JP2007275749A - Method for manufacturing resin roller, and coater of resin liquid for forming resin layer equipped with the manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve such a problem that in a method for applying a surface layer resin by a spray system, appearance defect due to air entrained between liquid drop particles of the surface layer resin applied onto a resin roller surface degrades the yield of a product in some cases and complicates the visual inspection process and eventually leads to cost increase in the product. <P>SOLUTION: The method for manufacturing the resin roller having a core body, a cylindrical molded body formed on an outer circumferential side of the core body, and a resin layer formed on at least the outer circumferential side of the molded body includes at least the following processes of (A) and (B). (A) the process of spraying and applying the resin liquid for forming the resin layer onto the surface or the outside of the cylindrical molded body and (B) the process of applying ultrasonic vibrations "near to the cylindrical molded body" and/or to "an end shaft of the core body of the cylindrical molded body". <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a manufacturing method for manufacturing a resin roller such as a developing resin roller, a charging resin roller, or a transfer resin roller incorporated in various apparatuses employing an electrophotographic system such as a laser beam printer, a copying machine, and a facsimile machine, and the manufacturing thereof The present invention relates to a coating apparatus including the method.

  Various apparatuses adopting an electrophotographic system such as a laser beam printer, a copying machine, and a facsimile machine incorporate resin rollers such as a developing resin roller, a charging resin roller, and a transfer resin roller. An example of such a resin roller is shown in FIG. The resin roller 10 includes a core body 11, a molded body 12 formed of resin, and a surface layer 13 formed of resin.

  As a method for covering the molded body 12 in the longitudinal direction of the outer periphery of the core body 11, a resin material to be the molded body 12 is extruded into a hollow cylinder and the core body 11 is inserted, or the core body in an appropriate molding die. 11 is installed in advance, and the resin molded body 12 is injection-molded.

  The outer periphery of the resin molded body 12 is covered with a surface layer 13 for the purpose of further improving functions such as electrical characteristics, triboelectric chargeability, and durability. Examples of the surface layer material include alcohol, A solution in which a resin such as urethane or nylon is dissolved in a solvent such as water, and in some cases a resin powder particle or carbon powder is dispersed is applied to the resin layer surface of the resin roller and heated to dry. is there.

  In general, a roll coater method, a dip method, a spray method, and the like are known as methods for applying a surface resin layer to a resin roller.

  However, in the roll coater method, liquid drawing when the resin roller is pulled away from the roll coater tends to cause uneven thickness of the surface layer, and in order to prevent this, a mechanism has been devised to pull the roller away from the roll coater (Patent Document) 1). Further, depending on the use of the resin roller, there may be a drawback that the resin of the surface layer cannot be applied to the side surface of the end portion of the resin roller.

  Further, in the dipping method, when the surface layer is applied to the resin roller, the surface layer resin liquid flows downward in the axial direction of the resin roller and is applied by gravity, so that there is uneven thickness in the axial direction of the resin roller. It is easy to generate | occur | produce, and the device of managing the temperature of a coating material at an appropriate temperature is made | formed in order to prevent it (patent document 2).

  On the other hand, as shown in FIG. 6, the spray method includes a rotational drive source 22 that rotates the resin roller 10, a nozzle 31 that ejects the surface resin layer, and an axial drive mechanism 23 that moves the nozzle in the axial direction of the resin roller. The resin roller is installed in the area where the surface resin layer is applied, and the resin roller is rotated at a rotation speed set by a driving source for rotating the resin roller, and the surface layer resin liquid is sprayed in the form of a mist. The nozzle is moved from the end of the resin roller at a constant speed to apply.

  However, when the surface layer resin is sprayed in the form of a mist, the droplet particles 13a of the surface layer resin are stacked as shown in FIG. 2 on the surface of the resin roller, and the air 14 is entrained between the droplet particles.

  Then, when the surface of the resin roller is heated and dried in the next heating and drying process, the surface layer resin is dried while the air between the droplet particles is confined, or is dried while the air is about to escape to the surface. Then, as shown in FIG. 3, convex bubble entrainment and concave bubble burst remain as marks on the roller surface.

  For example, if the resin roller is a developing roller, the convex and concave marks may be image defects and may be determined as appearance defects.

  Therefore, there is a method for preventing the surface layer resin from drying and solidifying while the air entrained between the droplets of the surface layer resin escapes to the surface.

  For example, there is a method of increasing the drying time by lowering the set temperature in the drying furnace or raising the boiling point temperature of the surface layer resin.

However, when the drying time is lengthened, there may be a problem that the surface layer resin flows and the surface layer resin drips and the film thickness becomes non-uniform. In addition, as described above, the surface layer resin needs to have functions such as the electrical characteristics, frictional chargeability, and durability of the resin roller depending on the application, and is formulated with a resin formulation that gives priority to the function, and has a high boiling point. There are cases where the intended material cannot be blended, and there is a possibility that the material may adversely affect other parts such as a photoreceptor.
Japanese Patent Laid-Open No. 7-024381. JP 2001-132732 A.

  Thus, in the surface layer resin coating method by the spray method, the appearance defect considered to be caused by the air entrained between the droplet particles of the surface layer resin applied to the surface of the resin roller may reduce the product yield, In addition, the appearance inspection process becomes complicated, which may increase the cost of the product.

The first of the present invention is
“A method for producing a resin roller having a core, a cylindrical molded body formed on the outer peripheral side of the core, and a resin layer formed at least on the outer peripheral side of the molded body,
A method for producing a resin roller, comprising at least the following steps (A) and (B):
(A) On the surface and / or outside of the cylindrical molded body,
The process of spray-coating the resin liquid for resin layer formation.
(B) "Near the cylindrical molded body" and / or "End shaft portion of the core of the cylindrical molded body"
A process of applying ultrasonic vibration. ".

  The present invention is also the method for producing a resin roller, wherein the resin layer is a surface layer of the resin roller.

The present invention is also the method of manufacturing the resin roller, wherein the step (A) and the step (B) include a step in which the steps are performed simultaneously.

  The present invention is also the method for producing the resin roller, characterized in that it includes a step in which the step (B) is performed immediately after the step (A).

  The present invention also provides a resin liquid coating apparatus for forming a resin layer, comprising the resin roller manufacturing method according to any one of the above.

  If the manufacturing method of the present invention and / or the coating apparatus of the present invention is used, it is possible to easily manufacture a resin roller having no appearance defect.

  The configuration of the resin roller manufacturing method of the present invention will be described.

  The core is not particularly limited, but in the case of conductivity, it is recommended to employ a metal such as stainless steel, SUM material, aluminum, etc., and a resin having conductivity may be used.

  The cylindrical molded body is not particularly limited as long as it can conduct ultrasonic vibrations. For example, the cylindrical molded body may be formed of metal and / or resin. When the cylindrical molded body is a resin, it is possible to use one or more known materials such as NBR, silicone, modified silicone, and urethane. The cylindrical molded body is preferably an elastic body, and the elastic body may be made of a solid material employed in a conventionally known resin roller, or may be made of a foam material. good. As the material of the cylindrical molded body, for example, adopting a low hardness solid material used in a conventionally known resin roller or a foam material, for example, rotates in contact with the photosensitive drum. It is preferable when the resin roller is used as a developing roller for supplying toner to the photosensitive drum.

The “resin roller having a core body, a cylindrical molded body formed on the outer peripheral side of the core body, and a resin layer formed at least on the outer peripheral side of the molded body” of the present invention,
There may be another layer having the same composition as the resin layer or another layer having a different composition from the resin layer between the cylindrical molded body and the resin layer.

Applying ultrasonic vibration to the “near the cylindrical molded body”
The ultrasonic vibration can be applied by operating the ultrasonic vibrator in a state where the ultrasonic vibrator is present “in a non-contact state” with respect to the cylindrical molded body and causing the ultrasonic vibration to be applied. ,
This is a preferred embodiment.

Applying ultrasonic vibration to the “end shaft portion of the core of the cylindrical molded body”
The ultrasonic transducer is operated and ultrasonically vibrated in a state where the ultrasonic transducer is in contact with the end shaft portion of the core of the cylindrical molded body through at least a vibration transmission member. By applying ultrasonic vibration,
This is a preferred embodiment.

The “surface and / or outside of the cylindrical molded body” in the step (A) is,
It may be the surface of a cylindrical shaped body,
After the surface of the cylindrical molded body is covered with some substance or the like, it may be outside of it,
Also,
It may be “the surface of the cylindrical molded body” and “the outer surface after the surface of the cylindrical molded body is covered with some substance or the like”.

  An apparatus for realizing the manufacturing method of the present invention includes, for example, as shown in FIG. 4, a rotational drive source 22 for rotationally driving the resin roller, a masking jig 21 for masking the core 11 at both ends of the resin roller, and An ultrasonic transducer 41 and a vibration transmission member 42 are included.

  First, with respect to the resin roller 10 having no surface layer, a rotational drive source 22 (for example, a servo motor) that inserts and fixes the core 11 at the end of the resin roller 10 into a masking jig 21 and rotates the resin roller at a set number of rotations. ) To rotate the resin roller 10. Next, the nozzle 31 is moved at a constant speed while spraying the surface layer resin liquid from the axial end of the resin roller 10 to the other end of the shaft by the axial drive mechanism 23, and the surface layer resin liquid is applied to the surface of the resin roller. Apply. Simultaneously, a signal is output from the ultrasonic transmitter 43 to the ultrasonic transducer 41, and the ultrasonic vibration is transmitted to the masking jig by the vibration transmitting member 42 and from the end of the core body of the resin roller to the surface of the resin roller. To make it happen.

  As a result, the air trapped between the droplet particles of the surface layer resin is activated by vibration and easily comes out to the surface, and bubbles are not present in the surface layer resin, and a resin roller having a good appearance can be obtained.

  Further, vibration may be applied to the resin roller immediately after the surface layer resin is applied without applying vibration while applying. At that time, the resin roller may be stopped or may be kept rotating.

  Regarding the application of vibration, as shown in FIG. 5 (the numbers in the figure have the same meaning as in FIG. 4), a vibrator is installed in the vicinity of the roller surface, and the roller surface is interposed via the air between the roller and the vibrator. You may transmit a vibration to. In that case, it is effective to transmit the vibration to the roller surface while moving the vibrator in the axial direction of the resin roller. The closer the distance between the vibrator and the roller surface, the more remarkable the effect. However, in order to prevent the vibrator from coming into contact with the undried roller surface immediately after application, the roller flutter and the dimensional accuracy of the device In consideration of the above, about 1 mm to 5 mm is preferable.

  The spray used for this invention can employ | adopt general 1 fluid and 2 fluid systems, and can also apply it to an electrostatic coating system.

  The vibration frequency of the vibrator is preferably 10 kHz to 5 MHz, more preferably 20 kHz to 1 MHz in a so-called ultrasonic region.

  Although the example of the typical structure of the apparatus used for this invention is specifically shown in FIG. 4, this invention is not limited to these.

  As one aspect of the present invention, the resin roller used has, for example, a resin roller outer diameter of φ16 mm and a resin molding portion length of 250 mm, and it is also preferable to use the coating apparatus of the present invention shown in FIG.

  The vibrator is an ultrasonic vibrator and the vibration frequency is set to 35 kHz, for example. A rubber pulley that freely rotates as a vibration transmitting member is attached to the tip of the ultrasonic vibrator and brought into contact with a masking jig. , One embodiment.

  The surface layer resin liquid (resin liquid for forming the resin layer) to be applied is, for example, 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan Co., Ltd.) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.). , N-dimethylformamide): MEK (methyl ethyl ketone) = 1: 1 diluted to 5% with a mixed solvent and allowed to stand for 1 hour are preferably used. As the surface layer resin liquid (resin liquid for forming a resin layer), in addition to the above, those described below are also preferably used.

  Since the surface layer of various electrophotographic rollers rotates while in contact with other members, urethane resin having excellent wear resistance is preferably used. The urethane resin constituting the surface layer is not particularly limited as long as it has a functional group formed in the process of producing a urethane resin such as a urethane group, a urea group, an allophanate group, and a burette group. Furthermore, the surface layer needs to have an appropriate flexibility, and from this viewpoint, it is preferably made of a urethane resin mainly composed of a resin having a polyether, polyester, or polycarbonate skeleton. It may be a urethane or polycarbonate urethane blend resin, or a urethane resin having at least one skeleton selected from the group consisting of a urethane bond, polyether, polyester, polycarbonate, and polysiloxane in one molecule. In general, the urethane resin includes a thermosetting urethane resin that polymerizes a compound having an active hydrogen such as a hydroxy group or an amino group and a compound having an isocyanate group into a three-dimensional network structure, and the compound having an active hydrogen and an isocyanate. There are two types of thermoplastic urethane resins obtained by polymerizing and chain-extending a group-containing compound.

  The thermoplastic urethane resin is soluble in various solvents such as N, N-dimethylformamide, methyl ethyl ketone, toluene, xylene, isopropanol, etc., so diluting the prepolymerized thermoplastic urethane resin with the solvent, coating, and drying. The surface layer can be formed by a simple process. In addition, prepolymerization means that a compound containing an isocyanate group, which is difficult to handle for safety, is polymerized in a closed system, and then can be coated in an open system as a thermoplastic urethane resin containing almost no residual isocyanate group. . Therefore, it is preferable to use a thermoplastic urethane resin from the viewpoint of workability and safety.

  As long as the composition and viscosity of the surface layer resin liquid (resin layer forming resin liquid) can be applied by a spray method, any known composition and viscosity are suitably used.

  It is also preferable that the resin layer is a surface layer of a resin roller.

  The spray coating process of the present invention may be used, for example, to form “a layer other than the surface layer, which is present between the cylindrical molded body and the surface layer”.

  It is an embodiment of the present invention that the surface layer solution is applied to a resin roller by a one-fluid spray method and at the same time vibration is applied by an ultrasonic vibrator.

  When the surface layer is applied and the surface layer resin is dried by the above method, bubbles are not generated on the surface of the resin roller, and even if some bubbles are generated, there is no problem in practical use.

  Examples will be given below, but the present invention is not limited thereto.

Example 1
The main component of the cylindrical molded body used is MS polymer manufactured by Kaneka Corporation, the outer diameter of the cylindrical molded body is φ16 mm, the resin molded part (the length of the molded part of the cylindrical molded body is 250 mm, The coating apparatus of the present invention shown in Fig. 4 was used (in the following examples and comparative examples, the same type of cylindrical molded body as in Example 1 was used).
As the vibrator, an ultrasonic vibrator is used, the vibration frequency is set to 35 kHz, and a rubber pulley that freely rotates as a vibration transmitting member is attached to the tip of the ultrasonic vibrator and is brought into contact with a masking jig.

  The surface layer resin solution to be applied is 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.): DMF (N, N-dimethylformamide): MEK ( Methyl ethyl ketone) = 1: 1 diluted with a mixed solvent of 1: 1 and allowed to stand for 1 hour.

  The surface layer solution was applied to a resin roller by a one-fluid spray method, and vibration was applied by an ultrasonic vibrator while the resin roller was rotated after the application was completed.

  As a result of applying the surface layer by the above method and drying the surface layer resin, no bubbles were generated on the surface of the resin roller.

(Example 2)
The main component of the cylindrical molded body used is MS polymer manufactured by Kaneka Corporation, the outer diameter of the cylindrical molded body is φ16 mm, the resin molded part (the length of the molded part of the cylindrical molded body is 250 mm, The coating apparatus of the present invention shown in FIG. 5 was used.

  The surface layer resin solution to be applied is 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.): DMF (N, N-dimethylformamide): MEK ( Methyl ethyl ketone) = 1: 1 diluted with a mixed solvent of 1: 1 and allowed to stand for 1 hour.

  The surface layer solution is applied to the resin roller by a one-fluid spray method, and after the application is completed, an ultrasonic vibrator is installed at a position 1 mm away from the surface of the resin roller while rotating the resin roller. Was set to 35 kHz and applied with vibration. The vibrator was traversed parallel to the surface of the resin roller.

  As a result of applying the surface layer by the above method and drying the surface layer resin, no bubbles were generated on the surface of the resin roller.

(Example 3)
The main component of the cylindrical molded body used is MS polymer manufactured by Kaneka Corporation, the outer diameter of the cylindrical molded body is φ16 mm, the resin molded part (the length of the molded part of the cylindrical molded body is 250 mm, The coating apparatus of the present invention shown in FIG. 5 was used.

  The surface layer resin solution to be applied is 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.): DMF (N, N-dimethylformamide): MEK ( Methyl ethyl ketone) = 1: 1 diluted with a mixed solvent of 1: 1 and allowed to stand for 1 hour.

  The surface layer solution is applied to the resin roller by a one-fluid spray method, and an ultrasonic vibrator is installed at a position 3 mm away from the surface of the resin roller while the resin roller is rotated after the application is completed. Was set to 35 kHz and applied with vibration. The vibrator was traversed parallel to the surface of the resin roller.

  As a result of applying the surface layer by the above method and drying the surface layer resin, no bubbles were generated on the surface of the resin roller.

(Comparative Example 1)
The resin roller used had a resin roller outer diameter of φ16 mm and a resin molded portion having a length of 250 mm, and a conventional coating apparatus (without an ultrasonic vibrator) shown in FIG. 6 was used.

  The surface layer resin solution to be applied is 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.): DMF (N, N-dimethylformamide): MEK ( Methyl ethyl ketone) = 1: 1 diluted with a mixed solvent of 1: 1 and allowed to stand for 1 hour.

The surface layer solution was applied in a state where the resin roller was rotated by a one-fluid spray method.
As a result of applying the surface layer by the above method and drying the surface layer resin, bubbles were generated on the surface of the resin roller.

Example 4
The main component of the cylindrical molded body used is MS polymer manufactured by Kaneka Corporation, the outer diameter of the cylindrical molded body is φ16 mm, the resin molded part (the length of the molded part of the cylindrical molded body is 250 mm, The coating apparatus of the present invention shown in FIG. 4 was used.

  As the vibrator, an ultrasonic vibrator is used, the vibration frequency is set to 5 kHz, and a rubber pulley that freely rotates as a vibration transmitting member is attached to the tip of the ultrasonic vibrator and is brought into contact with a masking jig.

  The surface layer resin solution to be applied is 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.): DMF (N, N-dimethylformamide): MEK ( Methyl ethyl ketone) = 1: 1 diluted with a mixed solvent of 1: 1 and allowed to stand for 1 hour.

  The surface layer solution was applied to a resin roller by a one-fluid spray method, and at the same time, vibration was applied by an ultrasonic vibrator.

  As a result of applying the surface layer by the above method and drying the surface layer resin, some bubbles were generated on the surface of the resin roller, but the level was not problematic in practical use.

(Example 5)
The main component of the cylindrical molded body used is MS polymer manufactured by Kaneka Corporation, the outer diameter of the cylindrical molded body is φ16 mm, the resin molded part (the length of the molded part of the cylindrical molded body is 250 mm, The coating apparatus of the present invention shown in FIG. 5 was used.

  The surface layer resin solution to be applied is 100 parts of polycarbonate urethane (“E980” manufactured by Nippon Milactolan) and 20 parts of urethane fine particles (“UP0908” manufactured by Dainichi Seika Co., Ltd.): DMF (N, N-dimethylformamide): MEK ( Methyl ethyl ketone) = 1: 1 diluted with a mixed solvent of 1: 1 and allowed to stand for 1 hour.

The surface layer solution is applied to the resin roller by a one-fluid spray method, and an ultrasonic vibrator is installed at a position 3 mm away from the surface of the resin roller while the resin roller is rotated after the application is completed. Was set to 35 kHz and applied with vibration. The vibrator was traversed parallel to the surface of the resin roller.
As a result of applying the surface layer by the above method and drying the surface layer resin, no bubbles were generated on the surface of the resin roller.

It is sectional drawing of a general resin roller. In the prior art, it is droplet particles immediately after being applied to the surface of a cylindrical molded body (resin roller). In the prior art, the surface layer resin and air bubbles after drying the surface of the cylindrical molded body (resin roller). 2 is an example in one embodiment of the present invention. 2 is an example in one embodiment of the present invention. It is a conventional coating apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Resin roller 11 Core 12 Resin molding part 13 Surface layer 13a Droplet particle 14 of surface layer resin Enclosed air 21 Masking jig 22 Rotation drive source (servo motor)
23 Axial direction drive mechanism 31 Surface layer resin coating nozzle 41 Ultrasonic vibrator 42 Vibration transmitting member 43 Ultrasonic transmitter 44 Axial direction drive mechanism

Claims (5)

A method for producing a resin roller comprising: a core body; a cylindrical molded body formed on an outer peripheral side of the core body; and a resin layer formed at least on the outer peripheral side of the molded body,
A method for producing a resin roller, comprising at least the following steps (A) and (B):
(A) On the surface and / or outside of the cylindrical molded body,
The process of spray-coating the resin liquid for resin layer formation.
(B) "Near the cylindrical molded body" and / or "End shaft portion of the core of the cylindrical molded body"
A process of applying ultrasonic vibration.   The method for producing a resin roller according to claim 1, wherein the resin layer is a surface layer of a resin roller. The method for manufacturing a resin roller according to claim 1, wherein the step (A) and the step (B) include a step in which the steps are performed simultaneously. The method for producing a resin roller according to claim 1, further comprising a step in which the step (B) is performed immediately after the step (A).   An apparatus for applying a resin liquid for forming a resin layer, comprising the method for producing a resin roller according to claim 1.

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