an electrophotographic photosensitive member according to claim 13, wherein the air blowing amount is 1% or less of the coating boot ventilation airflow. 14. The method of manufacturing an electrophotographic photosensitive member according to claim 13, wherein at least one set of exhaust ports of the coating booth is arranged in parallel and / or perpendicular to the blowing air direction. An electrophotographic photoreceptor coating method in which a coating layer having a thickness of 20 μm or more is formed on a substrate by spray coating, wherein the number of coating booths is A, the coating tact time is B (seconds), and the preliminary drying time is Coating of an electrophotographic photosensitive member, wherein C (second) and the number of spray guns is 1, and the relationship is 0.95 ≦ B / (C / (A-1)) ≦ 1.05 Method. An electrophotographic photosensitive member coating method in which two or more coating layers are formed on a substrate by spray coating, at least one of which is 20 μm or more. When the total coating tact time of the coating is B (seconds), the total preliminary drying time of two or more layers is C (seconds), and the number of spray guns is one per layer, 0.95 ≦ B / (C / (A− 1)) A coating method for an electrophotographic photosensitive member, wherein the relationship is ≦ 1.05. 27. The electrophotographic photosensitive member coating method according to claim 25 or 26, wherein the rotation speed during the preliminary drying is 60 to 130 rpm. An electrophotographic photoreceptor coating apparatus for forming a coating layer having a film thickness of 20 μm or more on a substrate by spray coating, wherein the number of coating booths is A, the coating tact is B (seconds), and the preliminary drying time is Application of an electrophotographic photosensitive member, wherein C (seconds) and the number of spray guns are one, wherein 0.95 ≦ B / (C / (A-1)) ≦ 1.05 apparatus. An electrophotographic photosensitive member coating apparatus in which two or more coating layers are formed on a substrate by spray coating, and at least one of the layers is 20 μm or more. When the total coating tact time of the coating is B (seconds), the total preliminary drying time of two or more layers is C (seconds), and the number of spray guns is one per layer, 0.95 ≦ B / (C / (A− 1)) A coating apparatus for an electrophotographic photosensitive member, wherein the relationship is ≦ 1.05. 30. The electrophotographic photosensitive member coating apparatus according to claim 28 or 29, wherein the rotation speed during the preliminary drying is 60 to 130 rpm. An electrophotographic photosensitive member using the electrophotographic photosensitive member manufacturing apparatus according to any one of claims 1 to 12 or the electrophotographic photosensitive member coating apparatus according to any one of claims 28 to 30. Production method. 28. A method for producing an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member coating method according to claim 25 is used. An electrophotographic photosensitive member produced by the method according to claim 31 or 32. 34. An electrophotographic apparatus comprising at least a charging step, an image exposure step, a development step, a transfer step, a cleaning step, a charge removal step, and an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is an electrophotographic method according to claim 33. An electrophotographic apparatus which is a photoconductor. 34. A process cartridge for an electrophotographic apparatus comprising at least an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the electrophotographic photosensitive member according to claim 33. 34. An electrophotographic apparatus comprising at least a charging unit, an image exposure unit, a developing unit, a transfer unit, a cleaning unit, a charge eliminating unit, and an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is an electrophotographic apparatus according to claim 33. An electrophotographic apparatus which is a photoconductor. 34. A process cartridge for an electrophotographic apparatus comprising at least an electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the electrophotographic photosensitive member according to claim 33. 34. An electrophotographic method comprising subjecting at least a charging step, an image exposure step, a development step, a transfer step, a cleaning step and a charge eliminating step to the electrophotographic photosensitive member, wherein the electrophotographic photosensitive member is the electrophotographic photosensitive member according to claim 33. An electrophotographic method comprising:

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