JP2525654B2 - Film forming method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a film forming method, for example, a method for coating a photosensitive layer of an electrophotographic photosensitive member.

B. 2. Description of the Related Art In forming a layer of a photoreceptor, each layer must be formed as a thin film and uniformly. As such a coating method, for example, spray coating, dip coating, blade coating, roll coating and the like have been studied. Of these, dip coating is often used to form a uniform coating film on a cylindrical conductive substrate or the like.

However, such a dip coating method has the following problems.

(A). Since the required amount of the coating liquid is very large and the ratio of the coating liquid effectively used for forming a coating film is low, the coating liquid is wasted a lot.

(B). By the vertical movement of the liquid level of the coating liquid, the coating liquid adheres to the wall surface of the coating tank, and the adhered coating liquid dries to produce a dry solid. Therefore, inconveniences such as coating defects occur.

(C). In the so-called overflow type dip coating device, the coating liquid is circulated between the coating tank and the tank by the power of the pump, so that the coating liquid is generated by the shearing force applied to the coating liquid when the coating liquid passes through the pump. to degrade.

As another method, there is a method in which a conductive substrate drum is passed through a coating device such as a slide hopper and the photosensitive liquid is coated on the outer peripheral surface of the drum during the passage. However, in this method, since the substrate drums are fed to the coating means one by one, the work is interrupted every time one drum is coated, and it is necessary to mount a new drum and clean the blades. It was impossible to apply a typical drum. For this reason, the work efficiency is lowered, and the physical properties of the coating solution are changed or the dried product is generated during the interruption of the work, which causes nonuniformity of the coating film and coating defects.

Further, in Japanese Patent Laid-Open No. 60-95546, a plurality of drums are arranged coaxially, a pressure roller is applied to the outer peripheral surface of the drum row, and the pressure roller is rotated to successively apply the drums to the coating means. Is disclosed. However, in this case, since the pressure contact roller is pressed against the outer circumference of the drum, scratches are generated on the outer circumference of the drum, and dust is apt to adhere, which causes a coating defect.

C. OBJECT OF THE INVENTION It is an object of the present invention to provide a film forming method capable of continuously performing a film forming process on a plurality of objects to be processed and preventing film defects.

D. The present invention is directed to a method for forming a film on a photoreceptor in which a drum-shaped substrate that is continuously stacked is moved relatively to the drum-shaped substrate so that the drum-shaped substrate is subjected to film-forming treatment. By holding the non-image portion of the stacked first drum-shaped substrates before the forming process and moving the first drum-shaped substrates relative to the film-forming means, the drum-shaped substrates are film-formed. And (b) holding the non-image part of the stacked second drum-shaped substrate before the film-forming treatment, moving the second drum-shaped substrate relative to the film-forming means, And a step of forming a film on the second drum-shaped substrate without stopping the film formation subsequent to the film-forming treatment on the first drum-shaped substrate. thing Is.

The phrase “without stopping the film forming process” means that the drum-shaped substrates are stacked and continuously supplied to the coating means, and each drum-shaped substrate during the film forming process is not stopped until the coating is completed. Changes in the moving speed of the drum-shaped substrate are allowed.

The "non-image portion of the drum-shaped substrate" includes not only the non-image portion in the film forming portion of the drum-shaped substrate, but also a member such as a spacer inserted to facilitate transportation.

E. Examples Hereinafter, examples of the present invention will be described.

 FIG. 1 is a schematic front view showing a coating device.

Ball screws 22 facing up and down are provided inside the pair of coating device main bodies 20 facing each other.
A lifting member 23 is attached to each ball screw 22. Spacer gripping tools 28A and 28B are respectively fixed to the ball screw 22, and the elevating member 23 and the spacer gripping tools 28A and 28B can be raised and lowered by driving the drive motor 21. Spacer gripping tool 28
A and 28B are both hand grips at the ends of the gripper bodies 34A and 34B.
30A and 30B are provided, and the spacer gripping hands 29A and 2 are provided in the respective hand gripping portions 30A and 30B.
9B is fixed.

An elevating device 24 is installed between each coating device body 20, and a drum supply hand 33 is attached to the elevating device 24. On the upper side of the hand 33, a spacer 26C, a conductive substrate drum (drum) 27C, a spacer 26B, a drum 27B, in that order.
Spacer 26A and drum 27A are connected.
A drum discharge hand 25 is arranged above A.
A protrusion 40 is provided on the spacer 26A, and the protrusion 40 is fitted in the hollow portion 27a of the drum 27A. Similarly, the drum 27B and the spacer 26B, and the drum 27C and the spacer 26C are also fitted and fixed, respectively.

The coating means 31 is mounted on a coating means mounting base 32, and the coating means mounting base 32 is held by holding means (not shown). The coating means 31 and the coating means mounting table 32 are for coating the coating liquid onto the drums 27A, 27B and 27C as in a coating device (see FIGS. 8 to 10) described later,
In the example of FIG. 1, as the drums 27A, 27B and 27C rise, coating films are sequentially formed on the drums 27A, 27B and 27C.

2A is an enlarged plan view showing the gripping hand and the hand gripping portion, and FIG. 2B is a right side view of FIG. 2A.

The hand grip 30 is provided with a piston 30a and a cylinder 30b, the spacer gripping hand main body 29c is attached to the piston 30a or the cylinder 30b with a screw 30e, and is attached to the main body of the hand grip 30 with a screw 30d. Two adjustment units 29b are fixed to each body 29c, and four adjustment units have spacers 26 facing each other.
It is sandwiched between 29b. Each adjustment unit 2
The position 9b is for position adjustment so that the center positions of the drums 27A and 27B are not displaced in the radial direction. A bearing 29a is provided at the tip of each adjusting unit 29b, and the spacer 26 has four
It is pressed and pinched by the individual bearings 29a.

In FIG. 2 (a), the cylinder 30 is indicated by the solid line.
By operating b (this operation is performed by a known means such as air pressure), the spacer 26 is gripped. Note that 30c is an adjusting screw.

Next, when the cylinder 30b is operated as indicated by the alternate long and short dash line, the main body 29c rotates about the screw 30d as the fulcrum as indicated by the alternate long and short dash line, the bearing 29a and the spacer 26 are separated, and the gripping of the spacer 26 is released. To be done.

FIGS. 3 (a) to 3 (e) are schematic front views of a main part showing a process of forming a coating film on the outer peripheral surface of the drum when the coating device as described above is used.

In the state shown in FIG. 3 (a), the spacer 26C is a spacer gripping tool (hereinafter sometimes referred to as a gripping tool) 28A.
It is held by a spacer gripping hand (hereinafter, also referred to as a hand) 29A provided in the. The drum 27C is fitted and fixed on the spacer 26C, and further, the spacer 26B, the drum 27B, the spacer 26A, and the drum. 26A is in a loaded state.

In FIGS. 3 and 4, an arrow G represents a state in which the spacer is held by the spacer gripping hand (hereinafter, referred to as a holding state). Spacer grip
The hand 29B on the 28B side is in a state of being released from the holding of the spacer (hereinafter, referred to as a released state). At this time, the drum supply hand is waiting while the spacer 26D is fitted and held, and the drum discharge hand 25 is the drum 27A.
The inner peripheral surface of is being fitted and held, and is starting to rise.

Next, as shown in FIG. 3 (b), the gripping tool 28A continues to rise while gripping the spacer 26C, and the coating liquid is applied to the outer peripheral surface of the drum 27C. Drum discharging hand 25
As a result, the already-applied drum 27A and spacer 26A are discharged out of the system, and post-treatment such as drying is performed if necessary. In the meantime, the gripping tool 28B descends and grips the spacer 26D, and the drum supply hand 33 moves the spacer 26D.
It is holding down D and descending. The gripping tool 28B continues to move upward while holding the spacer 26D.

Then, as shown in FIG. 3 (c), the grippers 28A, 28B
Both continue to rise and application of drum 27C progresses. Further, the drum supply hand 33 is newly fitted with the uncoated drum 27E and the spacer 26E by a supply means (not shown), and the drum supply hand 33 has started to rise.

Then, as shown in FIG. 3 (d), the grippers 28B, 28A
Both continue to rise, and at the end of application of drum 27C, drum 27D
The upper end surface of the spacer contacts the lower end surface of the spacer 26C. Then, in the state of FIG. 3D, the spacer 26D is held by the gripping tool 28B.
The drum 27D is fitted and fixed on the spacer 26C, the drum 26C, and the spacer 26.
B and the drum 26B are placed. Grasping tool 28
A is released. At this time, the drum discharge hand 25
Is gripping the inner peripheral surface of the drum 27B and is starting to rise. The drum supply hand 33 is on standby. In this state, the state becomes exactly the same as that in FIG. 3A (that is, the relationship between FIG. 3A and FIG. 3D is a mirror image relationship, and the left and right are interchanged).

Then, as shown in FIG. 3 (e), the gripping tool 28B continues to rise while gripping the spacer 26D, and the coating liquid is applied to the outer peripheral surface of the drum 27D. The already applied drum 27B and spacer 26B are discharged to the outside of the system. During this time, the gripping tool 28A is descending and gripping the spacer 26E, and the drum supply hand 33 is disengaging from the spacer 26E and descending.

After this, the grippers 28A and 28B both continue to rise,
The upper end surface of 27E and the lower end surface of the spacer 26D come into contact with each other to release the gripping tool 28B, the drum discharging hand 25 grips the drum 27C, and the drum supplying hand 33 newly adds an uncoated spacer and drum. Is retained and the state returns to the state shown in FIG.

This completes one cycle of the coating process,
The drum of the book is applied.

 According to this example, the following remarkable effects can be achieved.

(A). By alternately operating the two grippers, the drum can be continuously supplied to the coating means, and the coating layer can be continuously formed on the outer peripheral surface of the drum. As a result, since the coating means can be operated continuously, the productivity is significantly improved, and it is possible to prevent the deterioration of the physical properties of the coating liquid and the production of dry solids due to the interruption of the work, and to provide a uniform and high-quality coating. Can be stably supplied.

(B). After coating, the drum inner peripheral surface is held by the drum discharge hand, and the drum is discharged.
There is no adverse effect on the surface of the already coated or undried drum coating, and the drum discharge hand is not contaminated. If the drum discharging hand becomes dirty, it is necessary to stop the production line for cleaning the hand, but the coating apparatus of this example does not have such a problem and continuous coating of the drum can be continued without delay. In addition, it is possible to prevent dust from being generated due to dirt on the hand, and no coating defect due to dust occurs.

(C). As described in the section of the prior art, if a roller or the like is pressed against the outer peripheral surface of the drum, the outer peripheral surface of the drum may be scratched and dust may be attached.

On the other hand, in the coating apparatus of this example, only the outer peripheral surface of the spacer is directly gripped and the outer peripheral surface of the drum is not gripped before coating, so that no scratch can occur and dust is not attached. Therefore, coating defects caused by these can also be prevented.

(D). As shown in FIG. 3 (d), when the upper end surface of the drum 27D abuts on the lower end surface of the spacer 26C, the drum 27C being coated and the rising drum 27D are separated by the spacer 26C, and at this time Spacer 26C is hand 2
It is gripped by 9A, so drum 27D is spacer 2
The impact at the time of contacting 6C is absorbed, and the adverse effect on the coating film provided on the outer peripheral surface of the drum 27C can be prevented.

(E). When scratches and dust adhere to the drum, image scratches and image defects caused by coating defects appear on the image.

In this respect, according to this example, it is possible to prevent such an image defect,
A high quality image can be provided.

FIGS. 4 (a) to 4 (e) are schematic front views showing a process of applying the coating liquid onto the conductive substrate drum by using another coating device.

In the coating apparatus of this example, a hand for gripping the outer circumference of the drum is not provided, but only the inner peripheral surface of the drum or the spacer is gripped.

As shown in FIG. 4 (a), the lifting member 23 is attached to the two ball screws 22 fixed and connected to the driving means (not shown).
And a drum supply hand 33 or a drum discharge hand 25 are fixed to the elevating member 23 via L-shaped arms. 4 (b) to (e), the lifting member and the ball screw are not shown.

First, in the state of FIG. 4 (a), the drum supply hand is
33 is fitted and fixed to the inner peripheral surface of the spacer 26B, the drum 27B is fitted and fixed on the spacer 26B, and the spacer 26A and the drum 27A are further placed on the drum 27B. drum
The drum discharge hand 25 is fitted and fixed to the inner peripheral surface of 27A. The drum supply hand 33 and the drum discharge hand 25 are rising at the same speed.

Next, the drum discharge hand 25 moves up faster and the spacer 26A and the drum 27B are separated from each other. At this time, the drum supply hand 33 continues to rise, and the drum 27
The coating liquid is continuously applied to the outer peripheral surface of B.

Next, as shown in FIG. 4 (c), the drum discharging hand 25 descends and holds the drum 27B after the application is completed, and then the holding of the drum supplying hand 33 with respect to the spacer 26B is released. 27B is delivered. The drum discharge hand 25 continues to rise further.

Next, as shown in FIG. 4 (d), the drum supply hand 33 moves up while newly holding the uncoated spacer 26C and drum 27C.

Next, as shown in FIG. 4 (e), the upper end surface of the drum 27C contacts the lower end surface of the spacer 26B. In this state, the drum supply hand 33 decelerates and the drum discharge hand 25
Ascending at the same speed, the state becomes exactly the same as in FIG. 4 (a), one drum is coated, and one cycle of the drum coating process is completed.

In this example, in addition to the effects (a) to (e) described above, the device can be further simplified, and the outer peripheral surface of the spacer is not likely to be damaged.

FIG. 5 is a schematic front view showing still another coating device,
The same device as the coating device of FIG. 1 is shown.

However, in this example, the arms of the spacer grippers 51A and 51B are
51A and 51B have a Z shape, coil springs 50A and 50B are fixed to the ends of the arms 51A and 51B, respectively, and the other ends of the coil springs 50A and 50B are fixed to the elevating member 23. ing. Coil spring 50C for lifting device 24
Are fixed, and the drum supply hand 33 is attached through this. A lifting device (not shown) is provided above the drum discharging hand 25 via a coil spring 50D.

According to the coating apparatus of this example, in addition to the above (a) to (e),
The following effects can also be achieved.

(F). When the elevating member 23, the drum supply hand 33, and the drum discharge hand 25 are driven, there is a risk that vibrations coming from a drive source (motor or the like) will inevitably be transmitted to the spacer and the base drum. However, in this example, since the hands 25 and 33 and the base drum grippers 52A and 52B are connected and held to the drive source through the coil springs 50A, 50B, 50C, and 50D, the above-mentioned vibration is generated by the coil spring 50A. , 50B, 50C, 50D
Is absorbed and attenuated as a minute vibration of. Therefore, the vibration is not transmitted to the base drums 27A and 27B having the undried coating film. Therefore, the coating film is not disturbed and a uniform coating film can be formed.

(G). As shown in FIGS. 3 (c) to 3 (d), when the drum 27D contacts the lower end surface of the spacer 26C, the gripping tool 28 is used.
Since the ascending speed of the gripping tool 28B is higher than the ascending speed of A, the impact at the time of contact is unavoidable and the already applied substrate drum 27
It is transmitted to B and 27C. However, in this example, this impact is
It is absorbed and relaxed by the coil springs 50A and 50B on the A and 52B sides. Similarly, even when the drum discharge hand 25 is mounted on the drum (see FIG. 3 (d)), the coil springs 50D and 50A (fixed to the drum discharge hand 25 and the gripping tool 52A (52B), respectively ( 50B) absorbs and relaxes.

Therefore, it is not necessary to precisely control the speeds of the grippers 28A and 28B.

Moreover, in the present example, the above effects can be achieved by an extremely simple mechanism called a coil spring.

The coil spring used in this example may be provided above the drum discharge hand 25 or below the drum supply hand 33 in the coating apparatus of FIG. Thereby, the effects of the above (f) and (g) can be obtained. Moreover,
In the state shown in FIGS. 4A and 4E, if there is a difference in the rising speed between the drum discharge hand 25 and the drum supply hand 33, vibration based on this difference occurs. In order to eliminate this, it is conceivable to perform precise synchronization by using, for example, an electric control means, but this makes the mechanism complicated and raises the cost. However, when the coil spring is fixed to the hands 25 and 33 as described above, the vibration can be absorbed by the coil spring. Therefore, there is no need for sophisticated control for synchronizing the rising speeds of the hands 25 and 33.

In the above, other cushioning mechanism may be used instead of the coil spring. Here, "buffer mechanism" means a mechanism (combination of elements) that absorbs and absorbs energy such as impact, vibration, speed difference between both ends of the mechanism, and includes coil springs, cylinders (pneumatic pressure, hydraulic pressure, etc.), slide rails. ,
It includes any cushioning mechanism such as a cushioning rubber, and also a combination of any of these cushioning mechanisms.

FIG. 6 is a front view showing a state in which the base drum 27 and the spacer 26 are fitted together.

Here, both end portions 27a of the base drum 27 (areas indicated by alternate long and short dash lines) are portions that are not used as a photoconductor even after coating the base drum 27, and are not used by the gripping tool as described above before forming a coating film. 27a may be gripped, or may be gripped over the base drum unused portion 27a and the spacer 26. Even in this case, the used portion 27b of the base drum is not scratched and dust is not likely to adhere.

FIG. 7 is a schematic plan view showing another spacer holding hand.

A spacer is formed by a pair of spacer gripping hands 39A and 39B provided facing each other with the spacer 26 in between.
26 are held. Here, 39a is a bearing, 39b is an adjusting unit, and 39c is a hand main body. And another set of hands 39, which is also provided with the spacer 26 in between.
C and 39D are separated from the spacer 26, and the holding is released.

Spacer gripping hands 39A, 39B, 39C, 39D are all cylinders that operate pneumatically in the direction indicated by the arrow,
It can be operated by a known actuator such as a spring, and like the spacer gripping hand 29 in FIG. 2, it is possible to select a holding state in which the spacer is held or a released state in which the spacer is released. There is.

In this example, unlike the hand 29 of FIG. 2, a pair of separate hands 39B, 39A or 39 facing each other are provided.
The spacer 26 is held by C and 39D, and the pair of hands 39A and 39B or 39C and 39D perform the same function as the hand 29 of FIG.

When the hands 39A, 39B and the like of this example are used, the hands 39A, 39B, 39C, 3
It is necessary to raise and lower 9D respectively. Therefore, as shown in FIG. 7, ball screws 22 are installed on the back surfaces of the hands 39A, 39B, 39C, and 39D, respectively, to raise and lower the hands.

FIG. 8 exemplifies a coating means that can be used in the present invention. FIG. 8A is a sectional view showing a state in which the coating liquid is coated on the conductive substrate drum 27 using a slide hopper device. FIG. 1B is a perspective view showing the slide hopper device.

The coating liquid S supplied to the coating liquid supply pipe 14 by a pump (not shown) in an amount necessary for coating is supplied to the coating liquid distribution chamber 12
Are evenly distributed in the circumferential direction by the distribution slit 13
And flows down the slide surface 17 uniformly in the circumferential direction.
Thereafter, the coating liquid S forms a bead between the hopper edge 16 and the outer peripheral surface of the drum 27. When the conductive substrate 27 is driven in the direction of arrow A while the bead is in contact with the outer peripheral surface of the drum 27, the coating layer 3 is applied onto the outer peripheral surface of the drum 27. Incidentally, reference numeral 15 in FIG. 8 is a liquid receiver.

According to such a coating device, when the coating liquid S is coated on the conductive substrate drum, the solvent is quickly evaporated from the coating layer 3 which has been once coated. Further, since the coating liquid S is supplied in an amount necessary for coating, waste of the coating liquid is small and the cost of the material can be reduced.

Further, in the apparatus of this example, since the distribution slits are arranged seamlessly in the circumferential direction of the object to be coated, a uniform coating film having no seam is obtained, and the film thickness is the coating liquid supply amount,
It is controllable because it is determined by the viscosity and the moving speed of the conductive substrate, and rapid application is possible and the productivity is high.

Also, since the amount of coating liquid required for coating is supplied,
In particular, even when a coating liquid whose liquid physical properties are likely to change, such as a coating liquid for forming a carrier generating layer, is used, it is advantageous because the change in physical properties of the coating liquid can be suppressed.

FIG. 9 is a cross-sectional view showing a state in which the coating liquid is applied on the conductive substrate drum by the extrusion hopper device.

The coating liquid S, which is supplied to the coating liquid supply pipe 14 by a pump (not shown) in an amount necessary for coating, is evenly distributed in the circumferential direction by the coating liquid distribution chamber 12, and is pushed out through the distribution slit 13 to form a hopper. It uniformly and continuously flows out from the edge 16 to form a coating liquid bead with the outer peripheral surface of the drum 27, whereby the coating layer 3 is coated.

The length of the hopper edge 16 is 0.1-10 mm, preferably
0.5-4 mm is good. The angle of inclination of the hopper edge is preferably within the range of 30 degrees below the vertical, and more preferably within the range of 20 degrees below the vertical. When the inclination angle of the hopper edge exceeds 30 degrees, the cross-linking of the coating solution becomes short and it becomes difficult to obtain a good coating film.

When the object to be coated having an endless continuous surface is cylindrical, the coating liquid distribution slit is circular, and the circumference of the diameter is slightly larger than this cylindrical substrate diameter (0.05 to 1 mm larger diameter). The coating can be preferably carried out by using a coating device having a conical inclined surface with a curved end portion.

A pipe is preferably used as the coating liquid supply means for supplying the coating liquid to the coating liquid distribution chamber, and two or more pipes may be used. 2 for safety and uniformity of coating liquid
One or more pipes may be used.

The gap between the diameter of the end of the slide surface and the outer diameter of the body to be coated (cylindrical) is preferably 0.05 to 1 mm, more preferably 0.1 to 0.6 mm. The inclination angle of the slide surface is preferably 10 ° to 70 ° with respect to the horizontal, and more preferably 20 ° to 45 °.

The viscosity of the coating solution should be in the range of 0.5 to 700 Cp, 1 to 500 C
p is even better.

In order to make the coating liquid flow out uniformly from the coating liquid distribution slit in the circumferential direction, in the slide hopper device, the distribution chamber resistance (Pc) and the slit resistance when flowing through the coating liquid distribution slit. (Ps) is Ps / Pc ≧ 80,
It is more preferably in the range of 100 to 100,000, and in the extrusion hopper device, the distribution chamber resistance (Pc) and the slit resistance (Ps) when flowing through the coating liquid distribution slit are Ps / Pc ≧ 4.
By maintaining the relationship within the range of 0, more preferably 40 to 100,000, the coating solution can be applied stably and uniformly.

The distribution chamber resistance (Pc) and the slit resistance (Ps) may be determined according to the coating liquid supply speed, viscosity and supply pressure.

In the extrusion hopper device, the hopper edge is 0.05 to 1 mm larger than the outer diameter of the object to be coated, more preferably in the range of 2 homm to 4 homm when the coating film thickness is homm, and the coating direction length is 0.1 to 10 mm, more preferably 0.5. ~ 4 mm
It is desirable to have Further, the hopper edge is inclined vertically downward from the upper end and within 30 degrees from it, and is inclined toward the opposite side of the base material, more preferably vertically downward and inclined within 20 degrees from it. The one that extends is good. If the inclination of the hopper edge exceeds 30 degrees, the cross-linking of the coating solution becomes short, the bead becomes unstable, and it becomes difficult to obtain a good coating film.

Each coating liquid supplied to the coating device is temporarily stored in each coating liquid distribution chamber, and the coating liquid is evenly distributed to each coating liquid distribution slit connected thereto. The pressure loss ratio of each coating liquid distribution chamber to each coating liquid distribution slit is set so that each coating liquid evenly distributed to each slit and each coating liquid distributed to each slit can be uniformly coated on the substrate surface. Is a slide type
It is 80 or more, preferably in the range of 80 to 100,000, and in the extrusion type, the pressure loss ratio is 40 or more, preferably in the range of 40 to 100,000. When the pressure loss is less than 80 (slide type) and 40 (extrusion type), it becomes difficult to evenly distribute and apply the coating liquid.
If both exceed 100,000, it is necessary to enlarge the coating liquid distribution chamber or to lengthen the slit, which causes a problem in the structure of the apparatus.

The coating film formed on the object to be coated using the coating device is based on the coating liquid bead. That is, the layer of the coating liquid leaving the coating device is not directly applied to the object to be coated with a layer having the same thickness as when the coating device is leaving, but once a liquid pool (coating liquid bead) is formed, and from this bead The object to be coated draws off the coating liquid. Therefore, the coating film formed by this coating liquid bead is not actually directly formed on the object to be coated from the coating device, but the coating device simply maintains the bead of the coating liquid, and the object to be coated is coated from the bead. It The bead of the coating liquid is maintained by being cross-linked between the object to be coated and the hopper edge by the coating liquid extruded from the coating liquid distribution slit or the coating liquid flowing down on the liquid slide portion.
In coating with this bead, the thickness of the coating film applied on the object to be moved across the bead and intersecting with the bead is determined by the action of the bead, and the speed at which the object to be moved moves, It changes depending on the feed rate and feed pressure, the efficiency of the hopper structure, etc.

The coating liquid discharged from the discharge pipe may be circulated so that the coating liquid is supplied to the supply pipe as the coating liquid again after being subjected to treatment such as stirring by a stirrer.

A valve for regulating the discharge amount of the coating liquid may be provided at the coating liquid discharge port or the discharge pipe for discharging the coating liquid in the coating liquid distribution chamber, and the liquid amount may be adjusted not only on the supply side but also on the discharge side. Good.

The supply of the coating liquid is supplied from the supply pipe, part of which flows out to the coating surface through the coating liquid distribution slit, and the other part of which is discharged by the discharge pipe. The coating liquid may be supplied intermittently, for example, by supplying the coating liquid at regular intervals in consideration of the aggregation time of the liquid.

 FIG. 10 is a partial sectional view showing another coating means.

The bottom plate 62 is fixed to the loading plate 60, and the upper surface of the bottom plate 62 and the pressing plate
The blade 34 is sandwiched by 63. The coating liquid S is contained in the liquid tank 66, and a liquid supply plate 67 for replenishing the liquid tank 66 with the coating liquid S is attached to the upper surface of the liquid tank 66.
A pair of liquid supply ports 68 is provided at 67. The entire device is formed in a substantially cylindrical shape. The blade 64 is made of a flexible material such as rubber or synthetic resin, and is configured to hold and hold the drum 27.

The bottom plate 62, the pressing plate 63, the liquid tank 66 is provided with a hole portion 69a having substantially the same diameter, and the liquid supply plate 67 is provided with a hole portion 69b having a smaller diameter than the hole portion 69a. The blade 64 is provided with a hole portion 69c having a diameter smaller than that of the hole portion 69b. Then, with the drum 27 or the spacer fitted,
The peripheral edge of the hole portion 69c of the blade 64 is in close contact with the outer peripheral surface of the drum 27 and the spacer, and a slight gap is formed between the peripheral edge of the hole portion 69b of the liquid supply plate 67 and the outer peripheral surface of the drum 27 or the spacer.

Since the hole portion 69b is close to the drum 27 or the spacer, it is possible to suppress the evaporation of the solvent at the time of coating and also to prevent the abrupt drying of the surface of the already coated drum.

In the liquid tank 66, a photosensitive liquid storage portion 70 is provided in a lower half portion thereof, a liquid reservoir portion 71 is provided in an upper half portion thereof, and a plurality of communication holes 72 for flowing the coating liquid S in the liquid reservoir portion 72 are provided. Are formed in the circumferential direction. A recirculation hole 73 for overflow is provided on the outer peripheral wall of the container 70 so that the liquid surface can always be kept at a constant height. A plurality of air holes 44 are provided in the inner peripheral wall of the housing portion 40 in the circumferential direction, and communicate with the outside air through the hole portions 69b. As a result, the photosensitive liquid in the liquid reservoir 71 gradually passes through the communication hole 72 and gradually descends depending on the size of the air hole 44, so that the liquid surface is stabilized in a calm state.

The coating device and method shown in FIGS. 1 to 10 can be applied to the coating of the coating liquid for the organic electrophotographic photosensitive member.

At this time, the carrier generation layer, the carrier transport layer, and the like in the so-called function-separated type photoreceptor are
Alternatively, it can be provided by a method of applying a solution obtained by dissolving or dispersing and suspending a carrier transporting material in a suitable solvent or a solvent solution of a binder resin, and then drying.

Examples of the solvent include N, N-dimethylformamide, benzene, toluene, xylene, monochlorobenzene, 1,2-dichloroethane, dichloromethane, 1,1,2-trichloroethane, terrahydrofuran, methyl ethyl ketone, ethyl acetate, butyl acetate, etc. Can be mentioned.

In the case of forming a carrier generating layer and a carrier transporting layer by coating and drying a coating material in which a carrier generating substance and a carrier transporting substance are dispersed and suspended in a solvent or a binder resin solution, it is preferably provided by the following method. That is, a dispersion liquid obtained by making a carrier generating substance and a carrier transporting substance into fine particles in a dispersion medium by a ball mill, a homomixer or the like, adding a binder resin and mixing and dispersing the fine particles is used. In this method, it is preferable to uniformly disperse the particles under the action of ultrasonic waves.

As the carrier generating substance, both inorganic pigments and organic pigments can be used as long as they absorb electromagnetic waves and generate free carriers.

 The following are exemplified.

(1) amorphous selenium, trigonal selenium, selenium-arsenic alloy, selenium-tellurium alloy, cadmium sulfide, cadmium selenide, cadmium sulfate selenide, mercury sulfide, lead sulfide,
Inorganic pigments such as zinc oxide, titanium oxide, and amorphous silicon (2) Monoazo pigments, polyazo pigments, metal complex azo pigments, pyrazolone azo pigments, azo pigments such as stilbene azo and thiazole azo pigments (3) Anthraquinone derivatives, anthanthrone Derivatives, dibenzpyrenequinone derivatives, pyranthrone derivatives, violanthrone derivatives and isoviolanthrone derivatives, etc. Anthraquinone-based or polycyclic quinone pigments (4) Indigoide pigments such as indigo derivatives and thioindigo derivatives (5) Titanyl phthalocyanine, vanadyl phthalocyanine Various metal phthalocyanines such as α-type, β-type, γ
Type, τ type, τ ′ type, η type, η ′ type and other metal-free phthalocyanine-based pigments (6) Diphenylmethane-based pigments, triphenylmethane pigments, xanthene pigments, acridine pigments and other carbonium-based pigments (7) Quinone imine pigments such as azine pigments, oxazine pigments and thiazine pigments (8) Methine pigments such as cyanine pigments and azomethine pigments (9) Quinoline pigments (10) Nitro pigments (11) Nitroso pigments (12) Benzoquinone and naphthoquinone Pigments (13) Naphthalimide pigments (14) Perylene pigments such as bisbenzimidazole derivatives (15) Fluorenone pigments (16) Squarylium pigments (17) Azurenium compounds (18) Perylene anhydrides and perylene imides Perylene pigments Carrier transport materials include carbazole derivatives and oxazones. Derivative, oxadiazole derivative, thiazole derivative, thiadiazole derivative, triazole derivative, imidazole derivative, imidazolone derivative, imidazolidine derivative, bisimidazolidine derivative, styryl compound,
Hydrazone compounds, pyrazoline derivatives, oxazolone derivatives, benzothiazole derivatives, benzimidazole derivatives, quinazoline derivatives, benzofuran derivatives, acridine derivatives, phenazine derivatives, aminostilbene derivatives, triarylamine derivatives, phenylenediamine derivatives, stilbene derivatives, poly-N-vinyl It may be one or more selected from carbazole, poly-1-vinylpyrene, poly-9-vinylanthracene and the like.

Any one of the carrier generation layer, the carrier transport layer, the protective layer, or a plurality of layers thereof may have an electron-accepting substance, a surface modifier, a durability improver, an antioxidant (hindered phenol, hindered amine, etc.), high It may contain a molecular organic semiconductor or the like.

Examples of the binder resin that can be used for manufacturing the photoconductor include polyethylene, polypropylene, acrylic resin, methacrylic resin, vinyl chloride resin, vinyl acetate resin, epoxy resin, polyurethane resin, phenol resin, polyester resin, alkyd resin, polycarbonate resin,
Addition polymerization resins such as silicone resins and melamine resins, polyaddition resins, polycondensation resins and copolymer resins containing two or more of the repeating units of these resins, for example vinyl chloride-vinyl acetate copolymer resins. Insulating resin such as vinyl chloride-vinyl acetate-maleic anhydride copolymer resin,
Examples include polymer organic semiconductors such as poly-N-vinylcarbazole.

Examples of the material of the drum-shaped substrate include aluminum, palladium, and the like, and other various metals such as iron, copper, nickel may be contained. Examples of the spacer include stainless steel and the like. The drum-shaped substrate and the spacer may have the same diameter or substantially the same shape.

Although the present invention has been illustrated above, the embodiments of the present invention are not limited to the above-described embodiments, and various modifications can be made.

For example, the coating means is not limited to those shown in FIGS.

Further, in FIGS. 1 to 5, the structure, number, size, shape, etc. of the gripping hand can be variously changed, and the same applies to the gripping tool. Further, the means for raising and lowering the gripping tool is not limited to the ball screw.

In each of the processes shown in FIGS. 3 and 4, it is possible to change the operation procedure of the coating apparatus within the scope of the present invention.

Further, each process shown in FIG. 3 can be carried out by using the coating apparatus having a gripping hand as shown in FIG.

The coating film forming method of the present invention can be applied as various coating methods, and can also be applied to other coating film forming means, for example, a method of forming a vapor deposition film on a conductive substrate by vacuum vapor deposition.

F. EFFECTS OF THE INVENTION According to the method for forming a film on a photoreceptor of the present invention, the second drum-shaped substrate is subjected to the film-forming treatment without stopping the film-forming treatment subsequent to the film-forming treatment on the first drum-shaped substrate. Therefore, since the film forming apparatus can be continuously operated, the productivity is remarkably improved, and it is possible to prevent a change in the processing condition due to the interruption of the film forming process and to make the film uniform.

Further, since at least one of the unused portion of the drum-shaped substrate before the film-forming treatment and the spacing member before the film-forming treatment is held and the drum-shaped substrate is moved relative to the film-forming means, Since the used portion of the drum-shaped substrate before the film forming treatment is not scratched and dust is not attached, it is possible to prevent the film defect from occurring. This causes image scratches,
Image defects can be prevented.

[Brief description of drawings]

The drawings show examples, wherein FIG. 1 is a schematic front view showing a coating device, FIG. 2 (a) is an enlarged plan view showing the periphery of a spacer gripping hand, and FIG. FIG. 3A is a right side view, and FIG. 3A, FIG. 3B, FIG. 3C, FIG. 3D, and FIG. 4 (a), (b), (c), (d), and (e) are schematic front views of main parts showing another process of applying the coating liquid to the outer peripheral surface of the drum by another coating device. 5 is a schematic front view showing another coating device, FIG. 6 is a front view showing a drum and a spacer, FIG. 7 is a schematic plan view showing another spacer holding hand, and FIG. 8 (a) is a base drum. A cross-sectional view showing a state in which the coating solution is being applied to the slide hopper device in FIG. FIG. 9 is a perspective view showing a cutaway view, FIG. 9 is a cross-sectional view showing a state in which the coating liquid is applied on the substrate drum by the extrusion hopper device, and FIG. 10 is a sectional view showing the coating liquid applied on the substrate drum by another coating means. FIG. 4 is a partial cross-sectional view showing a state where In the reference numerals shown in the drawings, 16 ... Hopper edge 17 ... Sliding surface 20 ... Coating device main body 22 ... Ball screw 23 ... Lifting member 25 ... Drum discharging hand 26, 26A, 26B, 26C, 26D, 26E …… Spacer 27, 27A, 27B, 27C, 27D, 27E …… Conductive base drum 27a …… Drum outer peripheral unused part 27b …… Drum outer peripheral used part 28A, 28B …… Spacer gripping tool 29A, 29B, 39A, 39B, 39C, 39D …… Spacer gripping hand 33 …… Drum supply hand 34A, 34B …… Spacer gripping tool body 50A, 50B, 50C, 50D …… Coil spring G …… Holding state S …… It is coating liquid. .

Claims (1)

(57) [Claims] 1. A method of forming a film on a photosensitive member, wherein a drum-shaped substrate continuously stacked relative to a film-forming means is relatively moved to form a film on the drum-shaped substrate. By holding the non-image portion of the first stacked first drum-shaped substrates and moving the first drum-shaped substrates relative to the film-forming means, the drum-shaped substrates are subjected to the film-forming treatment. And (b) holding the non-image portion of the stacked second drum-shaped substrates before the film-forming treatment, moving the second drum-shaped substrates relative to the film-forming means, And a step of forming a coating film on the second drum-shaped substrate without stopping the film formation subsequent to the film-forming treatment on the drum-shaped substrate (1).