JP3709634B2

JP3709634B2 - Continuous coating apparatus and continuous coating method

Info

Publication number: JP3709634B2
Application number: JP32691896A
Authority: JP
Inventors: 晃大平; 淳二氏原; 真生浅野
Original assignee: Konica Minolta Inc
Current assignee: Konica Minolta Inc
Priority date: 1996-12-06
Filing date: 1996-12-06
Publication date: 2005-10-26
Anticipated expiration: 2016-12-06
Also published as: JPH10165877A

Description

【０００１】
【発明の属する技術分野】
本発明は、複数の円筒状基材外周面上に塗布液を連続的に塗布する垂直塗布装置及び方法に関し、特に、該円筒状基材を供給、搬送、位置決め、塗布、乾燥、搬出する連続塗布装置及び連続塗布方法に関する。
【０００２】
【従来の技術】
エンドレスに形成された連続面を有する円筒状基材の外面上への薄膜で均一な塗布に関連してスプレー塗布法、浸漬塗布法、ブレード塗布法、ロール塗布法等の種々の方法が検討されている。特に電子写真感光体ドラムのような薄膜で均一な塗布については生産性の優れた塗布装置を開発すべく検討されている。しかしながら、従来のエンドレスに形成された連続面を有する円筒状基材への塗布装置及び塗布方法においては、均一な塗膜が得られなかったり、生産性が悪い等の短所があった。
【０００３】
スプレー塗布法では、スプレーガンより噴出した塗布液滴が該エンドレスに形成された連続面を有する円筒状基材の外周面上に到達するまでに溶媒が蒸発するために塗布液滴の固形分濃度が上昇してしまい、それにともない塗布液滴の粘度上昇が起って液滴が面に到達したとき、液滴が面上を充分に広がらないために、或いは乾燥固化してしまった粒子が表面に付着するために、塗布表面の平滑性の良いものがえられない。また、該連続面を有する円筒状基材への液滴の到達率が１００％でなく塗布液のロスがあったり、部分的にも不均一であるため、膜厚コントロールが非常に困難である。更に、高分子溶液等では糸引きを起こす事があるため、使用する溶媒及び樹脂に制限がある。
【０００４】
ブレード塗布法、ロール塗布法は例えば円筒状基材の長さ方向にブレード若しくはロールを配置し、該円筒状基材を回転させて塗布を行い円筒状基材を１回転させたのち、ブレード若しくはロールを後退させるものである。しかしながらブレード若しくはロールを後退させる際、塗布液の粘性により、塗布膜厚の一部に他の部分より厚い部分が生じ、均一な塗膜が得られない欠点がある。
【０００５】
浸漬塗布法は、上記におけるような塗布液表面の平滑性、塗布膜の均一性の悪い点は改良される。
【０００６】
しかし、塗布膜厚の制御が塗布液物性例えば粘度、表面張力、密度、温度等と塗布速度に支配され、塗布液物性の調整が非常に重要となる。また塗布速度も低いし、塗布液槽を満たすためにはある一定量以上の液量が必要である。さらに重層する場合、下層成分が溶け出し塗布液槽が汚染されやすい等の欠点がある。
【０００７】
そこで特開昭５８−１８９０６１号公報に記載の如く円形量規制型塗布装置（この中にはスライドホッパー型塗布装置が含まれる）が開発された。このスライドホッパー型塗布装置はエンドレスに形成された連続周面を有する円筒状基材を連続的にその長手方向に移動させながら、その周囲を環状に取り囲み、円筒状基材の外周面に対して塗布液を塗布するものであって、さらにこの塗布装置は環状の塗布液溜まり室と、この塗布液溜まり室内の一部に対して外部から塗布液を供給する供給口と、前記塗布液溜まり室の内方に開口する塗布液分配スリットとを有し、このスリットから流出した塗布液を斜め下方に傾斜する塗布液スライド面上に流下させ、塗布液スライド面の下端のホッパー塗布面と円筒状基材との僅かな間隙部分にビードを形成し、円筒状基材の移動に伴ってその外周面に塗布するものである。このスライドホッパー型塗布装置を用いることにより、少ない液量で塗布でき、塗布液が汚染されず、生産性の高い、膜厚制御の容易な塗布が可能となった。
【０００８】
なお、円筒状基材の外周面を把持搬送する手段は特開平３−２１３７１号公報及び特開平４−５３９５５号公報に、位置決め手段は特開平３−２７４５６８号公報及び特開平３−２８００６３号公報に、乾燥手段は特開平６−３０８７４７号公報及び特開平７−６４３０６号公報にそれぞれ開示されている。
【０００９】
【発明が解決しようとする課題】
しかしながら、前記スライドホッパー型塗布装置を用いてもなお諸問題があり未だ満足のいくものではない。
【００１０】
本発明は従来の諸問題を解決するために提案されたものであり、その目的とするところのものは、
（イ）使用塗布液による塗膜が均一であり、塗布ムラや膜厚変動等の塗膜欠陥がなく、塗布性を向上する。
【００１１】
（ロ）円筒状基材の把持搬送性能を向上し、長期の安定塗布を可能にする。
【００１２】
（ハ）円筒状基材の把持搬送性能を安定化し、円筒状基材の変形や損傷を防止する。
【００１３】
（ニ）円筒状基材を供給、搬送、位置決め、塗布、乾燥、搬出する生産工程を連続安定生産にすることにより、生産性が向上する。
【００１４】
（ホ）上記工程を連続且つ完全自動化することにより、ゴミやほこり等の異物混入を防止し、高品質な製品を得る。
【００１５】
（ヘ）円筒状基材の把持時に振動が発生しても、塗布手段に振動が伝わることを防止することにより、塗布ムラや膜厚変動等の塗膜欠陥がなく、塗布性を向上する。
【００１６】
等の効果が達成される優れた連続塗布装置及び連続塗布方法を提供することにある。
【００１７】
【課題を解決するための手段】
（１）本発明の連続塗布装置は、円筒状基材の筒軸を合わせて積み重ね、環状塗布装置の環中を下から上へ垂直に押し上げながら前記円筒状基材の外周面上に塗布液を連続的に塗布する塗布手段、前記塗布手段に円筒状基材を供給するための供給手段、前記円筒状基材を把持段差修正して積み重ねしながら搬送する把持搬送手段、前記環状塗布装置の環状の中心に前記円筒状基材の中心を合わせる位置決め手段、前記塗布された円筒状基材を乾燥又は乾燥調整する手段及び前記塗布された後の円筒状基材を取り出す為の分離排出手段を具備する連続塗布装置において、前記位置決め手段が作動している時に、前記位置決め手段と前記把持搬送手段との間に、該把持搬送手段に把持されていない前記円筒状基材を少なくとも１つ存在させることを特徴とするものである（請求項１の発明）。
【００１８】
（２）本発明の連続塗布方法は、円筒状基材の筒軸を合わせて積み重ね、環状塗布装置の環中を下から上へ垂直に押し上げながら前記円筒状基材の外周面上に塗布液を連続的に塗布する塗布手段、前記塗布手段に円筒状基材を供給するための供給手段、前記円筒状基材を把持段差修正して積み重ねしながら搬送する把持搬送手段、前記環状塗布装置の環状の中心に前記円筒状基材の中心を合わせる位置決め手段、前記塗布された円筒状基材を乾燥又は乾燥調整する手段及び前記塗布された後の円筒状基材を取り出す為の分離排出手段により塗布される連続塗布方法において、前記位置決め手段が作動している時に、前記位置決め手段と前記把持搬送手段との間に、該把持搬送手段に把持されていない円筒状基材を少なくとも１つ存在させることを特徴とするものである。（請求項６の発明）。
【００１９】
【発明の実施の形態】
以下、図面を用いて本発明の一実施例を説明する。図１は本発明による連続塗布装置の全体構成を示す斜視図である。図において、１０は円筒状基材１を塗布手段の垂直下方の所定位置に供給して上方に押し上げる供給手段、２０は供給された円筒状基材１の外周面を把持して筒軸を合わせて積み重ね下から上へ垂直に押し上げて搬送する把持搬送手段、３０は前記円筒状基材１を塗布装置の環状塗布部の中心に位置合わせする位置決め手段、４０は前記円筒状基材の外周面上に塗布液を連続的に塗布する塗布手段、５０は円筒状基材１上に塗布された塗布液を乾燥させる乾燥手段、６０は乾燥されて垂直搬送されてきた積み重ね状の複数の円筒状基材から分離させて１個ずつ取り出し排出させる分離排出手段である。
【００２０】
本発明の連続塗布装置は、上記の各手段を連続して垂直中心線ＺＺ上に配置した構成であり、人手を要しない完全自動化生産が高精度で達成される。即ち、前記供給手段１０は前記円筒状基材１を載置するための複数の取り付け手段１１を備えた可動テーブル１２、該可動テーブル１２を回転させて前記把持搬送手段２０へつながる垂直ラインへ送り込む駆動手段１３、前記把持搬送手段２０により既に上方に把持搬送されている円筒状基材１を積み重なるように上方に押し上げる昇降手段１４、該昇降手段１４の上端に設けられた円筒状基材供給用のハンド手段１５及び前記駆動手段１３による回転や昇降手段１４による押し上げのタイミングを制御する図示しない制御手段等から構成されている。なお、前記可動テーブル１２上への円筒状基材１の供給は、ロボットハンドルにより行われる。
【００２１】
前記供給手段１０の上方に設けられた把持搬送手段２０は、円筒状基材１の外周面に圧接離間可能で且つ垂直上下方向に移動可能な２組の把持手段２１，２２を有し、円筒状基材１を位置決めして把持し上方に搬送する機能を有する。以下、上記各手段２０，３０，４０，５０，６０の詳細は後述する。
【００２２】
図２は本発明による連続塗布装置の他の実施例を示す斜視図である。この実施例では、前記把持搬送手段２０の上方の垂直中心線ＺＺ上に、位置決め手段３０、塗布手段４０、乾燥手段５０から成るユニットＡ，Ｂ，Ｃを複数組縦列配置したものである。最上段には前記分離排出手段６０が配置されている。各塗布手段４０Ａ，４０Ｂ，４０Ｃからそれぞれ吐出された塗布液は、円筒状基材１上に多層の塗布層を逐次形成する。
【００２３】
図３は前記把持搬送手段２０の正面図である。互いに相対向する一組の搬送装置本体２３Ａ，２３Ｂの内側には、それぞれ垂直上下方向に支持されたボールねじ２４Ａ，２４Ｂが設けられている。該各ボールねじ２４Ａ，２４Ｂはそれぞれ駆動用モータ２５Ａ，２５Ｂにより正逆回転される。各ボールねじ２４Ａ，２４Ｂにそれぞれ螺合する昇降部材２６Ａ，２６Ｂは、ボールねじ２４Ａ，２４Ｂの正逆回転により直進昇降する。該昇降部材２６Ａ，２６Ｂにはそれぞれアーム部材２７Ａ，２７Ｂが固定され、その各先端部にはそれぞれ前記把持手段２１，２２が取り付けられた構成になっている。
【００２４】
前記搬送装置本体２３Ａ，２３Ｂの間には、前記昇降手段１４が設置され、該昇降手段１４の上端には、円筒状基材供給用のハンド手段１５が取り付けられている。該ハンド手段１５の上側には順に円筒状基材１Ｄ，１Ｃ，１Ｂ，１Ａが積載されている。最上段の円筒状基材１Ａは前記分離排出手段６０の排出用ハンド６１により分離して取り出される。
【００２５】
前記塗布手段４０は位置決め手段３０の上に固定されており、位置決め手段３０は図示省略した保持手段により保持されている。位置決め手段３０は円筒状基材１を所定の位置に正確に保持する装置であり、例えばエアーベアリング等により非接触保持される。塗布手段４０は円筒状基材１（１Ａ，１Ｂ，１Ｃ，１Ｄ）の外周面上に塗布液を均一に塗布するものであり、円筒状基材１Ａ，１Ｂ，１Ｃ，１Ｄが前記把持搬送手段２０により把持搬送されるに従って、円筒状基材１Ａ，１Ｂ，１Ｃ，１Ｄ上に順次塗膜が形成される。
【００２６】
図４は前記把持手段２１，２２の斜視図である。上段側の把持手段２１は、２個の可動把手２１１，２１２と、該可動把手２１１，２１２の各揺動中心穴に嵌合して揺動可能に保持する支軸２１３と、該可動把手２１１，２１２の各先端部に形成されたＶ字形状のハンド部２１４，２１５の内側にそれぞれ固定された把持子２１６とから構成されている。前記可動把手２１１，２１２を図示しないピストンシリンダー等の駆動手段により開閉することにより、前記把持子２１６は円筒状基材の外周面に接離する。図示の把持子２１６は４箇所または３箇所で円筒状基材１に圧接する。
【００２７】
下段側の把持手段２２も、上記上段側の把持手段２１と同様の構成をなし、２２１，２２２は可動把手、２２３は支軸、２２４，２２５はハンド部、２２６は把持子である。なお、上段側の把持手段２１は、円筒状基材１Ｂ，１Ｃの接続位置の各外周面を把持した状態を示し、下段側の把持手段２２は円筒状基材１Ｃ，１Ｄの接続位置の各外周面から離間した状態を示す。
【００２８】
前記上段側の把持手段２１の把持子２１６は、図示の円筒状基材１Ｂ，１Ｃの端面間の接続部（繋ぎ部）Ｋ１付近の外周面を把持するのが好ましい。また、下段側の把持手段２２の把持子２２６は、円筒状基材１Ｃ，１Ｄの端面間の接続部（繋ぎ部）Ｋ２付近の外周面を把持するのが好ましい。前記接続部Ｋ１付近の外周面及びＫ２付近の外周面は、感光体ドラムの非画像形成領域である。
【００２９】
図５は把持手段２１の他の実施例を示す斜視図である。図５（ａ）は、Ｖ字形状のハンド部２８１，２８２の内側にそれぞれ固定された把持子２８０を有し、該ハンド部２８１，２８２をそれぞれ前進、後退させることにより、円筒状基材１を４点支持で圧接把持または離間する。図５（ｂ）は、切り欠き円筒形状のハンド部２８３，２８４の内側にそれぞれ固定された把持子２８０を有し、該ハンド部２８３，２８４を前進、後退させることにより、円筒状基材１を円筒状外周面支持で圧接把持または離間する。図５（ｃ）は、前記Ｖ字形状のハンド部２８１と平面状のハンド部２８５の内側にそれぞれ固定された把持子２８０を有し、該ハンド部２８１，２８５をそれぞれ前進、後退させることにより、円筒状基材１を３点支持で圧接把持または離間する。
【００３０】
図６は、位置決め手段３０と垂直型塗布手段４０とを示す断面図、図７は塗布手段４０の斜視図である。
【００３１】
図６に示されるように中心線Ｚ−Ｚに沿って垂直状に重ね合わせた複数の円筒状基材１Ａ，１Ｂ（以下、円筒状基材１と称す）を連続的に矢示方向に上昇移動させ、その周囲を取り囲み、円筒状基材１の外周面に対しスライドホッパー型の塗布手段１０の塗布に直接係わる部分（ホッパー塗布面）４１により塗布液（感光液）Ｌが塗布される。なお、円筒状基材１としては中空ドラム例えばアルミニウムドラム、プラスチックドラムのほかシームレスベルト型の基材でも良い。
【００３２】
前記ホッパー塗布面４１には、円筒状基材１側に開口する塗布液流出口４２を有する幅狭の塗布液分配スリット（スリットと略称する）４３が水平方向に形成されている。このスリット４３は環状の塗布液分配室（塗布液溜り室）４４に連通し、この環状の塗布液分配室４４には貯留タンク２内の塗布液Ｌを圧送ポンプ３により供給管４を介して供給するようになっている。
【００３３】
他方、スリット４３の塗布液流出口４２の下側には、連続して下方に傾斜し、円筒状基材１の外径寸法よりやや大なる寸法で終端をなすように形成された塗布液スライド面（以下、スライド面と称す）４５が形成されている。さらに、このスライド面４５終端より下方に延びる唇状部４６が形成されている。
【００３４】
かかる塗布手段（スライドホッパー型塗布装置）４０による塗布においては、円筒状基材１を引き上げる過程で、塗布液Ｌをスリット４３から押し出し、スライド面４５に沿って流下させると、スライド面４５の終端に至った塗布液は、そのスライド面４５の終端と円筒状基材１の外周面との間にビードを形成した後、円筒状基材１の表面に塗布される。
【００３５】
スライド面４５の終端と円筒状基材１は、ある間隙を持って配置されているため円筒状基材１を傷つける事なく、また性質の異なる層を多層形成させる場合においても、既に塗布された層を損傷することなく塗布できる。
【００３６】
一方、前記圧送ポンプ３の塗布液供給部より最も遠い位置で、前記塗布液分配室４４の一部には、塗布液分配室４４内の泡抜き用の空気抜き部材４６が設けられている。貯留タンク２内の塗布液Ｌが塗布液分配室４４に供給されて塗布液分配スリット４３から塗布液流出口４２に供給されるとき、開閉弁４７を開いて空気抜き部材４６より塗布液分配室４４内の空気を排出する。
【００３７】
前記スライドホッパー型塗布装置４０の下部には、円筒状基材の円周方向を位置決めする位置決め手段３０が固定されている。前記円筒状基材１の位置決め装置３０の本体３１には、複数の給気口３２と、複数の排気口３３が穿設されている。該複数の給気口３２は、図示しない給気ポンプに接続され、空気等の流体が圧送される。該給気口３２の一端部で円筒状基材１の外周面に対向する側には、吐出口３４が貫通している。該吐出口３４は前記円筒状基材１の外周面と所定の間隙を保って対向している。該間隙は、２０μｍ〜３ｍｍ、好ましくは３０μｍ〜２ｍｍである。この間隙が２０μｍより小さいと、円筒状基材１の僅かな振れで本体３１の内壁に接触して円筒状基材１を傷つけやすい。また、この間隙が３ｍｍより大であると、円筒状基材１の位置決め精度が低下する。前記吐出口３４は直径０．０１〜１．０ｍｍの小口径のノズルであり、好ましくは０．０５〜０．５ｍｍが良い。
【００３８】
前記本体３１の内壁下部の内周面は、入り口側が広がったテーパー面３５になっている。このテーパー面３５は、例えば軸方向の長さが５０ｍｍで、片側傾斜角が０．５ｍｍの円錐面である。このテーパー面３５を設けることにより、円筒状基材１が本体３１の内壁に進入するとき、円筒状基材１の先端部が内壁の内周面に接触することを防止している。
【００３９】
前記給気ポンプから圧送された流体は、複数の給気口３２から本体３１の内部に導入されて、複数の吐出口３４から吐出され、前記円筒状基材１Ａ（１Ｂ）の外周面と均一な流体膜層を形成する。吐出後の流体は複数の排気口３３から装置外に排出される。
【００４０】
前記吐出口３４の開口直径は０．０１〜１ｍｍ、好ましくは０．０５〜０．５ｍｍ、例えば０．２〜０．５ｍｍの円形に形成されている。排気口３３の開口直径は１．０〜１０ｍｍ、好ましくは２．０〜８．０ｍｍ、例えば３〜５ｍｍの円形に形成されている。
【００４１】
前記給気口３２に供給される流体は、空気、不活性ガス例えば窒素ガスが良い。そして該流体は、ＪＩＳ規格でクラス１００以上の清浄な気体が良い。
【００４２】
なお、本発明の位置決め装置に接続される垂直塗布装置としては、スライドホッパー型、押し出し型、リングコーター等の各種装置が用いられる。
【００４３】
図８は、本発明による把持搬送手段２０と位置決め手段３０の相対位置関係を示す断面図である。
【００４４】
図８（ａ）は、２個のハンド部２１４，２１５の内側にそれぞれ固定された把持子２１６を有する上段側の把持手段２１が、円筒状基材１Ｄ，１Ｅの端面間の接続部（繋ぎ部）Ｋ付近の外周面を把持した状態を示す。また、２個のハンド部２２４，２２５の内側にそれぞれ固定された把持子２２６を有する下段側の把持手段２２は、円筒状基材１Ｅの下端付近の外周面を把持するため待機している。
【００４５】
前記上段側の把持手段２１に把持された円筒状基材１Ｄの上端面の上部には、円筒状基材１Ｃが、更にその上方には円筒状基材１Ｂ，１Ａが自重で載置されている。把持手段２１に把持された前記円筒状基材１Ｄの上に載置されている円筒状基材１Ｃの上端側は、前記位置決め手段３０に未だ進入していない状態にあり、その円筒面には外力が加えられていない状態である。
【００４６】
前記把持搬送手段２０の上段側の把持手段２１の上面と、位置決め手段３０の入口部下面との間隔Ｄ１内には、外力の加えられていない長さＤ₀の円筒状基材１Ｃが少なくとも１個存在する。
【００４７】
円筒状基材１Ｂは、流体吐出口を有するリング状の位置決め手段３０により位置決めされている。通常、把持の中心と位置決めの中心をいつも一致させるのは極めて困難（ドラムの寸法や精度にバラツキがあるため）なため、外部把持されていない円筒状基材を少なくとも１つ以上有することにより、位置決め手段の修正が行いやすくなる。
【００４８】
前記上段側の把持手段２１による把持及び把持解除時や、昇降駆動時に発生した振動により、把持された円筒状基材１Ｄから伝達された振動は、前記外力の加えられていない円筒状基材１Ｃに吸収されて、位置決め中の円筒状基材１Ｂや、塗布中の円筒状基材１Ａには伝達されない。なお円筒状基材１Ａはリング状の塗布手段４０により塗布液が塗布されている。
【００４９】
図８（ｂ）は、上段側の把持手段２１が、円筒状基材１Ｄの円筒面の上端側付近で、円筒状基材１Ｃとの繋ぎ部Ｋの下方の位置を把持した状態を示す。また、下段側の把持手段２２は、円筒状基材１Ｄの下端付近の外周面を把持するため待機している。
【００５０】
前記上段側の把持手段２１の上面と、位置決め手段３０の入口部下面との間隔Ｄ２内には、外力の加えられていない長さＤ₀の円筒状基材（１Ｃ）が少なくとも１個存在する。このような円筒状基材の把持方法においても、前記上段側の把持手段２１による把持及び把持解除時や、昇降駆動時に発生した振動により、把持された円筒状基材１Ｄから伝達された振動は、前記外力の加えられていない円筒状基材１Ｃに吸収されて、位置決め中の円筒状基材１Ｂや、塗布中の円筒状基材１Ａには伝達されない。
【００５１】
前記塗布手段４０の上方には、乾燥フード５１と乾燥器５３とから成る乾燥手段５０が設けられている。
【００５２】
図９は前記塗布手段４０と該塗布手段４０の上部に設けた乾燥フード５１の断面図である。該乾燥フード５１は環状の壁面を有し、該壁面には多数の開口５１Ａが穿設されている。前記円筒状基材１を矢示方向に上昇させ、前記塗布手段４０のホッパー塗布面（塗布ヘッド）４１で塗布液Ｌを塗布し、感光層５を形成する。円筒状基材１上に形成された感光層５は前記乾燥フード５１内を通過しながら徐々に乾燥される。この乾燥は前記多数の開口５１Ａより塗布液Ｌに含まれている溶媒を壁面外に放出することにより行われる。
【００５３】
前記のように、塗布手段４０により円筒状基材１上に塗布液Ｌを塗布することにより、形成された感光層５は、塗布直後において乾燥フード５１により包囲されており、開口５１Ａからのみ溶媒が放出されるため、塗布直後における感光層５の乾燥速度は、前記開口５１Ａの開口面積にほぼ比例する。
【００５４】
図１０は乾燥フードの他の実施例を示す断面図である。この乾燥フード５２は前記図９における乾燥フード５１（Ａ部）の上部を延長してＢ部を形成したものである。このＡ部には複数個の５２Ａが、Ｂ部には複数個の５２Ｂがそれぞれ穿設されている。この乾燥フード５２を塗布手段４０の上部に設けることにより、円筒状基材１の外周面上に塗布された塗布液Ｌの溶媒蒸気濃度が制御される。従って塗膜乾燥速度が制御されることで塗膜の均一化を計ることが可能である。また前記のような乾燥フード５２を設けることで、ビード部分の溶媒蒸気濃度が高くなるため、急速な乾燥が防止され、ビード切れを防止できる。
【００５５】
図１１に本発明の乾燥器５３の断面図を示す。乾燥器５３は吸引スリット５３１、吸引チャンバー５３２、吸引ノズル５３３を有する吸引スリット部材５３４の下部に筒状部材５３５、上部に筒状部材５３６がそれぞれ同心に結合されている。
【００５６】
そして、複数設けられた吸引ノズル５３３から吸引を行ない、周方向均一な吸引チャンバー５３２、周方向均一な吸引スリット５３１により周方向の均一化がなされた吸引エアーが流れ、更に、吸引スリット部材５３４、その上下の筒状部材５３６，５３５の各内径面と塗布済みの円筒状基材１の外周面との間の空気流の乱れをバッファー空間５３７で極く僅かにおさえて、５３８に示す乾燥の為の均一吸引エアーの空気流を作り出している。
【００５７】
この乾燥ゾーンに矢印で示す方向に塗布済の円筒状基材１を搬送することにより、塗布膜の乾燥を行うものである。
【００５８】
次に、乾燥手段５０の他の実施例として図１２に示された排気乾燥装置５４について説明する。前記のように円筒状基体１Ａ、１Ｂに環状のスライドホッパー型塗布装置４０にて塗布液（感光液）Ｌが塗布されて感光層ＬＡが形成される。前記排気乾燥装置５４は塗布した直後の感光層ＬＡより蒸発する溶媒を吸引し、更に乾燥を行うもので、前記塗布装置４０の直上に設けられている。５４１は環状に形成された吸引ダクトで、該吸引ダクト５４１より前記感光層ＬＡに向けて吸引口５４２が形成されている。前記吸引ダクト５４１の一部には排気管５４３が接続され、該排気管５４３内に設けた排気ファン５４４により前記感光層ＬＡより蒸発する溶媒を吸引して、強制的に外部に排出し乾燥させる。
【００５９】
前記のように塗布装置４０にて感光液Ｌを塗布した直後に、該感光液Ｌより発生する溶媒蒸気を排気するため円筒状基体１Ａ、１Ｂに塗布された感光液Ｌが多量に流下するのを停止させることができる。その際、前記排気ファン５４４による排気風速を０．５〜５ｍ／ｓｅｃで行い、前記吸引口５４２は前記塗布ヘッド４１の位置より３００ｍｍ以下が望ましい。そして前記感光液Ｌ内の溶媒が３０％以上蒸発するまで前記円筒状基体１Ａ、１Ｂを連結状態に保ち、分離した後、感光層ＬＡを完全に乾燥させる。前記のような排気乾燥装置５４を作動させることにより、多数の円筒状基体を接続して感光液Ｌを塗布した場合でも感光層ＬＡの近傍より溶媒を急速に排出出来ると共に、感光液Ｌによる塗膜の流下を強制的に制御して感光層ＬＡに発生する前記薄膜や液溜りの発生を防止する事も出来る。尚、前記排気ファン５４４は、吸引ダクト５４１に複数箇所設けてもよい。
【００６０】
以上のようにして塗布及び塗布膜乾燥が行なわれた円筒状基体１Ａ，１Ｂ，１Ｃ〜・・・・を分離する方法を図１３の分離過程の各プロセスの状態図を用いて説明する。
【００６１】
分離排出手段６０は垂直移動ロボットステージ６１、エアーシリンダー６２、上チャック６３及び下チャック６４により構成される。
【００６２】
塗布済みの円筒状基体１は下方より上方へ向けて積み上げられ、上方向へ移動し、図１３（ａ）に示すように分離位置に達する。この時垂直ロボットが起動し被分離円筒状基体１Ａと同軸，等速度で同架された分離ユニット全体を移動する。
【００６３】
まず、図１３（ｂ）に示す位置で下チャック６４が被分離円筒状基体１Ａに隣接する円筒状基体１Ｂを保持する。次いで図１３（ｃ）に示す位置で上チャック６３が被分離円筒状基体１Ａを保持する。
【００６４】
エアーシリンダー６２により上チャック６３は被分離円筒状基体１Ａを保持したまま上方向へ移動して図１３（ｄ）に示す位置になる。この時被分離円筒状基体１Ａと隣接する円筒状基体１Ｂにまたがる塗布膜が切り裂かれて図１３（ｄ）図に示すように１Ａ，１Ｂの分離が行なわれる。
【００６５】
分離済み円筒状基体１Ａを回収する為、図１３（ｅ）に示すように下チャック６４はアンチャック状態となり、垂直移動ロボットステージ６１が急上昇を行い、隣接する円筒状基体１Ｂの位置よりはるか上方に配置された分離ドラム回収装置に該分離済み円筒状基体１Ａを置き（上チャック６３がアンチャックになり）行程を終了する。
【００６６】
そして次なる円筒状基体１Ｂの分離動作の為、垂直移動ロボットステージ６１が下降し、また、エアーシリンダー６２が下降し、初期状態の位置図１３（ａ）に戻る。
【００６７】
その他に、被分離円筒状基体１Ａと隣接円筒状基体１Ｂの分離を行なう際に被分離円筒状基体１Ａに回転を加えながら円筒状基体１Ａを引き上げる方法も有効である。これは、分離される膜に引張り力ではなく、剪断力を加えるものであり、ウェット状態の膜では分離部近傍の塗布膜プロフィールが薄膜化する現象を低減できる。また塗布膜の切断時に発生する膜の小片の飛散が該円筒状基体１内面へ引き込まれることにより、低減する。
【００６８】
［実施例］
次に、具体的な実施例により本発明を説明するが、本発明はこれに限定されるものではない。
【００６９】
実施例１
導電性支持体（円筒状基材）１としては鏡面加工を施した直径８０ｍｍ、高さ３５５ｍｍ、２８３ｇのアルミニウムドラム支持体を用いた。また、塗布液Ｌとしては下記記載の▲１▼ＵＣＬ−１塗布液組成物を用いた。
【００７０】
▲１▼ＵＣＬ−１塗布液組成物（３．０Ｗ／Ｖ％ポリマー濃度）
共重合ナイロン樹脂（ＣＭ−８０００東レ社製）３ｇ
メタノール／ｎ−ブタノール＝１０／１（Ｖｏｌ比）１０００ｍｌ
図１により円筒状基材１の連続塗布工程を説明する。円筒状基材１は図示されていない供給ロボットにより円筒状基材１（アルミニウムドラム）収納室より可動テーブル１２上にある円筒状基材１の１Ｆの位置に置かれる。円筒状基材１Ｆは可動テーブル１１の矢印方向の回転により１Ｅの位置に達する。この時、昇降手段１４の供給アームが下方より上方へ円筒状基材１Ｅを押し上げ、ハンド手段１５の位置まで供給される。好ましくは供給アームによる押し上げが完了すると同時に緩衝機構が作用し、先行の円筒状基材１Ｄの下端と後続の円筒状基材１Ｅの上端との接合時のショックを無くすのが良い。このようにして円筒状基材１Ｅ，１Ｆが順次、把持搬送手段２０のところまで運び込まれる。
【００７１】
円筒状基材１Ｄは可動把手２１，２２により把持されかつ上方に搬送される。把持される場所は円筒状基材１Ｄに悪影響が無ければどの場所でもよいが、円筒状基材１Ｄ，１Ｃとの繋ぎ部（接続部）Ｋを把持する事により円筒状基材１Ｄ，１Ｃ間の段差修正がある程度まで行われ好ましいし、上に積み重ねられた円筒状基材１Ｃの全重量に抗して強い力で把持するのだからキズや故障の発生を防ぐため、繋ぎ部Ｋの非画像部を把持するのが良い。
【００７２】
把持搬送手段２０については、図３〜５の説明の項を参照されたい。
【００７３】
このようにして図１の把持搬送手段２０により円筒状基材１Ｄが上方向へ移行され、位置決め手段３０へ至る。位置決め手段３０は、特開平３−２８００６３号公報に記載されている位置決め手段の他、図６に示した環状の位置決め手段が好ましく用いられる。本実施例では、把持手段と位置決め手段との間に、２個分のドラム長を採用した。
【００７４】
このようにして正確に位置決めされた円筒状基材１は図６、図７に示した塗布手段４０へ移行され塗布される。４０は垂直型の塗布手段であり、スライドホッパー型、押し出し型、リングコーター型、スプレーコーター型等、円筒状基材１を積み重ねて上方又は下方に相対的に移動する事により塗布するものであれば種類を問わないが、信頼性の高い連続安定塗布が得られる事によりスライドホッパー型コーターが好ましい。この塗布手段は特開昭５８−１８９０６１号公報に詳しい。また泡ぬき口やスペーサーを用いるのが良い。また、塗布手段４０の位置の微調整の為、公知のＸ−Ｙ軸可動制御テーブル上に塗布手段を設置するのが良い。また特開平３−２１３７１号公報の如く制御手段を設けても良い。このようにして塗布組成物▲１▼ＵＣＬ−１が円筒状基材１上に塗布される。
【００７５】
塗布された円筒状基材１は乾燥手段５０に移行される。５０は乾燥手段であり、図９、図１０の如くの乾燥フード５１（５２）と、吸引式乾燥器５３とを重ねて用いても良いし、塗布液Ｌの溶媒や液膜厚に応じて乾燥フード５１（５２）のみでも良いし、吸引式乾燥器５３のみでも良い。
【００７６】
円筒状基材１は乾燥処理の後、分離排出手段６０へ移行される。分離排出手段６０としては特願平５−１２４２７０号明細書に詳しく述べられているものが良い。別のものとしては特開昭６１−１２０６６２号、同６１−１２０６６４号公報等も良い。
【００７７】
分離された円筒状基材１は排出ロボットにより収納室、乾燥室あるいは次の工程に移行される。
【００７８】
以上のように▲１▼ＵＣＬ−１が塗布される。得られたドラムをＮｏ．１−１（実施例）及び１−２（比較例）とする。比較例は把持手段と位置決め手段との間に外部把持されていないドラムが無い場合である。
【００７９】
この上に下記▲２▼ＣＧＬ−１塗布液組成物からなるＣＧＬを、ＵＣＬ−１と同様にし乾燥膜厚０．７μのＣＧＬを塗布した。
【００８０】
▲２▼ＣＧＬ−１塗布液組成物
フルオレノン型ジスアゾ顔料（ＣＧＭ−１）２５ｇ
ブチラール樹脂（エスレックＢＸ−Ｌ積水化学社製）１０ｇ
メチルエチルケトン１４３０ｍｌ
上記塗布液組成物（固形分については固形分重量比ＣＧＭ−１：ＢＸ−Ｌ＝２：１に固定）をサンドミルを用いて２０時間分散したもの。
【００８１】
【化１】

【００８２】
更にこの上に下記▲３▼ＣＴＬ−１塗布液組成物を上記ＵＣＬ−１と同様に２６μになるように塗布した。
【００８３】
▲３▼ＣＴＬ−１塗布液組成物
ＣＴＭ−１５００ｇ
ポリカーボネート（Ｚ−２００三菱瓦斯化学社製）５６０ｇ
１，２−ジクロロエタン２８００ｍｌ
固形分については固形分重量比ＣＴＭ−１：Ｚ−２００＝０．８９：１に固定。
【００８４】
【化２】

【００８５】
得られた感光体ドラムの膜厚変動は中央部のＤ₀／２（Ｄ₀＝ドラム長）以内の部分に於いても、±０．５５μ以内であった。これに反し比較例のドラムは位置決め手段の入口でぶつかりキズを生じた。このように垂直型塗布機は振動に対し極めて敏感に作用する。
【００８６】
得られた感光体ドラムをコニカ社製Ｕ−ＢＩＸ３０３５複写機で、１０本目と１０００本目のドラムについて実写したところ、１０００コピー後の画像を評価をしたところ両者の差は無く、濃淡ムラ、カブリムラや画像欠陥（黒ポチ、白ポチ、ゴミ、スジ、キズ）等がなく良好であった。比較例ドラムＮｏ．１−２では、衝突キズによる画像欠陥が多発している。
【００８７】
このように外部把持されていない円筒状基材１が最上部の把持手段２１（外部チャック）から位置決め手段３０まで２個長設けることにより、主として接合、把持、塗布、分離の際に生ずる振動、衝撃による塗布ムラ、膜厚ムラ、キズ、ゴミ、ドラム損傷等の塗膜欠陥がなく、塗布性の良好な塗布ドラムが得られた。しかも長時間、多数本の安定な連続塗布や完全自動化ができるため、ホコリ、ゴミ等が混入せず高品質の製品が可能となった。
【００８８】
この理由としては、たとえ外部把持や位置決めを注意深く行ったとしても、円筒状基材の寸法のバラツキのため、垂直に搬送できず少し傾きのあるものがあったり、最上部の把持手段（外部チャック）から位置決め手段３０まで外部把持されてないドラムが無い時は、位置決め手段と衝突したり、柔らかいアルミニウム製円筒状基材自体や円筒状基材間の接続部Ｋで振動が吸収されず、塗布時振動が残り塗布ムラ、段ムラ等を生じる。
【００８９】
以上のように本発明の各手段１０，２０，３０，４０，５０，６０を設置することにより、塗布ムラ、膜厚ムラ、キズ、ゴミ、ドラム損傷等の塗膜欠陥がなく、塗布性の良好な塗布ドラムが得られた。しかも長時間、多数本の安定な連続塗布や完全自動化ができるため、ホコリ、ゴミ等が混入せず高品質の製品が可能となった。
【００９０】
実施例２
図２の逐次連続塗布装置を用い、鏡面加工を施した直径８０ｍｍ、高さ３５５ｍｍ、２８３ｇのアルミニウムドラム支持体上に、下記の如く各々塗布液組成物▲１▼ＵＣＬ−１（３．０Ｗ／Ｖ％ポリマー濃度）、▲２▼ＣＧＬ−１、▲３▼ＣＴＬ−１を調整し、第一のスライドホッパー型塗布装置４０Ａ（▲１▼ＵＣＬ−１用）、第二の塗布装置４０Ｂ（▲２▼ＣＧＬ−１用）、第三の塗布装置４０Ｃ（▲３▼ＣＴＬ−１用）にて実施例１と同様にして３層の逐次重層塗布を行った。なお、乾燥膜厚としてはＵＣＬ−１は０．３μｍ、ＣＧＬ−２は０．５μｍ、ＣＴＬ−１は２７μｍとした。また、本逐次塗布の場合、把持手段２１と位置決め手段３０との間に存在する円筒状基材の数を３本とした（図８（ａ）参照）。
【００９１】
▲１▼ＵＣＬ−１塗布液組成物
共重合ナイロン樹脂（ＣＭ−８０００東レ社製）３ｇ
メタノール／ｎ−ブタノール＝１０／１（Ｖｏｌ比）１０００ｍｌ
▲２▼ＣＧＬ−２塗布液組成物
ペリレン顔料（ＣＧＭ−２）５００ｇ
ブチラール樹脂（エスレックＢＸ−Ｌ積水化学社製）５００ｇ
メチルエチルケトン２４０００ｍｌ
上記塗布液組成物（固形分については固形分重量比ＣＧＭ−２：ＢＸ−Ｌ＝２：１に固定）をサンドミルを用いて２０時間分散したもの。
【００９２】
【化３】

【００９３】
▲３▼ＣＴＬ−１塗布液組成物
ＣＴＭ−１（前記化２と同じ）５００ｇ
ポリカーボネート（Ｚ−２００三菱瓦斯化学社製）５６０ｇ
１，２−ジクロロエタン２８００ｍｌ
固形分については固形分重量比ＣＴＭ−１：Ｚ−２００＝０．８９：１に固定得られた感光体ドラムの膜厚変動は中央部のＤ₀／２（Ｄ₀＝ドラム長）以内の部分に於いては、±０．６４μ以内であった。
【００９４】
得られた感光体をコニカ社製Ｕ−ＢＩＸ３０３５複写機で、１０本目と１０００本目のドラムについて実写したところ、１０００コピー後の画像を評価をしたところ両者の差は無く、濃淡ムラ、カブリムラや画像欠陥（黒ポチ、白ポチ、ゴミ、スジ、キズ）等がなく良好であった。
【００９５】
【発明の効果】
本発明の第１発明の連続塗布装置及び第２発明の連続塗布方法によるときは、円筒状基材の供給、把持搬送、位置決め、塗布、乾燥、分離排出の各手段を連続配置して、上記手段の各工程を連続処理することを可能にするもであるから、以下の優れた効果を奏する。
【００９６】
（１）円筒状基材上に形成された塗膜が均一であり、塗布ムラや塗膜欠陥がなく塗布性が良好である。
【００９７】
（２）円筒状基材の把持搬送性能をが高く、長期安定塗布ができる。
【００９８】
（３）円筒状基材の変形や損傷を受けることなく確実に保持できる。
【００９９】
（４）連続安定生産が可能となり、生産性が向上する。
【０１００】
（５）連続かつ完全自動化が達成されたからゴミやほこり等の異物が混入せず高品質な製品が得られる。
【０１０１】
（６）円筒状基材の把持時に振動が発生しても、塗布手段に振動が伝わることを防止することにより、塗布ムラや膜厚変動等の塗膜欠陥がなく、塗布性ガ向上する。
【図面の簡単な説明】
【図１】本発明による連続塗布装置の全体構成を示す斜視図。
【図２】本発明による連続塗布装置の他の実施例を示す斜視図。
【図３】把持搬送手段の正面図。
【図４】上記把持搬送手段の把持手段の斜視図。
【図５】上記把持搬送手段の把持手段の他の実施例を示す斜視図。
【図６】位置決め手段と塗布手段とを示す断面図。
【図７】上記塗布手段の斜視図。
【図８】本発明による把持搬送手段と位置決め手段の相対位置関係を示す断面図。
【図９】上記塗布手段と乾燥フードとを示す断面図。
【図１０】乾燥フードの他の実施例を示す断面図。
【図１１】乾燥器の断面図。
【図１２】乾燥手段の他の実施例としての排気乾燥装置の断面図。
【図１３】分離排出手段による分離過程を示す状態図。
【符号の説明】
１，１Ａ，１Ｂ，１Ｃ，１Ｄ，１Ｅ円筒状基材（導電性支持体）
１０供給手段
２０把持搬送手段
２１，２２把持手段
３０位置決め手段
４０，４０Ａ，４０Ｂ，４０Ｃ塗布手段
４１塗布ヘッド（コーター、ホッパー塗布面）
５０乾燥手段
５１，５２乾燥フード
５３乾燥器
５４排気乾燥装置
６０分離排出手段（分離器）
Ｄ₀ 円筒状基材の長さ（ドラム長）
Ｄ１，Ｄ２把持手段と位置決め手段間の間隔
Ｋ，Ｋ１，Ｋ２接続部（繋ぎ部）
Ｌ塗布液（感光液）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vertical coating apparatus and method for continuously coating a coating liquid on a plurality of cylindrical base material outer peripheral surfaces, and in particular, continuous feeding, transporting, positioning, coating, drying and unloading of the cylindrical base material. The present invention relates to a coating apparatus and a continuous coating method.
[0002]
[Prior art]
Various methods such as spray coating, dip coating, blade coating, roll coating, etc. have been studied in relation to uniform coating with a thin film on the outer surface of a cylindrical substrate having a continuous surface formed in an endless manner. ing. In particular, for a uniform coating with a thin film such as an electrophotographic photosensitive drum, studies are being made to develop a coating apparatus having excellent productivity. However, the conventional coating apparatus and coating method for a cylindrical substrate having a continuous surface formed endlessly have disadvantages such that a uniform coating film cannot be obtained and productivity is poor.
[0003]
In the spray coating method, since the solvent evaporates before the coating droplets ejected from the spray gun reach the outer peripheral surface of the cylindrical substrate having a continuous surface formed endlessly, the solid content concentration of the coating droplets When the viscosity of the coated droplet rises and the droplet reaches the surface, the droplet does not spread sufficiently on the surface, or the particles that have dried and solidified Therefore, it is difficult to obtain a coating with a smooth surface. In addition, it is very difficult to control the film thickness because the arrival rate of the liquid droplets on the cylindrical substrate having the continuous surface is not 100%, and there is a loss of coating liquid or is partially non-uniform. . Furthermore, stringing may occur in a polymer solution or the like, so that there are limitations on the solvent and resin used.
[0004]
In the blade coating method and the roll coating method, for example, a blade or a roll is arranged in the length direction of the cylindrical base material, the cylindrical base material is rotated, coating is performed, and the cylindrical base material is rotated once. The roll is retracted. However, when the blade or roll is retracted, there is a disadvantage that a part of the coating film thickness is thicker than the other part due to the viscosity of the coating liquid, and a uniform coating film cannot be obtained.
[0005]
In the dip coating method, the smoothness of the coating liquid surface and the poor uniformity of the coating film as described above are improved.
[0006]
However, the control of the coating film thickness is governed by the coating liquid properties such as viscosity, surface tension, density, temperature, and coating speed, and adjustment of the coating liquid properties is very important. Also, the coating speed is low, and a liquid amount of a certain amount or more is necessary to fill the coating liquid tank. In the case of further layering, there are disadvantages such that the lower layer components are dissolved and the coating solution tank is easily contaminated.
[0007]
Therefore, as described in Japanese Patent Application Laid-Open No. 58-189061, a circular amount regulating type coating device (including a slide hopper type coating device) has been developed. This slide hopper type coating device encircles the circumference of a cylindrical base material having a continuous peripheral surface formed endlessly while continuously moving in the longitudinal direction of the cylindrical base material. A coating liquid is applied, and the coating apparatus further includes an annular coating liquid reservoir chamber, a supply port for supplying the coating liquid from the outside to a part of the coating liquid reservoir chamber, and the coating liquid reservoir chamber A coating liquid distribution slit that opens inward, and the coating liquid that has flowed out of the slit is allowed to flow down on the coating liquid slide surface that is inclined obliquely downward. A bead is formed in a slight gap with the base material, and is applied to the outer peripheral surface as the cylindrical base material moves. By using this slide hopper type coating apparatus, coating can be performed with a small amount of liquid, the coating liquid is not contaminated, and high productivity and easy film thickness control can be achieved.
[0008]
Incidentally, means for gripping and transporting the outer peripheral surface of the cylindrical base material are disclosed in JP-A-3-21371 and JP-A-4-53955, and positioning means are disclosed in JP-A-3-274568 and JP-A-3-280063. Further, drying means are disclosed in JP-A-6-308747 and JP-A-7-64306, respectively.
[0009]
[Problems to be solved by the invention]
However, the use of the slide hopper type coating apparatus is still unsatisfactory due to various problems.
[0010]
The present invention has been proposed in order to solve the conventional problems.
(A) The coating film by the used coating liquid is uniform, and there are no coating film defects such as coating unevenness and film thickness fluctuation, thereby improving coating properties.
[0011]
(B) Improves gripping and conveying performance of the cylindrical base material and enables long-term stable application.
[0012]
(C) Stabilize the gripping and conveying performance of the cylindrical base material and prevent deformation and damage of the cylindrical base material.
[0013]
(D) Productivity is improved by making the production process of supplying, transporting, positioning, coating, drying and unloading the cylindrical base material continuous and stable.
[0014]
(E) By continuously and fully automating the above steps, foreign matter such as dust and dust is prevented from being mixed, and a high-quality product is obtained.
[0015]
(F) Even if vibration is generated during gripping of the cylindrical base material, by preventing the vibration from being transmitted to the coating means, there are no coating film defects such as coating unevenness and film thickness fluctuation, and coating properties are improved.
[0016]
It is an object of the present invention to provide an excellent continuous coating apparatus and a continuous coating method that achieve the above effects.
[0017]
[Means for Solving the Problems]
(1) The continuous coating apparatus of the present invention is formed by aligning the cylindrical axes of the cylindrical base material and stacking the coating liquid on the outer peripheral surface of the cylindrical base material while vertically pushing up the ring of the annular coating apparatus from bottom to top. Coating means for continuously coating the coating means, supply means for supplying the cylindrical base material to the coating means, gripping and transport means for transporting the cylindrical base material while correcting and stacking the cylindrical base material, and the annular coating device Positioning means for aligning the center of the cylindrical base material with the center of the ring, means for drying or drying adjustment of the coated cylindrical base material, and separation and discharge means for taking out the cylindrical base material after the application In the continuous coating apparatus provided, when the positioning unit is operating , at least one cylindrical base material that is not gripped by the gripping and transporting unit is present between the positioning unit and the gripping and transporting unit. thing (Invention of claim 1).
[0018]
(2) In the continuous coating method of the present invention, the cylindrical base materials are aligned and stacked, and the coating liquid is applied onto the outer peripheral surface of the cylindrical base material while vertically pushing up the ring of the annular coating device from bottom to top. Coating means for continuously coating the coating means, supply means for supplying the cylindrical base material to the coating means, gripping and transport means for transporting the cylindrical base material while correcting and stacking the cylindrical base material, and the annular coating device Positioning means for aligning the center of the cylindrical base material with an annular center, means for drying or drying adjustment of the coated cylindrical base material, and separation / discharge means for taking out the cylindrical base material after being applied In the continuous coating method to be applied, when the positioning means is operating , at least one cylindrical base material not gripped by the gripping and transporting means is present between the positioning means and the gripping and transporting means. This It is characterized by. (Invention of Claim 6).
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing the overall configuration of a continuous coating apparatus according to the present invention. In the figure, 10 is a supply means for supplying the cylindrical base material 1 to a predetermined position vertically below the coating means and pushing it upward, and 20 is a gripper for gripping the outer peripheral surface of the supplied cylindrical base material 1 and aligning the cylinder axis. Gripping and conveying means for vertically pushing up and conveying the stack from below, 30 is a positioning means for aligning the cylindrical base material 1 with the center of the annular application portion of the coating apparatus, and 40 is an outer peripheral surface of the cylindrical base material Application means for continuously applying the application liquid on the upper surface, 50 is a drying means for drying the application liquid applied on the

cylindrical substrate

1, and 60 is a plurality of stacked cylindrical shapes that have been dried and vertically conveyed. Separating and discharging means for separating and discharging one by one from the substrate.
[0020]
The continuous coating apparatus of the present invention has a configuration in which each of the above-described means is continuously arranged on the vertical center line ZZ, and fully automated production that does not require manual operation is achieved with high accuracy. That is, the supply means 10 is moved to a movable table 12 having a plurality of attachment means 11 for placing the cylindrical base material 1, and the movable table 12 is rotated and sent to a vertical line connected to the gripping and conveying means 20. Lifting means 14 for pushing up the cylindrical base material 1 already gripped and transported upward by the gripping and transporting means 20, and a cylindrical base material supply provided at the upper end of the lifting and lowering means 14. Control means for controlling the rotation by the hand means 15 and the drive means 13 and the push-up timing by the elevating means 14. The cylindrical substrate 1 is supplied onto the movable table 12 by a robot handle.
[0021]
The gripping and conveying means 20 provided above the supply means 10 has two sets of gripping

means

21 and 22 that can be pressed against and separated from the outer peripheral surface of the cylindrical base material 1 and can move vertically and vertically. The substrate 1 has a function of positioning, gripping, and transporting upward. Hereinafter, the details of each of the

means

20, 30, 40, 50, 60 will be described later.
[0022]
FIG. 2 is a perspective view showing another embodiment of the continuous coating apparatus according to the present invention. In this embodiment, a plurality of sets of units A, B, and C each including a positioning unit 30, a coating unit 40, and a drying unit 50 are arranged on a vertical center line ZZ above the gripping and conveying unit 20. The separation and discharge means 60 is disposed on the uppermost stage. The coating liquid discharged from each of the coating means 40A, 40B, and 40C sequentially forms a multilayer coating layer on the cylindrical substrate 1.
[0023]
FIG. 3 is a front view of the gripping and conveying means 20. Ball screws 24 A and 24 B supported vertically in the vertical direction are provided inside a pair of conveying device bodies 23 A and 23 B that face each other. The ball screws 24A and 24B are rotated forward and backward by driving

motors

25A and 25B, respectively. The elevating

members

26A and 26B screwed into the ball screws 24A and 24B move up and down linearly by forward and reverse rotation of the ball screws 24A and 24B.

Arm members

27A and 27B are fixed to the elevating

members

26A and 26B, respectively, and the gripping

means

21 and 22 are attached to the respective tip portions.
[0024]
The lifting / lowering means 14 is installed between the transfer apparatus

main bodies

23A and 23B, and a cylindrical base material supplying hand means 15 is attached to the upper end of the lifting / lowering means 14.

Cylindrical base materials

1D, 1C, 1B, and 1A are sequentially stacked on the upper side of the hand means 15. The uppermost cylindrical substrate 1A is separated and taken out by the discharge hand 61 of the separation and discharge means 60.
[0025]
The application means 40 is fixed on the positioning means 30, and the positioning means 30 is held by a holding means (not shown). The positioning means 30 is a device that accurately holds the cylindrical base material 1 at a predetermined position, and is held in a non-contact manner by, for example, an air bearing. The coating means 40 uniformly coats the coating liquid on the outer peripheral surface of the cylindrical substrate 1 (1A, 1B, 1C, 1D), and the

cylindrical substrates

1A, 1B, 1C, 1D A coating film is sequentially formed on the

cylindrical base materials

1A, 1B, 1C, and 1D as it is gripped and conveyed by the cylinder 20.
[0026]
FIG. 4 is a perspective view of the gripping

means

21, 22. The upper gripping means 21 includes two

movable handles

211 and 212, a support shaft 213 that fits and swingably holds in each swinging center hole of the

movable grips

211 and 212, and the movable handle 211. , 212 are formed from V-shaped

hand portions

214, 215 formed at the respective tip portions, and grippers 216 fixed inside. By opening and closing the

movable grips

211 and 212 by a driving means such as a piston cylinder (not shown), the gripper 216 is brought into contact with and separated from the outer peripheral surface of the cylindrical base material. The illustrated gripper 216 is in pressure contact with the cylindrical substrate 1 at four or three locations.
[0027]
The lower gripping means 22 has the same configuration as the upper gripping means 21, 221 and 222 are movable handles, 223 are support shafts, 224 and 225 are hand portions, and 226 is a gripper. Note that the upper gripping means 21 indicates a state where the outer peripheral surfaces of the connection positions of the

cylindrical base materials

1B and 1C are gripped, and the lower gripping means 22 indicates each of the connection positions of the

cylindrical base materials

1C and 1D. The state separated from the outer peripheral surface is shown.
[0028]
The gripper 216 of the gripping means 21 on the upper side preferably grips the outer peripheral surface in the vicinity of the connecting portion (connecting portion) K1 between the end surfaces of the illustrated

cylindrical base materials

1B and 1C. Moreover, it is preferable that the gripping element 226 of the lower-side gripping means 22 grips the outer peripheral surface in the vicinity of the connecting portion (connecting portion) K2 between the end surfaces of the

cylindrical base materials

1C and 1D. The outer peripheral surface near the connecting portion K1 and the outer peripheral surface near K2 are non-image forming regions of the photosensitive drum.
[0029]
FIG. 5 is a perspective view showing another embodiment of the gripping means 21. FIG. 5 (a) has grips 280 fixed inside the V-shaped

hand portions

281 and 282, respectively, and the cylindrical base member 1 is moved forward and backward by moving the

hand portions

281 and 282, respectively. Is gripped or separated by four-point support. FIG. 5 (b) shows grippers 280 fixed inside the notched

cylindrical hand portions

283, 284, respectively, and the

hand portions

283, 284 are advanced and retracted to move the cylindrical base material 1. Is pressed against or separated from the cylindrical outer peripheral surface support. FIG. 5 (c) has grips 280 fixed inside the V-shaped hand portion 281 and the planar hand portion 285, respectively, and the

hand portions

281 and 285 are moved forward and backward, respectively. The cylindrical base material 1 is pressed and held or separated by three-point support.
[0030]
FIG. 6 is a cross-sectional view showing the positioning means 30 and the vertical application means 40, and FIG. 7 is a perspective view of the application means 40.
[0031]
As shown in FIG. 6, a plurality of

cylindrical base materials

1A and 1B (hereinafter referred to as cylindrical base material 1) superimposed vertically along the center line ZZ are continuously raised in the direction of the arrow. The coating solution (photosensitive solution) L is applied by a portion (hopper coating surface) 41 directly surrounding the coating of the slide hopper type coating means 10 on the outer peripheral surface of the cylindrical substrate 1. The cylindrical substrate 1 may be a hollow drum, for example, an aluminum drum, a plastic drum, or a seamless belt type substrate.
[0032]
On the hopper coating surface 41, a narrow coating liquid distribution slit (abbreviated as a slit) 43 having a coating liquid outlet 42 opened to the cylindrical substrate 1 side is formed in the horizontal direction. The slit 43 communicates with an annular coating liquid distribution chamber (coating liquid reservoir chamber) 44, and the coating liquid L in the storage tank 2 is fed into the annular coating liquid distribution chamber 44 via the supply pipe 4 by the pressure pump 3. It comes to supply.
[0033]
On the other hand, below the coating solution outlet 42 of the slit 43, the coating solution slide is formed so as to continuously incline and end with a dimension slightly larger than the outer diameter of the cylindrical base material 1. A surface (hereinafter referred to as a slide surface) 45 is formed. Furthermore, a lip 46 extending downward from the end of the slide surface 45 is formed.
[0034]
In the application by the application means (slide hopper type application device) 40, when the coating liquid L is pushed out from the slit 43 and allowed to flow down along the slide surface 45 in the process of pulling up the cylindrical substrate 1, the end of the slide surface 45 is reached. The coating solution that has reached is formed on the surface of the cylindrical substrate 1 after forming a bead between the end of the slide surface 45 and the outer peripheral surface of the cylindrical substrate 1.
[0035]
Since the end of the slide surface 45 and the cylindrical base material 1 are disposed with a certain gap, the cylindrical base material 1 is not applied to the cylindrical base material 1 even when it is formed in multiple layers without damaging the cylindrical base material 1. Can be applied without damaging the layer.
[0036]
On the other hand, an air vent member 46 for removing bubbles in the coating liquid distribution chamber 44 is provided in a part of the coating liquid distribution chamber 44 at a position farthest from the coating liquid supply portion of the pressure feed pump 3. When the coating liquid L in the storage tank 2 is supplied to the coating liquid distribution chamber 44 and supplied from the coating liquid distribution slit 43 to the coating liquid outlet 42, the on-off valve 47 is opened and the coating liquid distribution chamber 44 is opened from the air vent member 46. The air inside is exhausted.
[0037]
Positioning means 30 for positioning the circumferential direction of the cylindrical base material is fixed to the lower portion of the slide hopper type coating device 40. A plurality of air supply ports 32 and a plurality of exhaust ports 33 are formed in the main body 31 of the positioning device 30 for the cylindrical base material 1. The plurality of air supply ports 32 are connected to an air supply pump (not shown), and fluid such as air is pumped. A discharge port 34 passes through one end of the air supply port 32 that faces the outer peripheral surface of the cylindrical base material 1. The discharge port 34 faces the outer peripheral surface of the cylindrical base material 1 with a predetermined gap. The gap is 20 μm to 3 mm, preferably 30 μm to 2 mm. When this gap is smaller than 20 μm, the cylindrical base material 1 is likely to be damaged by coming into contact with the inner wall of the main body 31 by slight vibration of the cylindrical base material 1. Further, when the gap is larger than 3 mm, the positioning accuracy of the cylindrical base material 1 is lowered. The discharge port 34 is a nozzle having a small diameter of 0.01 to 1.0 mm, and preferably 0.05 to 0.5 mm.
[0038]
The inner peripheral surface of the lower part of the inner wall of the main body 31 is a tapered surface 35 having an entrance side widened. The tapered surface 35 is, for example, a conical surface having an axial length of 50 mm and a one-side inclination angle of 0.5 mm. By providing the tapered surface 35, when the cylindrical base material 1 enters the inner wall of the main body 31, the tip of the cylindrical base material 1 is prevented from coming into contact with the inner peripheral surface of the inner wall.
[0039]
The fluid pumped from the air supply pump is introduced into the main body 31 from the plurality of air supply ports 32 and discharged from the plurality of discharge ports 34, and is uniform with the outer peripheral surface of the cylindrical substrate 1A (1B). A fluid film layer is formed. The discharged fluid is discharged from the plurality of exhaust ports 33 to the outside of the apparatus.
[0040]
The discharge port 34 has an opening diameter of 0.01 to 1 mm, preferably 0.05 to 0.5 mm, for example 0.2 to 0.5 mm. The opening diameter of the exhaust port 33 is 1.0 to 10 mm, preferably 2.0 to 8.0 mm, for example, 3 to 5 mm.
[0041]
The fluid supplied to the air supply port 32 is preferably air or an inert gas such as nitrogen gas. The fluid is preferably a clean gas of class 100 or higher according to JIS standards.
[0042]
In addition, various apparatuses, such as a slide hopper type | mold, an extrusion type | mold, a ring coater, are used as a perpendicular | vertical coating apparatus connected to the positioning apparatus of this invention.
[0043]
FIG. 8 is a sectional view showing the relative positional relationship between the gripping and conveying means 20 and the positioning means 30 according to the present invention.
[0044]
FIG. 8 (a) shows that the upper gripping means 21 having grips 216 fixed inside the two

hand portions

214 and 215 is connected to the end portion of the

cylindrical base materials

1D and 1E. (Part) The state which hold | gripped the outer peripheral surface of K vicinity is shown. Further, the lower gripping means 22 having gripping elements 226 fixed inside the two

hand portions

224 and 225 are on standby to grip the outer peripheral surface near the lower end of the cylindrical base material 1E.
[0045]
The cylindrical base material 1C is placed on the upper end surface of the cylindrical base material 1D gripped by the upper gripping means 21, and the

cylindrical base materials

1B and 1A are placed under its own weight on the upper side. Yes. The upper end side of the cylindrical base material 1C placed on the cylindrical base material 1D gripped by the gripping means 21 has not yet entered the positioning means 30, and the cylindrical surface has The external force is not applied.
[0046]
Wherein the upper surface of the gripping means 21 of the upper side of the grip transport unit 20, within the distance D1 of the inlet lower surface of the positioning means 30, the cylindrical substrate 1C length D ₀ that no added external force is at least 1 There are.
[0047]
The cylindrical substrate 1B is positioned by a ring-shaped positioning means 30 having a fluid discharge port. Usually, it is extremely difficult to always match the center of gripping with the center of positioning (due to variations in drum dimensions and accuracy), so by having at least one cylindrical base that is not externally gripped, It becomes easy to correct the positioning means.
[0048]
The vibration transmitted from the gripped cylindrical base material 1D due to vibration generated when gripping and releasing the grip by the grip means 21 on the upper stage side or when driving up and down is applied to the cylindrical base material 1C to which the external force is not applied. And is not transmitted to the cylindrical substrate 1B being positioned or the cylindrical substrate 1A being applied. The cylindrical substrate 1A is coated with a coating solution by a ring-shaped coating means 40.
[0049]
FIG. 8B shows a state where the upper gripping means 21 grips the position below the connecting portion K with the cylindrical substrate 1C in the vicinity of the upper end side of the cylindrical surface of the cylindrical substrate 1D. Further, the lower holding means 22 stands by to hold the outer peripheral surface near the lower end of the cylindrical substrate 1D.
[0050]
At least one cylindrical base material (1C) having a length D ₀ to which no external force is applied is present in the distance D2 between the upper surface of the upper gripping means 21 and the lower surface of the inlet portion of the positioning means 30. . In such a cylindrical base material gripping method, vibrations transmitted from the gripped cylindrical base material 1D due to vibrations generated during gripping and releasing by the upper gripping means 21 and when driving up and down are also performed. It is absorbed by the cylindrical base material 1C to which no external force is applied and is not transmitted to the cylindrical base material 1B being positioned or the cylindrical base material 1A being applied.
[0051]
Above the coating means 40, a drying means 50 comprising a drying hood 51 and a dryer 53 is provided.
[0052]
FIG. 9 is a cross-sectional view of the coating means 40 and a drying hood 51 provided on the top of the coating means 40. The dry hood 51 has an annular wall surface, and a plurality of openings 51A are formed in the wall surface. The cylindrical substrate 1 is raised in the direction of the arrow, and the coating liquid L is applied by the hopper coating surface (coating head) 41 of the coating means 40 to form the photosensitive layer 5. The photosensitive layer 5 formed on the cylindrical substrate 1 is gradually dried while passing through the drying hood 51. This drying is performed by releasing the solvent contained in the coating liquid L out of the wall surface through the multiple openings 51A.
[0053]
As described above, the coating layer L is coated on the cylindrical substrate 1 by the coating means 40, and the formed photosensitive layer 5 is surrounded by the drying hood 51 immediately after coating, and the solvent is formed only from the opening 51A. Therefore, the drying speed of the photosensitive layer 5 immediately after coating is substantially proportional to the opening area of the opening 51A.
[0054]
FIG. 10 is a cross-sectional view showing another embodiment of the dry hood. The dry hood 52 is formed by extending the upper part of the dry hood 51 (A part) in FIG. 9 to form a B part. A plurality of 52A are formed in the A portion, and a plurality of 52B are formed in the B portion. By providing this dry hood 52 on the upper part of the coating means 40, the solvent vapor concentration of the coating liquid L applied on the outer peripheral surface of the cylindrical substrate 1 is controlled. Therefore, it is possible to make the coating film uniform by controlling the coating film drying speed. Further, by providing the drying hood 52 as described above, the solvent vapor concentration in the bead portion is increased, so that rapid drying can be prevented and bead breakage can be prevented.
[0055]
FIG. 11 shows a cross-sectional view of the dryer 53 of the present invention. In the dryer 53, a cylindrical member 535 and a cylindrical member 536 are concentrically coupled to a lower portion of a suction slit member 534 having a suction slit 531, a suction chamber 532, and a suction nozzle 533, respectively.
[0056]
Then, suction is performed from a plurality of suction nozzles 533, suction air that has been made uniform in the circumferential direction by a suction chamber 532 that is uniform in the circumferential direction, and a suction slit 531 that is uniform in the circumferential direction flows, and further, a suction slit member 534, The turbulence of the air flow between the inner diameter surfaces of the upper and lower

cylindrical members

536 and 535 and the outer peripheral surface of the coated cylindrical base material 1 is suppressed by the buffer space 537, and the drying process shown in 538 is performed. The air flow of uniform suction air is created.
[0057]
The coated film is dried by conveying the coated cylindrical substrate 1 in the direction indicated by the arrow to the drying zone.
[0058]
Next, an exhaust drying apparatus 54 shown in FIG. 12 will be described as another embodiment of the drying means 50. As described above, the coating solution (photosensitive solution) L is applied to the

cylindrical substrates

1A and 1B by the annular slide hopper type coating device 40, thereby forming the photosensitive layer LA. The exhaust drying device 54 sucks the solvent evaporated from the photosensitive layer LA immediately after coating, and further performs drying, and is provided immediately above the coating device 40. Reference numeral 541 denotes an annular suction duct, and a suction port 542 is formed from the suction duct 541 toward the photosensitive layer LA. An exhaust pipe 543 is connected to a part of the suction duct 541, and the solvent evaporating from the photosensitive layer LA is sucked by an exhaust fan 544 provided in the exhaust pipe 543, forcibly discharged outside and dried. .
[0059]
As described above, immediately after the photosensitive solution L is applied by the coating device 40, a large amount of the photosensitive solution L applied to the

cylindrical substrates

1A and 1B flows down to exhaust the solvent vapor generated from the photosensitive solution L. Can be stopped. At this time, the exhaust air velocity by the exhaust fan 544 is 0.5 to 5 m / sec, and the suction port 542 is preferably 300 mm or less from the position of the coating head 41. The

cylindrical substrates

1A and 1B are kept in a connected state until the solvent in the photosensitive solution L evaporates by 30% or more, and after separation, the photosensitive layer LA is completely dried. By operating the exhaust dryer 54 as described above, even when a large number of cylindrical substrates are connected and the photosensitive solution L is applied, the solvent can be rapidly discharged from the vicinity of the photosensitive layer LA, and coating with the photosensitive solution L can be performed. It is also possible to prevent the occurrence of the thin film and liquid pool generated in the photosensitive layer LA by forcibly controlling the flow of the film. The exhaust fan 544 may be provided at a plurality of locations in the suction duct 541.
[0060]
A method of separating the

cylindrical substrates

1A, 1B, 1C,... That have been coated and dried as described above will be described with reference to the state diagrams of the individual separation processes in FIG.
[0061]
The separation / discharge unit 60 includes a vertical moving robot stage 61, an air cylinder 62, an upper chuck 63 and a lower chuck 64.
[0062]
The coated cylindrical substrate 1 is stacked upward from below, moves upward, and reaches a separation position as shown in FIG. At this time, the vertical robot is activated to move the entire separation unit that is coaxial with the cylindrical substrate 1A to be separated at the same speed.
[0063]
First, the lower chuck 64 holds the cylindrical substrate 1B adjacent to the cylindrical substrate 1A to be separated at the position shown in FIG. Next, the upper chuck 63 holds the cylindrical substrate 1A to be separated at the position shown in FIG.
[0064]
With the air cylinder 62, the upper chuck 63 moves upward while holding the cylindrical substrate 1A to be separated, and reaches the position shown in FIG. At this time, the coating film straddling the cylindrical substrate 1B adjacent to the cylindrical substrate 1A to be separated is torn, and 1A and 1B are separated as shown in FIG. 13 (d).
[0065]
In order to recover the separated cylindrical substrate 1A, the lower chuck 64 is in an unchucked state as shown in FIG. 13E, and the vertical moving robot stage 61 is rapidly raised, far above the position of the adjacent cylindrical substrate 1B. The separated cylindrical base body 1A is placed on the separation drum collection device arranged in (the upper chuck 63 becomes an unchuck), and the process is completed.
[0066]
Then, for the next separation operation of the cylindrical substrate 1B, the vertical moving robot stage 61 is lowered, and the air cylinder 62 is lowered to return to the initial position diagram 13 (a).
[0067]
In addition, a method of pulling up the cylindrical substrate 1A while rotating the separated cylindrical substrate 1A when separating the separated cylindrical substrate 1A and the adjacent cylindrical substrate 1B is also effective. This applies not a tensile force but a shearing force to the separated film, and the phenomenon that the coating film profile in the vicinity of the separation part becomes thin can be reduced in the wet film. Further, scattering of small pieces of the film generated when the coating film is cut is reduced by being drawn into the inner surface of the cylindrical substrate 1.
[0068]
[Example]
Next, the present invention will be described with reference to specific examples, but the present invention is not limited thereto.
[0069]
Example 1
As the conductive support (cylindrical base material) 1, a mirror-finished aluminum drum support having a diameter of 80 mm, a height of 355 mm, and 283 g was used. As the coating liquid L, (1) UCL-1 coating liquid composition described below was used.
[0070]
(1) UCL-1 coating composition (3.0 W / V% polymer concentration)
Copolymer nylon resin (CM-8000, manufactured by Toray Industries, Inc.) 3g
Methanol / n-butanol = 10/1 (Vol ratio) 1000 ml
The continuous coating process of the cylindrical substrate 1 will be described with reference to FIG. The cylindrical substrate 1 is placed at a position 1F of the cylindrical substrate 1 on the movable table 12 from the cylindrical substrate 1 (aluminum drum) storage chamber by a supply robot (not shown). The cylindrical base material 1F reaches the position 1E by the rotation of the movable table 11 in the arrow direction. At this time, the supply arm of the lifting / lowering means 14 pushes up the cylindrical base material 1 E upward from below and is supplied to the position of the hand means 15. Preferably, the shock absorbing mechanism acts simultaneously with completion of the push-up by the supply arm, and the shock at the time of joining the lower end of the preceding cylindrical base 1D and the upper end of the subsequent cylindrical base 1E is eliminated. In this way, the

cylindrical base materials

1E and 1F are sequentially carried to the gripping and conveying means 20.
[0071]
The cylindrical substrate 1D is gripped by the

movable handles

21 and 22 and conveyed upward. The place to be gripped may be any place as long as the cylindrical base material 1D is not adversely affected. However, the gripping portion (connection part) K between the

cylindrical base materials

1D and 1C is held between the

cylindrical base materials

1D and 1C. In order to prevent the occurrence of scratches and malfunctions, the non-image of the connecting portion K is preferable because the step is corrected to a certain extent and is held with a strong force against the total weight of the cylindrical base material 1C stacked thereon. It is better to grip the part.
[0072]
For the gripping and conveying means 20, refer to the description section of FIGS.
[0073]
In this way, the cylindrical substrate 1D is moved upward by the gripping and conveying means 20 of FIG. As the positioning means 30, in addition to the positioning means described in JP-A-3-280063, the annular positioning means shown in FIG. 6 is preferably used. In this embodiment, two drum lengths are employed between the gripping means and the positioning means.
[0074]
The cylindrical base material 1 accurately positioned in this way is transferred to the application means 40 shown in FIGS. 6 and 7 and applied. Reference numeral 40 denotes a vertical application means, such as a slide hopper type, an extrusion type, a ring coater type, or a spray coater type, which is applied by stacking the cylindrical base materials 1 and moving them relatively upward or downward. Any type of slide hopper type coater is preferable because it provides a highly reliable continuous stable coating. This coating means is detailed in Japanese Patent Application Laid-Open No. 58-189061. It is preferable to use a bubble opening or a spacer. Further, for fine adjustment of the position of the coating means 40, it is preferable to install the coating means on a known XY axis movable control table. Further, a control means may be provided as disclosed in JP-A-3-21371. In this way, the coating composition {circle around (1)} UCL-1 is applied onto the cylindrical substrate 1.
[0075]
The coated cylindrical substrate 1 is transferred to the drying means 50. Reference numeral 50 denotes a drying means, and a drying hood 51 (52) as shown in FIGS. 9 and 10 and a suction dryer 53 may be used in an overlapping manner, or depending on the solvent and liquid film thickness of the coating liquid L. Only the drying hood 51 (52) may be used, or only the suction dryer 53 may be used.
[0076]
The cylindrical substrate 1 is transferred to the separation and discharge means 60 after the drying process. As the separation and discharge means 60, those described in detail in Japanese Patent Application No. 5-124270 are preferable. As another example, JP-A-61-120662 and JP-A-61-120664 may be used.
[0077]
The separated cylindrical base material 1 is transferred to a storage room, a drying room or the next process by a discharge robot.
[0078]
(1) UCL-1 is applied as described above. The obtained drum was No. It shall be 1-1 (Example) and 1-2 (Comparative example). In the comparative example, there is no drum that is not externally gripped between the gripping means and the positioning means.
[0079]
On top of this, CGL comprising the following (2) CGL-1 coating solution composition was applied in the same manner as UCL-1, with a dry film thickness of 0.7 μm.
[0080]
(2) CGL-1 coating solution composition fluorenone type disazo pigment (CGM-1) 25 g
Butyral resin (S-REC BX-L manufactured by Sekisui Chemical Co., Ltd.) 10g
Methyl ethyl ketone 1430ml
A composition obtained by dispersing the coating composition (solid content: solid content weight ratio CGM-1: BX-L = 2: 1) using a sand mill for 20 hours.
[0081]
[Chemical 1]

[0082]
Further, the following (3) CTL-1 coating solution composition was coated on the coating so as to have a thickness of 26 μm as in the case of UCL-1.
[0083]
(3) CTL-1 coating liquid composition CTM-1 500 g
Polycarbonate (Z-200 manufactured by Mitsubishi Gas Chemical Company) 560 g
1,2-dichloroethane 2800ml
About solid content, solid content weight ratio CTM-1: Z-200 = 0.89: 1 is fixed.
[0084]
[Chemical formula 2]

[0085]
Thickness variation of the resulting photosensitive drum even in a portion within D of the central portion _{_0/2} (D ₀ = drum length) was within ± 0.55. On the other hand, the drum of the comparative example collided at the entrance of the positioning means and was scratched. As described above, the vertical coater is extremely sensitive to vibration.
[0086]
The obtained photoconductor drum was photographed on the 10th and 1000th drums with a U-BIX 3035 copier manufactured by Konica, and the image after 1000 copies was evaluated. And image defects (black spots, white spots, dust, streaks, scratches) and the like were good. Comparative drum No. In 1-2, image defects due to collision scratches frequently occur.
[0087]
By providing two cylindrical bases 1 that are not externally gripped from the uppermost gripping means 21 (external chuck) to the positioning means 30, vibrations that occur mainly during joining, gripping, application, and separation, A coating drum having good coating properties without coating film defects such as coating unevenness due to impact, film thickness unevenness, scratches, dust, and drum damage was obtained. In addition, since a large number of stable continuous coatings and complete automation can be performed over a long period of time, high-quality products can be produced without dust and dust.
[0088]
The reason for this is that even if external gripping and positioning are carefully performed, there are some cases where the cylindrical substrate cannot be transported vertically due to variation in dimensions, and there is a slight inclination, or the uppermost gripping means (external chuck) When there is no drum that is not gripped externally from the positioning means 30 to the positioning means 30, it collides with the positioning means, and the vibration is not absorbed by the soft aluminum cylindrical base material itself or the connecting portion K between the cylindrical base materials. Oscillations remain and cause uneven coating and unevenness of steps.
[0089]
By installing each means 10, 20, 30, 40, 50, 60 of the present invention as described above, there are no coating film defects such as coating unevenness, film thickness unevenness, scratches, dust, drum damage, and the like. A good coating drum was obtained. In addition, since a large number of stable continuous coatings and complete automation can be performed over a long period of time, high-quality products can be produced without dust and dust.
[0090]
Example 2
The coating liquid composition {circle around (1)} UCL-1 (3.0 W / w) is applied on a mirror-finished aluminum drum support having a diameter of 80 mm, a height of 355 mm, and 283 g using the sequential sequential coating apparatus shown in FIG. V% polymer concentration), (2) CGL-1, and (3) CTL-1 are adjusted, the first slide hopper type coating device 40A (1) for UCL-1 and the second coating device 40B (▲ (2) for CGL-1) and 3rd coating apparatus 40C (3) for CTL-1 were applied in the same manner as in Example 1 to apply three layers successively. The dry film thickness was 0.3 μm for UCL-1, 0.5 μm for CGL-2, and 27 μm for CTL-1. In the case of this sequential application, the number of cylindrical base materials existing between the gripping means 21 and the positioning means 30 is set to three (see FIG. 8A).
[0091]
(1) UCL-1 coating liquid composition copolymer nylon resin (CM-8000, manufactured by Toray Industries, Inc.) 3 g
Methanol / n-butanol = 10/1 (Vol ratio) 1000 ml
(2) CGL-2 coating solution composition perylene pigment (CGM-2) 500 g
Butyral resin (S-REC BX-L manufactured by Sekisui Chemical Co., Ltd.) 500g
Methyl ethyl ketone 24000ml
A composition obtained by dispersing the above coating composition (solid content: solid content weight ratio CGM-2: BX-L = 2: 1) using a sand mill for 20 hours.
[0092]
[Chemical 3]

[0093]
(3) CTL-1 coating liquid composition CTM-1 (same as the chemical formula 2) 500 g
Polycarbonate (Z-200 manufactured by Mitsubishi Gas Chemical Company) 560 g
1,2-dichloroethane 2800ml
The solids weight ratio between solids CTM-1: Z-200 = 0.89: fixed obtained photosensitive drum 1 thickness variation D _{_0/2} (D ₀ = drum length) of the central portion within the In the portion, it was within ± 0.64 μm.
[0094]
When the obtained photoconductor was photographed on the 10th and 1000th drums with a U-BIX 3035 copier manufactured by Konica, the image after 1000 copies was evaluated, and there was no difference between them. There were no image defects (black spots, white spots, dust, streaks, scratches) and the like, and it was good.
[0095]
【The invention's effect】
When the continuous coating apparatus according to the first invention of the present invention and the continuous coating method of the second invention are used, the cylindrical base material supply, gripping and conveying, positioning, coating, drying, and separating / discharging units are continuously arranged, and Since each step of the means can be continuously processed, the following excellent effects are obtained.
[0096]
(1) The coating film formed on the cylindrical substrate is uniform, and there is no coating unevenness or coating film defect, and the coating property is good.
[0097]
(2) The gripping and conveying performance of the cylindrical base material is high, and long-term stable application can be performed.
[0098]
(3) It can hold | maintain reliably, without receiving a deformation | transformation and damage of a cylindrical base material.
[0099]
(4) Continuous and stable production is possible and productivity is improved.
[0100]
(5) Since continuous and complete automation has been achieved, foreign substances such as dust and dirt are not mixed, and a high-quality product can be obtained.
[0101]
(6) Even if vibration is generated during gripping of the cylindrical base material, by preventing the vibration from being transmitted to the coating means, there is no coating film defect such as coating unevenness and film thickness variation, and coating properties are improved.
[Brief description of the drawings]
FIG. 1 is a perspective view showing the overall configuration of a continuous coating apparatus according to the present invention.
FIG. 2 is a perspective view showing another embodiment of the continuous coating apparatus according to the present invention.
FIG. 3 is a front view of gripping and conveying means.
FIG. 4 is a perspective view of the gripping means of the gripping and transporting means.
FIG. 5 is a perspective view showing another embodiment of the gripping means of the gripping and transporting means.
FIG. 6 is a cross-sectional view showing positioning means and application means.
FIG. 7 is a perspective view of the application unit.
FIG. 8 is a cross-sectional view showing the relative positional relationship between the gripping and conveying means and the positioning means according to the present invention.
FIG. 9 is a cross-sectional view showing the coating means and a drying hood.
FIG. 10 is a sectional view showing another embodiment of a dry hood.
FIG. 11 is a cross-sectional view of a dryer.
FIG. 12 is a cross-sectional view of an exhaust drying apparatus as another embodiment of the drying means.
FIG. 13 is a state diagram showing a separation process by the separation discharge means.
[Explanation of symbols]
1,1A, 1B, 1C, 1D, 1E Cylindrical base material (conductive support)
DESCRIPTION OF SYMBOLS 10 Supply means 20 Grip conveyance means 21, 22 Grip means 30 Positioning means 40, 40A, 40B, 40C Application means 41 Application head (coater, hopper application surface)
50 Drying means 51, 52 Drying hood 53 Dryer 54 Exhaust drying device 60 Separation discharge means (separator)
D ₀ Length of cylindrical substrate (drum length)
D1, D2 Distances K, K1, K2 between gripping means and positioning means
L Coating solution (photosensitive solution)

Claims

The coating means for continuously applying the coating liquid on the outer peripheral surface of the cylindrical base material while stacking the cylindrical shafts of the cylindrical base material together and vertically pushing up the ring of the annular coating device from bottom to top. Supply means for supplying a cylindrical base material to the means, gripping and transport means for transporting the cylindrical base material while correcting and stacking the cylindrical base material, and the center of the cylindrical base material at the annular center of the annular coating device In a continuous coating apparatus comprising positioning means for aligning, a means for drying or drying adjustment of the coated cylindrical base material, and a separation and discharge means for taking out the cylindrical base material after coating,
When the positioning means is operating , at least one cylindrical base material not gripped by the gripping and transporting means is present between the positioning means and the gripping and transporting means. apparatus.

The continuous coating apparatus according to claim 1, wherein the coating unit is a slide hopper type coating apparatus.

3. The continuous coating apparatus according to claim 1, wherein the positioning unit is a ring-shaped positioning device having a discharge port that sprays fluid onto an outer peripheral surface of a cylindrical base material.

The continuous coating apparatus according to claim 1, wherein the gripping and conveying unit is a device that externally grips a joint portion between cylindrical substrates.

3. The continuous coating apparatus according to claim 1, wherein there are a plurality of the coating units, and a plurality of coating layers are sequentially formed on the outer peripheral surface of the cylindrical base material.

The coating means for continuously applying the coating liquid on the outer peripheral surface of the cylindrical base material while stacking the cylindrical shafts of the cylindrical base material together and vertically pushing up the ring of the annular coating device from bottom to top. Supply means for supplying a cylindrical base material to the means, gripping and transport means for transporting the cylindrical base material while correcting and stacking the cylindrical base material, and the center of the cylindrical base material at the annular center of the annular coating device In a continuous coating method applied by positioning means for aligning, means for drying or drying adjustment of the coated cylindrical base material, and separation and discharge means for taking out the cylindrical base material after coating,
A continuous coating method characterized in that at least one cylindrical base material not gripped by the gripping and transporting means is present between the positioning means and the gripping and transporting means when the positioning means is operating. .