JP2009015011A - Processing method of saw-tooth electrode, charging device, and image forming apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a charging device provided with a corona electrode of a low manufacture cost by having durability superior to ozone and moisture in the air, and by stably charging the surface of a photosensitive drum over the whole durable period of an image forming apparatus. <P>SOLUTION: A grid electrode 50 used for the charging device 24 includes a gold plating layer on the surface and performs pressure processing by a pressure roller on the gold plated layer. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a saw electrode processing method, a charging device, and an image forming apparatus.

  An electrophotographic image forming apparatus (hereinafter simply referred to as an “image forming apparatus”) can form a high-quality image in a short time and with a simple operation, and maintenance is easy. Widely used as printers and facsimile machines. The electrophotographic image forming apparatus includes, for example, a photosensitive drum, a charging device, an exposure unit, a developing unit, a transfer unit, and a fixing unit. The photosensitive drum is a roller-shaped member having a photosensitive layer on the surface thereof. The charging device charges the surface of the photosensitive drum to a predetermined potential and polarity. The exposure unit forms an electrostatic latent image on the surface of the charged photosensitive drum. The developing means supplies toner to the electrostatic latent image on the surface of the photosensitive drum to form a toner image. The transfer unit transfers the toner image on the surface of the photosensitive drum to a recording medium. The fixing unit fixes the toner image on the recording medium. As a result, an image is formed on the recording medium.

  In the image forming apparatus, a corona charging device including a corona electrode, a grid electrode, a shield case, and a support member is mainly used as the charging device. The corona electrode charges the surface of the photosensitive drum to a predetermined potential and polarity by corona discharge. The grid electrode is provided between the photosensitive drum and the corona electrode, and controls the charging potential on the surface of the photosensitive drum by adjusting the amount of charge applied from the corona electrode to the surface of the photosensitive drum. The shield case is provided around the corona electrode except for the space between the corona electrode and the photosensitive drum. The support member supports the corona electrode and the grid electrode. In this corona charging device, the charging potential on the surface of the photosensitive drum can be controlled almost accurately by the grid electrode. In this corona charging device, as the corona electrode, for example, a metal plate electrode (hereinafter referred to as “sawtooth electrode”) having a plurality of needle-like portions (pointed protrusions) is used. The sawtooth electrode has the advantages that it has fewer components than a wire electrode and the like, has a long service life, has a small amount of ozone generation, and is unlikely to break down. The sawtooth electrode is manufactured by forming a plurality of needle-like portions by etching on a metal plate mainly made of an iron-based metal material such as stainless steel or nickel. Such a sawtooth electrode made of an iron-based metal material has high durability, but has a drawback that it is easily oxidized by moisture, ozone generated by corona discharge of the corona electrode, and the like. If the sawtooth electrode is used for a long period of time, it cannot be used in a high humidity environment (environment containing a relatively large amount of water) or contact with ozone, and corrosion such as rust occurs due to moisture in the air, ozone, etc. However, durability is reduced by the nitrogen oxides adhering to the surface. At the same time, the ability to control the voltage applied to the sawtooth electrode due to corona discharge from the needle-like portion is reduced, the charged potential on the surface of the photosensitive drum becomes uneven, and the desired charged potential is always stably maintained. There is a problem to be solved that cannot be applied to the drum surface.

  In view of such a problem, for example, in a corona charging device including a sawtooth electrode, there is provided a corona charging device in which an ozone decomposition catalyst layer is provided on the surface of the sawtooth electrode excluding the apex (tip) of the needle-like portion of the sawtooth electrode and the vicinity thereof. Proposed (see, for example, Patent Document 1). Examples of the ozonolysis catalyst include metal oxides and coconut husk activated carbon as described in paragraph [0035]. The technique of Patent Document 1 intends to prevent a decrease in durability of the sawtooth electrode due to ozone by providing an ozone decomposition catalyst layer in a portion other than the corona discharge region of the sawtooth electrode. However, since the sawtooth electrode receives a high voltage and performs corona discharge, the ozone decomposition catalyst layer itself is damaged over time due to the influence of the corona discharge, and its ozone resolution is lowered. Therefore, with the technique of Patent Document 1, it is impossible to prevent a decrease in durability of the sawtooth electrode due to ozone over the entire life (life) of the image forming apparatus.

  Further, paragraph [0041] of Patent Document 1 describes a sawtooth electrode in which a coating layer such as a gold plating layer or a platinum plating layer is provided on the surface of a nickel plate. The gold plating layer and the platinum plating layer are effective in reducing the generation of ozone and preventing the corrosion of nickel.

  However, even if a grid electrode plated with gold is used, if an aging test is performed, corrosion occurs and charging failure occurs. As a cause of this, it was found that pinholes were generated in the gold plating layer, corrosion progressed with the pinholes serving as nuclei, and defective charging was caused. It is difficult to prevent the occurrence of gold-plated pinholes due to contamination of impurities and defects on the stainless steel surface.

JP-A-10-090974

  An object of the present invention is to have excellent durability against ozone and moisture in the air, and can stably charge the surface of the photosensitive drum over the entire life of the image forming apparatus, and the production cost can be reduced. A low sawtooth electrode processing method, a charging device, and an image forming apparatus are provided.

  The present invention is used in a corona charger that charges a surface of a photosensitive drum by corona discharge under application of a voltage, and a sharp projection that charges the surface by applying a voltage to the surface of the photosensitive drum by corona discharge. In the method for processing a sawtooth electrode having a portion, the surface of the protruding portion is subjected to gold plating, and then the gold plating surface is pressurized.

  Further, the present invention is characterized in that the pressure on the gold plating layer is performed by a metal pressure roller, and a speed difference is provided between the surface peripheral speed of the pressure roller and the roller feed speed.

In the present invention, a sawtooth electrode is arranged on a flat plate by a fixing pin and subjected to pressure processing,
The pressure roller is provided with a recess at a position corresponding to the fixing pin.

  Further, the present invention is characterized in that an elastic member is laid on a flat plate and a grid electrode is disposed on the elastic member to perform pressure processing.

  Further, the present invention is characterized in that the sawtooth electrode is fixed on the base side of the protrusion, and the feeding direction of the pressure roller is a direction from the base of the protrusion of the sawtooth electrode toward the tip.

Further, the present invention is characterized in that nickel plating is applied as a base plating for gold plating.
Further, the present invention is characterized in that pressure is applied to both surfaces of the sawtooth electrode.

Further, the present invention is characterized in that the pressure roller is pressed with a linear pressure of 10 kg or more.
According to another aspect of the present invention, there is provided a charging device using the sawtooth electrode manufactured by the above processing method.

The present invention also provides a photosensitive drum having a photosensitive layer for forming an electrostatic latent image on the surface, charging means for charging the surface of the photosensitive drum, and an electrostatic latent image corresponding to image information on the surface of the photosensitive drum. Exposure means for forming; developing means for supplying toner to the electrostatic latent image on the surface of the photoconductor to form a toner image; transfer means for transferring the toner image on the surface of the photoconductor to a recording medium; and a toner image on the recording medium An image forming apparatus for forming an image by an electrophotographic method,
The charging unit is an image forming apparatus that is the above-described charging device.

  According to the present invention, the surface of the metal plate processed into a sawtooth shape is subjected to gold plating, and then the gold plating layer is pressurized to obtain a sawtooth electrode.

  As a result, the generation of pinholes can be suppressed, and the surface of the photosensitive drum can be stably charged over the entire life of the image forming apparatus, having excellent durability against ozone and moisture in the air.

  According to the present invention, the pressure on the gold plating layer is performed by a metal pressure roller, and a speed difference is provided between the surface peripheral speed of the pressure roller and the roller feed speed.

Thereby, generation | occurrence | production of a pinhole can be suppressed more reliably.
Further, according to the present invention, the sawtooth electrode is arranged on the flat plate by the fixing pin and subjected to pressure processing,
The pressure roller is provided with a recess at a position corresponding to a fixing pin for fixing the sawtooth electrode to the jig.

Thereby, the pressure roller can be moved without interfering with the fixing pin.
Further, according to the present invention, an elastic member is laid on a flat plate, and a sawtooth electrode is disposed on the elastic member to perform pressure processing.

Thereby, it can pressurize, suppressing a deformation of a sawtooth electrode.
According to the present invention, the feeding direction of the pressure roller is the direction from the root of the projection of the sawtooth electrode toward the tip.

  As a result, the sawtooth electrode can be fixed on the base side of the protrusion, and the upturning during processing can be prevented.

Further, according to the present invention, nickel plating is applied as a base plating for gold plating.
Thereby, the peeling strength of a gold plating layer can be increased and the plating peeling by the stress of a pressurization process can be prevented.

According to the present invention, pressure is applied to both surfaces of the sawtooth electrode.
Thereby, the outstanding durability with respect to ozone and the water | moisture content in air can be shown more reliably.

According to the present invention, the pressure roller is pressurized with a linear pressure of 10 kg or more.
As a result, the pinhole can be completely filled.

  According to the invention, the charging device uses the sawtooth electrode manufactured by the above processing method.

  Thereby, it has excellent durability against ozone and moisture in the air, and the surface of the photosensitive drum can be stably charged over the entire life of the image forming apparatus.

  Further, according to the present invention, by using the above-described charging device as the charging means, the photosensitive drum is almost uniformly charged over the entire life (life), and an image having a constant high image quality can be stably and long-term. An image forming apparatus capable of forming is provided.

  FIG. 1 is a cross-sectional view schematically showing a configuration of an image forming apparatus 1 according to a first embodiment of the present invention. FIG. 2 is a perspective view schematically showing a configuration of a charging device 24 according to another embodiment of the present invention. FIG. 3 is a cross-sectional view of the charging device 24 shown in FIG. The image forming apparatus 1 is a multifunction machine having both a copying function, a printer function, and a facsimile function. That is, the image forming apparatus 1 has three types of printing modes, ie, a copier mode (copying mode), a printer mode, and a FAX mode, and an operation input from an operation unit (not shown) or an external host device such as a personal computer. In response to the reception of the print job, an appropriate print mode is selected by a control unit (not shown). The image forming apparatus 1 includes a paper feed unit 2, an image forming unit 3, a paper discharge unit 4, and a document reading unit 5. The paper feeding unit 2 stores the recording medium and feeds the recording medium to the image forming unit 3. The image forming unit 3 forms an image on a recording medium. The paper discharge unit 4 discharges the recording medium on which the image is formed to the outside of the image forming apparatus 1. The document reading unit 5 reads an image and / or characters described on a copy document, converts the information into an electrical signal, and transmits it to the image forming unit 3.

  The paper feed unit 2 includes paper feed trays 10, 11, 12 and 13 (hereinafter referred to as “paper feed trays 10 to 13”), first and second transport paths 14 and 15, and a third transport path 33. The frame 16 and the manual feed portion 17 are included. The paper feed trays 10 to 13 accommodate recording media such as recording paper and OHP (overhead projector) films. The paper feed trays 10 and 11 are arranged in parallel with each other, the paper feed tray 12 is arranged below them, and the paper feed tray 13 is arranged below them. For example, the supply of the recording medium to the paper feed trays 10 to 13 is performed by pulling out the paper feed trays 10 to 13 to the front side (operation side) of the image forming apparatus 1. For example, different sizes and / or types of recording media can be accommodated in the paper feed trays 10 to 13. Here, the size means, for example, a size such as A3, A4, B4, and B5 defined in JIS P 0138 or JIS P 0202. Further, the present invention is not limited to these sizes, and an irregular recording medium can be accommodated. On the other hand, the type means recording paper such as plain paper, color copy paper, coated paper, cardboard, postcard, OHP film, and the like. Of course, the same size and the same type of recording media can be accommodated in the paper feed trays 10 to 13.

  The first conveyance path 14 is provided so as to extend in a substantially vertical direction that is perpendicular to the installation surface 100 of the image forming apparatus 1 along the frame 16 and to be connected to the third conveyance path 33. , 12 and 13 are fed to the image forming unit 3. The second conveyance path 15 extends along the frame 16 of the paper feeding unit 2 in a substantially horizontal direction parallel to the installation surface 100 of the image forming apparatus 1 and is connected to the third conveyance path 33. The recording medium that is provided in this manner and is accommodated in the paper feed tray 11 is fed to the image forming unit 3. Since the paper feed trays 10 to 13 and the first and second transport paths 14 and 15 are efficiently arranged in the frame 16, space can be saved. The third conveyance path 33 conveys the recording medium conveyed from the first and second conveyance paths 14 and 15 to a transfer nip portion described later.

  The manual feed portion 17 is provided above the frame 16 in the vertical direction, and includes a manual feed tray 18, paper feed rollers 19 a and 19 b, and a manual feed path 20. The manual feed tray 18 is fixed to the upper side of the frame 16 inside the image forming apparatus 1, and a part thereof is provided so as to protrude outward from the side surface 1 a of the image forming apparatus 1. The manual feed tray 18 is provided so as to be housed inside the image forming apparatus 1. A document on which image information is formed is placed on the manual feed tray 18, and a recording medium is supplied to the inside of the image forming apparatus 1. The paper feed rollers 19 a and 19 b take the recording medium placed on the manual feed tray 18 into the image forming apparatus 1. The paper feed rollers 19a and 19b are provided so as to be in pressure contact with each other and to be rotatable around an axis by driving means (not shown). The recording medium supplied from the manual feed tray 18 to the pressure contact portions of the paper feed rollers 19a and 19b is sent to the manual feed path 20 by the rotational drive of the paper feed rollers 19a and 19b. The manual feed path 20 is provided so as to pass through the frame 16 and connect to the second transport path 15, and the recording medium taken into the image forming apparatus 1 by the paper feed rollers 19 a and 19 b is transferred to the second transport path. 15 and the third conveyance path 33 to the image forming unit 3. According to the manual feed section 17, the recording medium placed on the manual feed tray 18 is fed to the manual feed path 20 by the paper feed rollers 19 a and 19 b, and further, via the second transport path 15, the image forming section 3. Sent to.

  According to the sheet feeding unit 2, when an image is formed on a recording medium, a tray for storing a recording medium of a predetermined size and type is selected from the sheet feeding trays 10 to 13, and the tray Are separated one by one from the recording medium and fed to the image forming unit 3 through either the first conveyance path 14 or the second conveyance path 15 to form an image. Alternatively, the recording medium supplied from the manual feed unit 17 is similarly fed to the image forming unit 3 to form an image.

  The image forming unit 3 includes an electrophotographic process unit 21 and a fixing unit 22. The electrophotographic process unit 21 includes a photosensitive drum 23, a charging device 24, an optical scanning unit 25, a developing unit 26, a developer storage unit 27, a transfer unit 28, and a cleaning unit 29, and includes image information. The toner image formed in response to this is transferred onto a recording medium.

  The photosensitive drum 23 is a member that is provided so as to be rotatable around an axis by a driving unit (not shown) and includes a conductive substrate and a photosensitive layer. The conductive substrate is not particularly limited as long as it exhibits conductivity, and examples thereof include a conductive substrate having a shape such as a cylindrical shape, a columnar shape, or a thin film sheet shape. The conductive substrate is preferably cylindrical. As the conductive material forming the conductive substrate, those commonly used in this field can be used. For example, aluminum, copper, brass, zinc, nickel, stainless steel, chromium, molybdenum, vanadium, indium, titanium, gold, Conductivity comprising one or more metals such as aluminum, aluminum alloy, tin oxide, gold, and indium oxide on a film substrate such as a metal such as platinum, an alloy of two or more of these, a synthetic resin film, a metal film, and paper. Examples thereof include a conductive film formed by forming a conductive layer, a resin composition containing conductive particles and / or a conductive polymer. In addition, as a film-form base | substrate used for an electroconductive film, a synthetic resin film is preferable and a polyester film is especially preferable. Moreover, as a formation method of the electroconductive layer in an electroconductive film, vapor deposition, application | coating, etc. are preferable.

  Examples of the photosensitive layer include a two-layer separation type photosensitive layer formed by laminating a charge generation layer containing a charge generation material and a charge transport layer containing a charge transport material. The charge generation layer is mainly composed of a charge generation material that generates a charge when irradiated with light, and contains a known binder resin, plasticizer, sensitizer and the like as necessary. As the charge generation material, those commonly used in this field can be used. Phthalocyanine pigments such as metal-free phthalocyanine, squalium dye, azulenium dye, thiapyrylium dye, carbazole skeleton, styryl stilbene skeleton, triphenylamine skeleton, dibenzothiophene skeleton, oxadiazole skeleton, fluorenone skeleton, bis stilbene skeleton, distyryl oxa And azo pigments having a diazole skeleton or a distyrylcarbazole skeleton. Among these, metal-free phthalocyanine pigments, oxotitanyl phthalocyanine pigments, bisazo pigments containing a fluorene ring and / or a fluorenone ring, bisazo pigments composed of aromatic amines, trisazo pigments, etc. have high charge generation ability and high sensitivity. Suitable for obtaining a photosensitive layer. As the binder resin for the charge generation layer, those commonly used in this field can be used. For example, melamine resin, epoxy resin, silicone resin, polyurethane, acrylic resin, vinyl chloride-vinyl acetate copolymer resin, polycarbonate, phenoxy resin , Polyvinyl butyral, polyarylate, polyamide, polyester and the like. Binder resin can be used individually by 1 type, or can use 2 or more types together as needed. The ratio of the charge generating material to the binder resin is not particularly limited, but is preferably 5 to 500 parts by weight, more preferably 10 to 200 parts by weight with respect to 100 parts by weight of the binder resin. The charge generation layer generates charge by dissolving or dispersing appropriate amounts of charge generation materials, binder resins and, if necessary, plasticizers and sensitizers in an appropriate organic solvent capable of dissolving or dispersing these components. It can be formed by preparing a layer coating solution, applying this charge generation layer coating solution to the surface of the conductive substrate and drying. The film thickness of the charge generation layer thus obtained is not particularly limited, but is preferably 0.05 to 5 μm, more preferably 0.1 to 2.5 μm.

  The charge transport layer comprises a charge transport material having the ability to accept and transport charges generated from the charge generation material and a binder resin for the charge transport layer as essential components, and if necessary, known antioxidants, plasticizers, Contains sensitizer and lubricant. As the charge transport material, those commonly used in this field can be used, for example, poly-N-vinylcarbazole and derivatives thereof, poly-γ-carbazolylethyl glutamate and derivatives thereof, pyrene-formaldehyde condensation product and derivatives thereof, Polyvinylpyrene, polyvinylphenanthrene, oxazole derivatives, oxadiazole derivatives, imidazole derivatives, 9- (p-diethylaminostyryl) anthracene, 1,1-bis (4-dibenzylaminophenyl) propane, styrylanthracene, styrylpyrazoline, pyrazoline Derivatives, phenylhydrazones, hydrazone derivatives, triphenylamine compounds, tetraphenyldiamine compounds, triphenylmethane compounds, stilbene compounds, 3-methyl-2-benzothiazoline -Donating substances such as azine compounds, fluorenone derivatives, dibenzothiophene derivatives, indenothiophene derivatives, phenanthrenequinone derivatives, indenopyridine derivatives, thioxanthone derivatives, benzo [c] cinnoline derivatives, phenazine oxide derivatives, tetracyano Examples include electron-accepting substances such as ethylene, tetracyanoquinodimethane, promanyl, chloranil, and benzoquinone. The charge transport materials can be used alone or in combination of two or more. As the binder resin for the charge transport layer, those commonly used in this field and capable of uniformly dispersing the charge transport material can be used. For example, polycarbonate, polyarylate, polyvinyl butyral, polyamide, polyester, polyketone, epoxy resin, polyurethane , Polyvinyl ketone, polystyrene, polyacrylamide, phenol resin, phenoxy resin, polysulfone resin, and copolymer resins thereof. Among these, in consideration of film formability, wear resistance of the resulting charge transport layer, electrical characteristics, etc., polycarbonate containing bisphenol Z as a monomer component (hereinafter referred to as “bisphenol Z type polycarbonate”), bisphenol Z type polycarbonate And a mixture of polycarbonate with other polycarbonates are preferred. Binder resin can be used individually by 1 type, or can use 2 or more types together. Although the ratio of the charge transport material to the binder resin is not particularly limited, it is preferably 10 to 300 parts by weight, more preferably 30 to 150 parts by weight with respect to 100 parts by weight of the binder resin.

  The charge transport layer preferably contains an antioxidant together with the charge transport material and the binder resin for the charge transport layer. As the antioxidant, those commonly used in this field can be used, and examples thereof include vitamin E, hydroquinone, hindered amine, hindered phenol, paraphenylenediamine, arylalkane and derivatives thereof, organic sulfur compounds, and organic phosphorus compounds. It is done. One antioxidant can be used alone, or two or more antioxidants can be used in combination. The content of the antioxidant is not particularly limited, but is 0.01 to 10% by weight, preferably 0.05 to 5% by weight, based on the total amount of components constituting the charge transport layer. The charge transport layer is dissolved or dispersed in a suitable organic solvent that can dissolve or disperse these components in an appropriate amount such as a charge transport material and a binder resin, and if necessary, an antioxidant, a plasticizer, and a sensitizer. The charge transport layer coating liquid is prepared, and the charge transport layer coating liquid is applied to the surface of the charge generation layer and dried. The film thickness of the charge generation layer thus obtained is not particularly limited, but is preferably 10 to 50 μm, more preferably 15 to 40 μm.

As the photosensitive layer, a single layer type photoreceptor containing a charge generating substance and a charge transporting substance in the same resin layer may be used. In that case, the type, content, binder resin, and other additives of the charge generation material and the charge transport material may be the same as in the case of separately forming the charge generation layer and the charge transport layer. Moreover, it is preferable to provide an undercoat layer between the photosensitive layer and the conductive substrate. By providing an undercoat layer, the scratches and irregularities present on the surface of the conductive substrate are coated to smooth the surface of the photosensitive layer, to prevent deterioration of the chargeability of the photosensitive layer during repeated use. Alternatively, an advantage of improving the charging characteristics of the photosensitive layer in a low humidity environment can be obtained. In the present embodiment, the photosensitive drum formed by forming the organic photosensitive layer using the charge generation material and the charge transport material as described above is used, but instead, an inorganic photosensitive material containing silicon or the like on the surface of the conductive substrate is used. A photosensitive drum formed with a layer can be used.

  The charging device 24 has the configuration shown in FIGS. The charging device 24 includes a corona electrode 50, a first power source (not shown), a support member 51, a shield case 55, a grid electrode 56, and a second power source (not shown). The charging device 24 is disposed in the electrophotographic process unit 21 along the longitudinal direction of the photosensitive drum 23 while facing the photosensitive drum 23.

  The corona electrode 50 is a plate-like member including a flat plate portion 57 and a sharp projecting portion 58. Since the corona electrode 50 has a sharp protrusion 58 having an acute-angled tip, when a voltage is applied from the first power source, an uneven electric field is formed and corona discharge occurs, and the surface of the photosensitive drum 23 is predetermined. Is charged to the potential and polarity. The flat plate portion 57 is a plate-like member provided on a virtual surface that is spaced apart from the photosensitive drum 23 and extends in the longitudinal direction of the photosensitive drum 23, includes the axis of the photosensitive drum 23, and extends in the radial direction of the photosensitive drum 23. is there. The sharp protrusion 58 includes a plurality of sharp protrusions 58a. The sharp projection 58a is formed so as to protrude in the short direction of the flat plate portion 57 from one end facing the photosensitive drum 23 in the short direction of the flat plate portion 57, and has a predetermined pitch TP in the longitudinal direction of the flat plate portion 57. Arranged in a row with space. In the present embodiment, the length L1 in the short direction of the flat plate portion 57 is 10 mm, the length L2 in the protruding direction of the sharpened protrusion is 2 mm, the radius of curvature of the tip of the sharpened protrusion is 40 μm, and the pitch TP of the sharpened protrusion is 2 mm. In the present embodiment, as shown in FIG. 2, the sharp projection has a sawtooth shape, but the present invention is not limited to this, and a sharp projection having a needle shape may be formed.

  In the corona electrode 50, a gold plating layer is provided on the surface of the tip 58b of the sharp projection 58a. In providing a gold plating layer on the surface of the tip 58b of the sharpened protrusion 58a, for example, a plating method can be used. According to the plating method, for example, a chemical polishing step, a water washing step, an acid dipping step, a water washing step, a pure water dipping step, a nickel plating step, a gold plating step, a water washing step and a drying step are sequentially performed on a corona electrode sheet metal. Thus, the corona electrode 50 used in the present invention is obtained. Of the steps described above, the nickel plating step is not an essential step and is performed as necessary.

  In the chemical polishing step, the sharp projection 58 is formed by masking and etching the corona electrode sheet metal. Masking can be performed according to a known method. Etching can also be performed according to a known method, and examples thereof include a method of spraying an etching solution such as a ferric chloride aqueous solution onto a corona electrode sheet metal. Here, the corona electrode sheet metal is preferably a sheet metal made of an iron-based metal material such as stainless steel, nickel, or iron. Among these, stainless steel is preferable from the viewpoint of improving the durability of the corona electrode 50. Specific examples of the stainless steel include SUS304, SUS309, SUS316, and the like. Among these, SUS304 is preferable. The thickness of the corona electrode sheet metal is not particularly limited, but is preferably 0.05 to 1 mm, more preferably 0.05 to 0.3 mm. The corona electrode sheet metal on which the sharp projections 58 are formed in the chemical polishing process is subjected to water washing, acid washing or pure water washing in the water washing process, the acid dipping process, the water washing process and the pure water dipping process. Foreign matter is removed and a corona electrode substrate is obtained.

Although the nickel plating step is not an essential step, it is preferably carried out in order to improve the adhesion and adhesion of the gold plating layer to the corona electrode substrate. Here, although nickel plating is performed by a general method, it is preferable to perform electroplating in consideration of forming a gold plating layer later. Here, as a nickel electroplating bath (electroplating solution), known ones can be used, and examples thereof include a watt bath, a sulfamine bath, a high chloride bath, and a total chloride bath. The Watt bath is mainly composed of, for example, nickel sulfate, nickel chloride and boric acid. The sulfamine bath contains, for example, a nickel source compound such as nickel chloride and nickel bromide and an alkali metal salt of sulfamic acid as main components. There are a number of commercially available nickel electroplating baths that can be used as they are. Although the nickel plating conditions are not particularly limited, for example, the current density is 1 to 100 A / dm ² , the pH of the plating bath is ^{2 to 5} , the liquid temperature of the plating bath is 30 to 90 ° C., and the plating time is about 0.1 to 2 hours. The thickness of the nickel plating layer is not particularly limited, but is preferably 0.03 to 3 μm, more preferably 0.5 to 1.5 μm, and particularly preferably about 1 μm.

  Note that a nickel plating layer may be formed only on the tip 58b of the sharp projection 58a of the corona electrode substrate 50a by the electroplating apparatus 70 shown in FIG. FIG. 4 is a cross-sectional view schematically showing the configuration of the electroplating apparatus 70. The electroplating apparatus 70 includes a plating tank 72, an electrode 73, a sponge member 74, and an electrode 75. The plating tank 72 is a container-like member that opens upward in the vertical direction, and an electroplating bath 71 is stored in the internal space, and an electrode 73 and a sponge member 74 are provided. The electroplating bath 71 in the plating tank 72 is heated to an appropriate temperature by a heating means (not shown) provided in the vicinity of the plating tank 72. The electrode 74 is a plate-like electrode provided so as to be immersed in the plating bath 71 stored in the plating tank 72, and is supported by a support means (not shown). The sponge-like member 74 is partially immersed in the electroplating bath 71 on the upper surface in the vertical direction of the electrode 73, and the vertical upper surface of the sponge-like member 74 itself is higher in the vertical direction than the liquid surface of the electroplating bath 71. To be present. The electroplating bath 71 is uniformly impregnated in the sponge member 74. The power source 75 is provided outside the plating tank 72, one end is connected to the electrode 73, the other end is connected to the material to be plated (here, the corona electrode base material 50a), and direct current is applied between the electrode 73 and the material to be plated. Apply voltage. According to the electroplating apparatus 70, the tip 58b of the sharpened protrusion 58a in the corona electrode substrate 50a is pressed against the upper surface in the vertical direction of the sponge member 74, and the surface of the tip 58b and the electroplating bath 71 are placed in contact with each other. By applying a voltage in this state, a nickel plating layer is selectively formed only on the tip 58b of the sharp projection 58a. At this time, the length of the nickel plating layer from the apex of the front end portion 58b can be controlled, for example, by appropriately changing the pressing force of the corona electrode substrate 50a against the sponge-like member 74. It can also be controlled by appropriately changing the composition of the electroplating solution, the bath temperature of the electroplating bath, the plating time, and the like. For the selective formation of the nickel plating layer, the sharp protrusion 58a of the corona electrode substrate 50a and the electrode 71 are arranged to face each other and a voltage is applied, thereby causing an unequal electric field due to the shape of the sharp protrusion 58a. Contributes to the formation.

In the gold plating process, a general electrogold plating bath and an electroplating apparatus 70 shown in FIG. 4 are used, and electroplating is performed under the general plating conditions of gold plating, thereby providing a gold plating having a desired thickness. Layers can be formed. One example of the gold plating method is a gold plating method including a degreasing step, a pickling step, a strike nickel plating step, a nickel plating step, a gold plating step, a water washing step, and a drying step. It is done. In the degreasing process, processing oil and the like adhering to the surface of the object to be plated are removed. In the pickling process, the surface of the object to be plated is washed with acid and activated. In the strike nickel plating step, a thin nickel plating layer is formed on the surface of the object to be plated after pickling. In this case, chemical plating or electroplating may be used. The strike nickel plating step may be omitted. In the nickel plating step, electro nickel plating is performed. Electro gold plating is performed in the gold plating process. Examples of the electrogold plating bath include a cyan gold plating bath and a non-cyan gold plating bath. As the cyan gold plating bath, known ones can be used, and examples thereof include a gold plating bath containing potassium gold cyanide, potassium cyanide and dipotassium hydrogen phosphate. A known non-cyanide gold plating bath can be used, and includes, for example, sodium chloride (III) chloride, potassium ferrocyanide and sodium carbonate, pH 6, bath temperature 60 ° C., current density 0.5 A / dm ^2. Cyan gold plating bath, containing gold and potassium phosphate, pH 5.8, bath temperature 70 ° C., soft gold bath with 0.3 A / dm ² , acetylcysteine gold complex, cysteine gold complex, mercaptosuccinate gold complex, chloride A non-cyanide gold plating bath containing one or more non-cyanide gold compounds selected from an alkali metal salt and / or an ammonium salt of a gold complex and a gold sulfite complex, and acetylcysteine (complexing agent); A non-cyanide gold plating bath containing gold, 1,2-ethanediamine dihydrochloric acid, boric acid and 2,2-bibilidyl and having a pH of 3.8 And the like. Although the thickness of the gold plating layer is not particularly limited, it is preferably 0.3 to 3 μm, more preferably 0.5 to 1.5 μm, and particularly preferably about 1 μm. In the water washing step, the gold plating layer applied to the surface of the object to be plated is washed with water. In the drying process, moisture on the surface of the gold plating layer is removed by hot air or the like. Thus, the corona electrode 50 in which the gold plating layer is formed is obtained.

  The gold plating layer thus obtained is pressed by a pressure roller. FIG. 5 is a schematic view showing the configuration of the electrode pressurizing device 80. Fig.5 (a) shows a top view and FIG.5 (b) shows a side view.

  In the grid pressurizing device 80, an elastic member (rubber) 82 is laid on a flat jig 81 serving as a device base, and the corona electrode 50 that is a sawtooth electrode is fixed on the elastic member 82. A fixing pin 83 is attached to the base side of the projection of the corona electrode 50 and fixed to the jig 81. The corona electrode 50 is pressed by rotating the pressure roller 84 while maintaining a predetermined height and moving the corona electrode 50 from the root of the protrusion of the corona electrode 50 toward the tip. At this time, it is preferable to provide a speed difference between the surface circumferential speed of the pressure roller 84 and the feed speed in the longitudinal direction, and it is preferable to make the surface circumferential speed faster than the feed speed.

  The jig 81 is made of, for example, a plate-like member made of iron and having a thickness of 20 mm. The elastic member 82 is a sheet-like member made of, for example, fluororubber and having a thickness of 2 mm.

  The pressure roller 84 is made of a hard metal cylindrical member, and is configured to apply pressure in a direction perpendicular to the surface of the jig 81 to both ends of the central shaft.

  The rotation speed of the pressure roller 84 is preferably 250 to 350 rpm (surface peripheral speed is 390 to 550 mm / s), and the feed speed of the pressure roller 86 is preferably 40 to 60 mm / s. The applied linear pressure is preferably 10 kg / cm or more.

  It is preferable that the corona electrode 50 is pressed by the pressure roller 84 on both surfaces of the corona electrode 50 protrusion.

  The first power source is controlled to apply a predetermined voltage to the corona electrode 50 by a control unit (not shown) provided in the image forming apparatus 1. In the present embodiment, the first power supply applies a voltage of about 4 to 5 kV to the corona electrode 50. As a result, a constant current of 400 to 800 μA flows through the sharp projection 58 of the corona electrode 50.

  The support member 51 is a member that extends in the longitudinal direction of the photosensitive drum 23 like the corona electrode 50 and has a T-shaped cross section perpendicular to the longitudinal direction. Both ends in the longitudinal direction of the flat plate portion 57 of the corona electrode 50 are screwed by screw members 59 to both ends in the longitudinal direction on one side surface of the protruding portion of the support member 51. As a result, the support member 51 supports the corona electrode 50. The support member 51 is formed of, for example, a synthetic resin. The shield case 55 is a rectangular parallelepiped container-like member that extends in the longitudinal direction of the photosensitive drum 23 and opens toward the surface of the photosensitive drum 23, and accommodates the corona electrode 50 and the support member 51 in its internal space. The support member 51 is attached to the bottom surface 63 of the shield case 55.

  The grid electrode 56 is provided between the corona electrode 50 and the photosensitive drum 23, receives a voltage applied from a second power source (not shown), adjusts the variation in the charged state on the surface of the photosensitive drum 23, and is charged with electric potential. It is a thin plate-like member that makes more uniform. The grid electrode 56 is a porous thin plate member having a plurality of through holes (not shown) formed so as to penetrate in the thickness direction. The grid electrode 56 is provided so that its longitudinal direction is parallel to the longitudinal direction of the photosensitive drum 23. FIG. 7 is a plan view schematically showing the configuration of the grid electrode 56. The grid electrode 56 includes an opening 56y and a fitting hole 56z. Opening 56y includes a plurality of through holes formed to be parallel at a predetermined pitch. The fitting holes 56z are formed at both ends of the grid electrode 56 in the longitudinal direction. The grid electrode 56 is detachably supported by the shield case 55 by fitting the two fitting holes 56z to a support member (not shown) provided in the internal space of the shield case 55. The grid electrode 56 can be manufactured according to a known method. For example, the grid electrode 56 is manufactured by processing the sheet metal for the grid electrode by a manufacturing method including a chemical polishing process, a water washing process, an acid dipping process, a water washing process, and a pure water dipping process. The grid electrode sheet metal is made of, for example, a metal material such as stainless steel, aluminum, nickel, copper, or iron. In the chemical polishing step, masking and etching are performed so that a large number of through holes are formed in the grid electrode sheet metal in the thickness direction of the sheet metal. The grid electrode 56 may be subjected to gold plating similar to that of the corona electrode 50 as necessary.

  A second power source (not shown) is controlled to apply a predetermined voltage to the grid electrode 56 by a control means (not shown) provided in the image forming apparatus 1. In the present embodiment, the second power source applies a voltage of 550 to 600 V to the grid electrode 56.

  According to the charging device 24, corona discharge occurs when a voltage is applied to the corona electrode 50, the surface of the photosensitive drum 23 is charged, and a predetermined grid voltage is applied to the grid electrode 56. Since the charged state of the surface of the photosensitive drum 23 is made uniform, the surface of the photosensitive drum 23 can be charged to a predetermined potential and polarity.

  The optical scanning unit 25 includes a laser light source 25a, a polygon mirror 25b, a lens 25c, and mirrors 25d and 25e. The laser light source 25a emits signal light that is laser light modulated in accordance with image information input from the document reading unit 5 or an external device. For example, a semiconductor laser can be used as the laser light source 25a. The polygon mirror 25b deflects the laser light emitted from the laser light source 25a in the main scanning direction. The lens 25 c converges so that the laser beam deflected in the main scanning direction by the polygon mirror 25 b forms an image on the surface of the photosensitive drum 23. The mirrors 25d and 25e reflect the laser beam converged by the lens 25c and irradiate the surface of the photosensitive drum 23 charged to a predetermined potential and polarity. Thereby, an electrostatic latent image corresponding to the surface of the photosensitive drum 23 is formed. According to the optical scanning unit 25, the laser light emitted from the laser light source 25a is deflected by the polygon mirror 25b, further converged by the lens 25c, reflected by the mirrors 25d and 25e, and irradiated onto the surface of the photosensitive drum 23. As a result, an electrostatic latent image is formed.

  The developing unit 26 includes a developing roller 26a, a supply roller 26b, and a casing 26c. The developing roller 26a is a roller-like member provided in pressure contact with the surface of the photosensitive drum 23 and capable of being rotationally driven by a driving unit (not shown). A pressure-contact portion between the developing roller 26a and the photosensitive drum 23 is a developing nip portion. The developing roller 26a supplies toner to the electrostatic latent image on the surface of the photosensitive drum 23 to form a toner image at the developing nip portion. A developing bias voltage may be applied to the developing roller 26a. The supply roller 26b is a roller-like member provided in pressure contact with the developing roller 26a and rotatably driven by a driving unit (not shown), and supplies the developer containing toner to the developing roller 26a. The casing 26c is a container-like member having an internal space. The developer is accommodated in the internal space and rotatably supports the developing roller 26a and the supply roller 26b. According to the developing unit 26, the developer accommodated in the casing 26c adheres to the surface of the developing roller 26a by the rotational driving of the supply roller 26b, and further, from the surface of the developing roller 26a to the surface of the photosensitive drum 23 in the developing nip portion. The electrostatic latent image is developed, and the electrostatic latent image is developed to obtain a toner image.

  The transfer unit 28 includes a driving roller 28a, driven rollers 28b and 28c, and an endless belt 28d. The drive roller 28a is a roller-like member provided in pressure contact with the surface of the photosensitive drum 23 via an endless belt 28d and capable of being driven to rotate about an axis by a drive unit (not shown). A pressure contact portion between the driving roller 28a and the photosensitive drum 23 is a transfer nip portion. The endless belt 28d and thus the driven rollers 28b and 28c are driven to rotate by the rotational driving of the driving roller 28a. A transfer bias voltage may be applied to the driving roller 28a. The driven rollers 28b and 28c are roller-like members that are rotatably supported by support means (not shown) and are rotated by the rotation of the driving roller 28a. The driven rollers 28b and 28c apply an appropriate tension to the endless belt 28d so that the endless belt 28d is smoothly rotated. The endless belt 28d is an endless belt-like member that is stretched around the driving roller 28a and the driven rollers 28b and 28c to form a loop-shaped movement path, and is rotated by the rotational driving of the driving roller 28a. The endless belt 28d conveys the recording medium on which the toner image is transferred at the transfer nip portion toward the fixing portion 22 by the driven rotation. According to the transfer unit 28, the recording medium passes from the paper feeding unit 2 through the third conveyance path 32 and is supplied to the transfer nip portion, and the recording medium is pressed against the surface of the photosensitive drum 23 by pressing by the driving roller 28 a. The toner image on the surface is transferred to a recording medium. The recording medium to which the toner image is transferred is fed to the fixing unit 22.

  After the transfer unit 28 transfers the toner image to the recording medium, the cleaning unit 29 removes the toner remaining on the surface of the photosensitive drum 23 and cleans the surface of the photosensitive drum 23. As the cleaning unit 29, for example, a cleaning unit including a cleaning roller and a toner container can be used. The cleaning roller is a roller-like member provided so as to come into pressure contact with the photosensitive drum 23, and removes toner, paper dust, and the like remaining on the surface of the photosensitive drum 23. The toner container temporarily stores toner, paper powder and the like removed from the surface of the photosensitive drum 23 by the cleaning roller. Further, a cleaning blade can be used in place of the cleaning roller. The cleaning blade extends in the longitudinal direction of the photosensitive drum 23 and is provided so that one end in the short direction abuts the surface of the photosensitive drum 23. In the image forming apparatus 1 of the present invention, an organic photosensitive drum is mainly used as the photosensitive drum 23, and the surface of the organic photosensitive drum is mainly composed of a resin component. Surface degradation is likely to proceed due to the chemical action of ozone generated by the discharge. However, the deteriorated surface portion is worn by receiving a rubbing action by the cleaning unit 29 and is gradually but surely removed. Therefore, the problem of surface deterioration due to ozone or the like is practically solved, and the charging potential by the charging operation can be stably maintained over a long period of time.

  According to the electrophotographic process unit 21, as the photosensitive drum 23 is driven to rotate, an electrostatic latent image is formed by charging and exposure, a toner image is formed by developing the electrostatic latent image, and the toner image is transferred to a recording medium. , And a series of operations of cleaning the surface of the photosensitive drum 23, the toner image is transferred to the recording medium, and the recording medium is fed to the fixing unit 22.

  The fixing unit 22 includes a fixing roller 30, a pressure roller 31, and a temperature sensor 32, and fixes the toner image transferred onto the recording medium in the electrophotographic process unit 21 to the recording medium. The fixing roller 30 is a roller-like member that is rotatably provided around an axis line by a driving unit (not shown) and has a heating unit (not shown) therein. As the heating means, an infrared heater, a halogen lamp, or the like can be used. The pressure roller 31 is a roller-shaped member that is in pressure contact with the surface of the fixing roller 30, is rotatably supported about an axis, and is provided to rotate following the rotation driving of the fixing roller 30. A pressure contact portion between the fixing roller 30 and the pressure roller 31 is a fixing nip portion. The temperature sensor 32 is provided near the surface of the fixing roller 30 and detects the surface temperature of the fixing roller 30. The amount of electric power supplied to the heater is controlled by a control unit (not shown) so that the surface temperature of the fixing roller 30 is maintained at a predetermined temperature according to the detection result by the temperature sensor 32. According to the fixing unit 22, the recording medium onto which the toner image has been transferred, obtained in the electrophotographic process unit 21, is supplied to the fixing nip unit, and the fixing nip unit is moved along with the rotational driving of the fixing roller 30 and the pressure roller 31. By being pressurized and heated as it passes, the toner image is fixed on the recording medium, and an image-recorded recording medium is obtained.

  According to the image forming unit 3, the toner image corresponding to the image information is transferred to the recording medium fed from the paper feeding unit unit 2, and further heated and pressurized to fix the toner image on the recording medium. As a result, a recording medium on which a high-quality image is formed can be obtained.

  The paper discharge unit 4 includes a fourth transport path 34, a fifth transport path 35, reverse rollers 36a and 36b, a sixth transport path 37, a paper discharge tray (not shown), and a switching gate (not shown). The fourth conveying path 34 supplies the image-recorded recording medium obtained in the fixing unit 22 of the image forming unit 3 to the reversing rollers 36a and 36b. The fifth conveyance path 35 conveys the image-recorded recording medium to the paper discharge tray or the sixth conveyance path 37. Each of the reversing rollers 36a and 36b is provided so as to be able to rotate forward and backward around the axis and press-contact, and changes the conveyance direction of the recording medium on which the image has been recorded. The image-recorded recording medium supplied to the pressure contact portions of the reverse rollers 36a and 36b via the fourth conveying path 34 is sandwiched between the reverse rollers 36a and 36b by the forward rotation of the reverse rollers 36a and 36b. Is done. Thereafter, the reverse rollers 36a and 36b are conveyed in the fifth conveyance path 35 by rotation in the reverse direction. The sixth transport path 37 is provided so as to be connected to the third transport path 33, and transports the recording medium having an image recorded on one side thereof to the third transport path 33 again. The paper discharge tray is provided outside the image forming apparatus 1. The switching gate switches the conveyance direction of the image-recorded recording medium that is sent back through the fifth conveyance path 35 to the direction of the arrow 101 or the sixth conveyance path 37. According to the paper discharge unit 4, when an image is recorded only on one side of the recording medium, the image forming apparatus 1 is moved in the direction of the arrow 101 by the operation of a switching gate (not shown) via the fifth conveyance path 35. The paper is discharged to an external paper discharge tray (not shown). Further, when images are formed on both sides of the recording medium, the image is transferred from the fifth transfer path 35 to the sixth transfer path 37 by the operation of a switching gate (not shown), and is turned upside down and then passes through the third transfer path. Then, the toner image is conveyed to the image forming unit 3 where the toner image is transferred and fixed.

  The document reading unit 5 includes a document supply unit 38 and an image reading unit 39. The document supply unit 38 includes a document tray 40, a document restriction plate 41, a curved conveyance path 42, a protective mat 43, and a discharge roller 49. The document tray 40 is placed so that the image surface of the document faces upward. The document regulating plate 41 feeds documents one by one to the curved conveyance path 42. The curved conveyance path 42 conveys the document to a position directly above the document table 45, which will be described later, while being inverted so that the image surface of the document faces downward. The protective mat 43 is provided on the contact surface between the raw material supply unit 38 and the document table 45 and protects the document table 45 mainly formed of platen glass. The discharge roller 49 discharges the document after the image information is read by the image reading unit 39 on the document table 45 to a discharge tray (not shown) provided outside the image forming apparatus 1. According to the document supply unit 38, a document is placed on the document tray 40 with the image surface facing vertically upward, and printing is performed using a condition input key on an operation panel (not shown) disposed on the exterior front surface of the image forming apparatus 1. After inputting the printing conditions such as the number of sheets, the printing magnification, and the paper size, the copy operation is started by pressing the start key. The documents placed on the document tray 40 are automatically conveyed one by one, and are reversed so that the image surface faces downward in the middle of conveyance, and conveyed to just above the document table 45. Then, image information of the document is read by the image reading unit 39 while the document passes over the document table 45. Thereafter, the document is discharged by a discharge roller 49 to a discharge tray (not shown) outside the image forming apparatus 1.

  The image reading unit 39 includes a document table 44, a document table 45, a light source unit 46, a mirror unit 47, and a CCD reading unit 48. The document table 44 is made of, for example, hapten glass, and is provided for placing a document that cannot be automatically conveyed and reading the image information. The document table 45 is made of, for example, hapten glass, and is provided so as to be separated from the document table 44 in the sub-scanning direction. The document table 45 is provided for allowing a document that can be automatically conveyed from the document tray 40 to pass therethrough and reading the image information when the document passes. The light source unit 46 includes a light source 46a, a reflector (not shown), a slit (not shown), and a mirror 46b. The light source 46a is provided so as to be movable in a direction (sub-scanning direction) parallel to the surfaces of the document tables 44 and 45, and emits illumination light for reading onto the document. The reflector is a concave reflector that condenses the illumination light for reading emitted from the light source 46 a at a predetermined reading position on the document table 44 or the document table 45. The slit selectively allows only reflected light from the document to pass through. The mirror 46b reflects the reflected light from the original by 90 °. According to the light source unit 46, the illumination light for reading is emitted to the document, and the light reflected from the document is supplied to the mirror unit 47. The mirror unit 47 includes a pair of mirrors 47a and 47b. The pair of mirrors 47 a and 47 b are arranged so that the reflection surfaces are orthogonal to each other, change the optical path of the reflected light from the document supplied from the light source unit 46 by 180 °, and guide it to the CCD reading unit 48. The CCD reading unit 48 includes an imaging lens 48a and a CCD image sensor 48b, and converts the reflected light from the document into an electrical signal. The imaging lens 48 a forms an image of the reflected light from the mirror unit 47. The CCD image sensor 48b outputs an electrical signal corresponding to the light imaged by the imaging lens 48a. According to the CCD reading unit 48, the reflected light incident on the imaging lens 48a from the mirror unit 47 is imaged, and the image is converted into an electric signal by the CCD image sensor 48b. Is input to the optical scanning unit 25, and image formation corresponding to the image information is executed.

  According to the image reading unit 39, image information of the document placed on the document tables 44 and 45 is captured as reflected light from the document by light irradiation from the light source unit 46, and this reflected light further passes through the mirror unit 47. To the CCD reading unit 48 and converted into image information of an electrical signal. This information is subjected to image processing under preset conditions, transmitted to the optical scanning unit 25 of the image forming unit 3, and image formation is performed.

  A control unit (not shown) is provided in the upper part of the internal space of the image forming apparatus 1. The control means includes a storage unit, a calculation unit, and a control unit. Various information and programs for performing various controls in the image forming apparatus 1 are input to the storage unit. Further, in the storage unit, various setting values set via display means (not shown) arranged on the upper surface in the vertical direction of the image forming apparatus 1, detection from sensors (not shown) arranged at various locations inside the image forming apparatus 1, etc. As a result, image information included in a print command from an external device is input. As the storage unit, those commonly used in this field can be used, and examples thereof include a read only memory (ROM), a random access memory (RAM), and a hard disk drive (HDD). The calculation unit retrieves various data (printing instructions, detection results, image information, etc.) input to the storage unit and programs of various means, and performs various determinations. A control part sends a control signal to an applicable apparatus according to the determination result in a calculating part, and performs operation control. A control part and a calculating part are processing circuits implement | achieved by the microcomputer provided with a central processing unit (CPU, Central Processing Unit), a microprocessor, etc., for example. The control means includes a main power supply together with the storage unit, the calculation unit, and the control unit.

  The image forming apparatus 1 has excellent durability against ozone and moisture in the air, and uniformly and stably charges the surface of the photosensitive drum 23 throughout the life of the image forming apparatus 1. In addition, by providing the charging device 24 having the corona electrode 50 with low manufacturing cost, an image having a certain high image quality can be formed stably and for a long time.

  In the present embodiment, the charging device 24 is used. However, the present invention is not limited to this, and for example, the charging device 24a shown in FIGS. 6 and 7 can also be used. FIG. 6 is a perspective view schematically showing a configuration of another type of charging device 24a. FIG. 7 is a front view schematically showing a configuration of a main part of the charging device 24a shown in FIG. The charging device 24a is similar to the charging device 24, and corresponding portions are denoted by the same reference numerals and description thereof is omitted. In addition to the corona electrode 50, the support member 51, the shield case 55, and the grid electrode 56, the charging device 24a includes cleaning members 52a and 52b, a holding member 53, and a moving member 54. The corona electrode 50, the support member 51, the shield case 55, and the grid electrode 56 have the same configuration as that of the charging device 24. The cleaning members 52 a and 52 b, the holding member 53, and the moving member 54 are provided for cleaning the corona electrode 50.

  The cleaning members 52a and 52b are plate-like members having a T-shaped planar projection shape, and are provided so as to be movable relative to the corona electrode 50. By rubbing the corona electrode 50 during movement, the corona electrode 50 is cleaned. Clean the surface. The cleaning members 52a and 52b are formed of, for example, an elastic body made of a metal material or a polymer material. Among these, a metal material is preferable. For example, phosphor bronze, plain steel, stainless steel, etc. can be used as the metal material. Among these, considering that the cleaning members 52a and 52b are used in an ozone atmosphere generated by corona discharge, stainless steel is preferable from the viewpoint of durability life based on oxidation resistance. As the stainless steel, known ones can be used, and examples thereof include SUS304, which is an austenitic stainless steel defined in Japanese Industrial Standard (JIS) G4305, SUS430, which is a ferritic stainless steel, and the like. The thickness t of the cleaning members 52a and 52b is 20 to 40 μm. If the thickness t is less than 20 μm, it easily deforms when it comes into contact with the corona electrode 50, but the pressing force against the corona electrode 50, which is a reaction force accompanying the deformation, becomes weak, so that the contaminants adhering to the corona electrode 50 are sufficiently removed. May not be removed. If the thickness t exceeds 40 μm, contaminants attached to the corona electrode 50 can be sufficiently removed, but the rigidity becomes so high that the pressing force against the corona electrode 50 becomes too strong. There is a risk that the tip 58b may be deformed and damaged. Further, if the thickness t is out of the range of 20 to 40 μm, there is a possibility that image unevenness due to charging failure occurs. The cleaning members 52a and 52b are configured.

  The hardness of the cleaning members 52a and 52b is preferably 115 or more, and more preferably 115 to 130, as Rockwell hardness M scale defined in American Society for Testing and Materials (ASTM) standard D785. If the Rockwell hardness is less than 115, the hardness is too soft, so that when cleaning the corona electrode 50, the cleaning members 52a and 52b are deformed excessively and the cleaning effect cannot be obtained. On the other hand, the Rockwell hardness 130 is the upper limit value of the ASTM standard D785 at present, and the ASTM standard D785 does not define a higher hardness. The cleaning members 52a and 52b may be harder than the Rockwell hardness 130.

  The width dimension w of the T-shaped vertical bar portion of the cleaning members 52a and 52b that is in contact with the corona electrode 50, that is, the direction perpendicular to the moving direction of the cleaning members 52a and 52b and the direction in which the protrusion 58 extends. The dimension w of the cleaning members 52a and 52b in the vertical direction is preferably 3.5 mm or more, and preferably 3.5 mm to 10 mm. When the width dimension w is less than 3.5 mm, the value per unit area of the force generated when being deformed by being pressed by the corona electrode 50 is increased, so that fatigue failure due to repeated deformation is likely to occur, and the service life is reduced. If the dimension w is 3.5 mm or more, the value per unit area of the force described above can be reduced, and durability against repeated deformation can be improved. However, if the width is excessively wide, the rigidity becomes too strong and the apparatus becomes large, so it is desirable that the upper limit be set to about 10 mm.

  In addition, it is preferable that the cleaning members 52a and 52b and the corona electrode 50 are arranged so that the amount d of the protrusion 58 of the corona electrode 50 with respect to the cleaning members 52a and 52b is 0.2 to 0.8 mm. . Here, the biting amount d is a state in which the cleaning members 52a and 52b and the protrusion 58 are projected on a virtual plane perpendicular to the direction in which the cleaning members 52a and 52b move relative to the corona electrode 50. The cleaning members 52a and 52b and the protruding portion 58 mean a length that overlaps in the extending direction of the protruding portion 58. When the biting amount d is less than 0.2 mm, the pressing force against the corona electrode 50, which is a reaction force associated with the deformation of the cleaning members 52a and 52b, is weakened, so that contaminants attached to the corona electrode 50 cannot be sufficiently removed. If the amount of bite d exceeds 0.8 mm, contaminants adhering to the corona electrode 50 can be sufficiently removed, but the reaction force (pressing force against the corona electrode 50) accompanying the deformation of the cleaning members 52a and 52b becomes too strong. There is a risk that the tip of the projection 58 of the corona electrode 50 may be deformed and damaged. As a result, if the biting amount d is out of the range of 0.2 to 0.8 mm, there is a possibility that image unevenness or the like due to defective charging occurs.

  The holding member 53 is a member having an inverted L shape that supports the cleaning members 52a and 52b, and arm portions of the cleaning members 52a and 52b having a T shape are attached to the beam-like portions. The two cleaning members 52a and 52b are provided to have a predetermined interval L3 with respect to the direction of movement relative to the corona electrode 50. The interval L3 is selected such that when one of the cleaning members 52a contacts the corona electrode 50 and deforms, the other cleaning member 52b does not hit the deformed cleaning member 52a, and the mounting member 53 is mounted. It can be adjusted by the thickness of the beam. Since the deformation state varies depending on the material constituting the cleaning members 52a and 52b, it is desirable to determine the distance L3 by testing the deformation state of the material in advance. When the cleaning members 52a and 52b are made of stainless steel with a thickness t = 30 μm, for example, the distance L3 is preferably 2 mm. By providing the interval L3 between the two cleaning members 52a and 52b, the pressing force within a preferable range without the deformation of the other cleaning member 52b being disturbed by the other cleaning member 52b while the one cleaning member 52a scrapes the corona electrode 50. Thus, the tip of the corona electrode 50 can be sufficiently cleaned without being deformed and damaged.

  The pressing force of the cleaning members 52a and 52b against the corona electrode 50 is preferably 10 to 30 gf. When the pressing force is less than 10 gf, there is a possibility that contaminants such as toner and paper dust adhering to the corona electrode 50 cannot be sufficiently removed. On the other hand, if it exceeds 30 gf, the tip of the projection 58 of the corona electrode 50 may be deformed and damaged. The pressing force of the cleaning members 52a and 52b against the corona electrode 50 can be adjusted as follows, for example. The magnitude of the force applied to the cleaning member 52a or 52b is measured in a state where a weight is suspended from one end of the moving member 54 described later. The measurement is performed, for example, by connecting a spring balance to the cleaning member 52a or 52b. Then, a weight with a force applied to the cleaning member 52a or 52b of 10 to 30 gf is selected, and when the corona electrode 50 is cleaned, the weight selected in advance is suspended from the end of the moving member 54 to obtain a predetermined value. It can be cleaned with a pressing force of. Further, an electric motor whose rotational torque is adjusted may be connected to the end of the moving member 54 so that a predetermined pressing force can be applied.

  The holding member 53 has a columnar portion and a support portion, and is a member that supports the cleaning members 52a and 52b. The columnar portion extends in the vertical direction, and a lower end portion in the vertical direction is slidably inserted into a groove portion 62 formed by the inner side surface 61 of the shield case 55 and the support member 51. Further, a through hole 60 that penetrates in the longitudinal direction of the shield case 55 is formed in the columnar portion. The support portion is provided so as to extend in the horizontal direction from the upper end portion in the vertical direction of the columnar portion toward the upper side of the corona electrode 50 in the vertical direction. Cleaning members 52 a and 52 b are attached to both side surfaces (not shown) of the support portion in the longitudinal direction of the shield case 55. Thus, the cleaning members 52a and 52b are supported.

  The moving member 54 is inserted into a through hole 60 formed in the columnar portion of the holding member 53 so as to extend parallel to the longitudinal direction of the shield case 55, and is fixed to the holding member 53 in the through hole 60. Further, the moving member 54 extends outward from the shield case 55 through a hole or gap formed in the shield case 55, and is moved via pulleys 64 a and 64 b provided on the outer surface of the shield case 55 or the body of the image forming apparatus 1. The end is drooped. In FIG. 6, illustration of the end portions of the pulleys 64a and 64b and the moving member 54 is omitted. The end of the moving member 54 is preferably extended to the outside of the image forming apparatus 1. With this configuration, when the end of the moving member 54 is pulled in the longitudinal direction of the shield case 55, the holding member 53 slides with respect to the groove 62 and is guided by the groove 62 in the longitudinal direction of the shield case 55. I can move. That is, the cleaning members 52 a and 52 b supported by the holding member 53 can be abutted against the corona electrode 50 and rubbed. Accordingly, the corona electrode 50 can be cleaned without removing the charging device 24a from the image forming apparatus 1 or without opening the image forming apparatus 1.

  The charging device 24a includes a corona electrode 50 and a cleaning mechanism. The corona electrode 50 has excellent durability against ozone and moisture in the air, and can uniformly and stably charge the surface of the photosensitive drum 23 throughout the life of the image forming apparatus 1. Moreover, the manufacturing cost is low. The cleaning mechanism efficiently cleans the corona electrode 50 surface. Therefore, in the charging device 24a, the discharge to the surface of the photosensitive drum 23 by the corona electrode 50 is further stabilized, and the surface of the photosensitive drum 23 is stably charged to a predetermined potential and polarity even if the environmental conditions slightly change. It becomes possible.

The present invention will be specifically described below with reference examples, examples and comparative examples.
(Reference Example 1)
Etching is performed by masking a sheet metal (size 20 mm x 310 mm x thickness 0.1 mm) made of stainless steel (SUS304) and spraying a 30 wt% aqueous solution of ferric chloride at a liquid temperature of 90 ° C for 2 hours. Then, further washing with water and pure water were performed to produce a grid electrode having a plurality of through holes. The grid electrode is the grid electrode shown in FIG. 7, the longitudinal width W1 of the opening is 325.5 mm, the overall length in the longitudinal direction is 364 mm, the lateral width W2 of the opening is 12 mm, the overall length in the lateral direction is 14 mm, The inclination angle of the through hole in the opening with respect to the grid electrode longitudinal direction is 45 °, the width of the through hole in the grid electrode longitudinal direction is 0.3 mm, and the grid electrode longitudinal direction of the metal portion between the through hole and the adjacent through hole The width at was 0.1 mm.

Example 1
Etching is performed by masking a sheet metal (size 20 mm x 310 mm x thickness 0.1 mm) made of stainless steel (SUS304) and spraying a 30 wt% aqueous solution of ferric chloride at a liquid temperature of 90 ° C for 2 hours. Then, washing with water and washing with pure water were performed to prepare a corona electrode substrate. On the surface of this corona electrode base material, a 1 mm long Ni plating layer extending from the apex of the tip 58b of the sharp projection 58a to the root of the projection by the electroplating apparatus 70 shown in FIG. Formed. Next, the corona electrode base material (sawtooth electrode) on which the Ni plating layer was formed was mounted on the electroplating apparatus 70 shown in FIG. 4, and gold plating was performed to manufacture the sawtooth electrode 50. The composition of the gold plating bath 71 was gold hydroxide 10 g / liter, 1,2-ethanediamine dihydrochloric acid chloride 100 g / liter, boric acid 35 g / liter, 2,2-bibilidyl 5 mg / liter, pH 3.8. The plating conditions were a plating bath temperature of 65 ° C. The saw-tooth electrode 50 provided with the gold plating layer thus manufactured is provided with a long hole for fitting the fixing pin 83 at the root of the tooth, and is fitted with the fixing pin 83 fixed to the jig 81. The sawtooth electrode 50 is fixed to a jig 81 with a fluoro rubber having a thickness of 2 mm (rubber hardness JIS A 80 degrees), and a super hard metal roller having a roller diameter of 30 mm is lined by a press device 80 shown in FIG. A pressure treatment performed by scanning in a direction from the root of the tooth of the sawtooth electrode toward the tip at a pressure of 50 kg / cm, a rotation speed of 300 rpm, and a feed rate of 50 mm / s is applied to both the front and back surfaces of the sawtooth electrode and used in the present invention. A sawtooth electrode was produced. In order to avoid contact with the fixing pin 83, the pressing roller 84 is provided with a recess 85 at a position corresponding to the fixing pin 83 in order to avoid interference with the fixing pin 83 during pressing.

  In the obtained sawtooth electrode 50, the gold plating layer provided on the tip 58b of the sharp projection 58a was 1 μm in thickness and 1 mm in length from the apex of the tip 58b of the sharp projection 58a. Further, in the obtained sawtooth electrode 50, the length L1 in the short direction of the flat plate portion is 10 mm, the length L2 in the protruding direction of the sharpened protrusion is 2 mm, the radius of curvature of the tip of the sharpened protrusion is 40 μm, and the sharpened protrusion The pitch TP was 2 mm.

(Comparative Example 1)
Similar to the plating method of Example 1, a Ni plating layer having a thickness of 0.5 μm and a length of 1 mm from the apex of the tip 58b of the sharp projection 58a was provided on the surface of the sawtooth electrode substrate. The sawtooth electrode was manufactured.

(Comparative Example 2)
In the same manner as the plating method of Example 1, a Ni-plated layer having a thickness of 0.5 μm and a length of 1 mm from the apex of the tip 58b of the sharp projection 58a and a gold having a thickness of 1 μm are formed on the surface of the sawtooth electrode substrate. A comparative sawtooth electrode provided with a plating layer was produced.

  Replacing the sawtooth electrode obtained in Example 1 or Comparative Examples 1 and 2 with the sawtooth electrode of the charging device in a commercially available image forming apparatus (trade name: AR625, manufactured by Sharp Corporation), the charging of the present invention An apparatus and an image forming apparatus were manufactured. The following tests were carried out using this image forming apparatus.

[Impact on images]
Using a commercially available image forming apparatus (trade name: AR625, manufactured by Sharp Corporation), printing 300,000 black single-color halftone images (printing rate 100%) on A4 paper under normal temperature and humidity conditions, and uneven charging The presence or absence of white streaks and vitiligo due to was visually confirmed to determine the effect on the image.

[Detection of nitrogen oxides and rust]
The detection of rust and nitrogen oxides was performed by observing the sawtooth electrode after discharge with a microscope.

  As a result, the surface of the sawtooth electrode of Comparative Examples 1 and 2 had many small pinholes as shown in the electron micrograph of FIG. 8, and the plating was not completely covered. It was found that Ni nitrate was precipitated.

  On the other hand, precipitation of rust etc. was not seen on the surface of the sawtooth electrode of Example 1. Further, as shown in Table 1, in each image forming apparatus equipped with the charging device including the sawtooth electrode of Example 1 and Comparative Examples 1 and 2, the output image after printing 300000 halftone images, The difference from the output image of the grid used was affected in the sawtooth electrode of Comparative Example 1 and Comparative Example 2, but no effect on the image was observed in the sawtooth electrode of Example 1.

  The sawtooth electrode of Example 1 was found to have increased plating by pressurization, filling the pinhole, and suppressing the precipitation of nitrogen oxides and rust. In addition, it was found that the saw-tooth electrode of Example 1 had no effect on the image even under a severe condition of 300 K life compared to the saw-tooth electrodes of Comparative Examples 1 and 2.

(Example 2)
A gold-plated sawtooth electrode is manufactured by applying pressure treatment in the same manner as in Example 1 except that the pressurizing process of the sawtooth electrode is changed to a linear pressure of 10 kg / cm, and the surface of the pressing surface of the sawtooth electrode is observed with a microscope. did.

(Comparative Example 3)
A gold-plated sawtooth electrode is manufactured by applying pressure treatment in the same manner as in Example 1 except that the pressurizing process of the sawtooth electrode is set at 5 kg / cm, and the surface of the pressurization surface of the sawtooth electrode is observed with a microscope. did.

  No pinhole was observed on the surface of the sawtooth electrode obtained in Example 2, and a pinhole was confirmed on the surface of the sawtooth electrode obtained in Comparative Example 3. From this, it was found that it is desirable to perform the pressurization of the sawtooth electrode at a linear pressure of 10 kg or more. When the linear pressure is increased, the plating is peeled off and the sawtooth electrode is deformed / damaged. Therefore, the linear pressure is desirably 200 kg or less.

1 is a cross-sectional view schematically showing a configuration of an image forming apparatus according to a first embodiment of the present invention. It is a perspective view which shows typically the structure of the charging device which is other embodiment of this invention. FIG. 3 is a cross-sectional view schematically illustrating a configuration of a main part of the charging device illustrated in FIG. 2. It is sectional drawing which shows the structure of an electroplating apparatus typically. It is the schematic which shows the structure of an electrode pressurization apparatus. It is a perspective view which shows typically the structure of the charging device of another form. It is a front view which shows typically the structure of the principal part of the charging device shown in FIG. It is an electron micrograph which shows the gold-plated pinhole of a corona electrode.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Image forming apparatus 2 Paper feed unit part 3 Image forming part 4 Paper discharge part 5 Document reading part 21 Electrophotographic process part 22 Fixing part 24 Charging device 26 Developing unit 28 Transfer unit 29 Cleaning unit 38 Document supply part 39 Image reading part 50 Corona electrode 51 Support member 53 Holding member 55 Shield case 56 Grid electrode 57 Flat plate portion 58 Sharp projection 80 Electrode pressing device 81 Jig 82 Elastic member 83 Fixing pin 84 Pressure roller

Claims (10)

A saw-tooth having a sharp projection that is used in a corona charger that charges the surface of the photosensitive drum by corona discharge under application of a voltage, and charges the surface by applying a voltage to the surface of the photosensitive drum by corona discharge In the electrode processing method,
A method for processing a sawtooth electrode, characterized by pressurizing a gold plating surface after gold plating is applied to the surface of the protrusion.   2. The sawtooth electrode processing method according to claim 1, wherein the pressure on the gold plating layer is performed by a metal pressure roller, and a speed difference is provided between the surface peripheral speed of the pressure roller and the roller feed speed. . Place the sawtooth electrode on the flat plate with the fixing pin and apply pressure processing,
3. The sawtooth electrode machining method according to claim 2, wherein the pressure roller is provided with a recess at a position corresponding to the fixed pin.   The sawtooth electrode processing method according to any one of claims 1 to 3, wherein an elastic member is laid on a flat plate, a grid electrode is disposed on the elastic member, and pressure processing is performed.   The sawtooth electrode is fixed on the base side of the protrusion, and the feeding direction of the pressure roller is a direction from the base of the protrusion of the sawtooth electrode toward the tip. Machining method for sawtooth electrode.   6. The sawtooth electrode processing method according to claim 1, wherein nickel plating is applied as a base plating for gold plating.   The sawtooth electrode machining method according to any one of claims 1 to 6, wherein pressure is applied to both surfaces of the sawtooth electrode.   The sawtooth electrode processing method according to any one of claims 1 to 7, wherein the pressure roller is pressed with a linear pressure of 10 kg or more.   A charging device using a sawtooth electrode manufactured by the method for processing a sawtooth electrode according to claim 1. A photosensitive drum having a photosensitive layer for forming an electrostatic latent image on the surface; charging means for charging the surface of the photosensitive drum; and exposure means for forming an electrostatic latent image corresponding to image information on the surface of the photosensitive body. A developing unit that supplies toner to the electrostatic latent image on the surface of the photoconductor to form a toner image, a transfer unit that transfers the toner image on the surface of the photoconductor to a recording medium, and a fixing unit that fixes the toner image to the recording medium. In an image forming apparatus that forms an image by electrophotography,
The image forming apparatus according to claim 9, wherein the charging unit is the charging device according to claim 9.