JP4326729B2 - Metal mold for electroforming, and method for producing seamless endless member without seam - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a seamless and flexible endless member such as a metal mold for electroforming and a photoreceptor substrate for an image forming apparatus. The present invention can be widely applied to technical fields related to electroforming.
[0002]
[Prior art]
As an example of a method for forming a photoreceptor substrate for an image forming apparatus, which is a kind of seamless endless member, by electroforming, the thickness of the cylindrical portion of the cylindrical metal matrix is plated (plated). After depositing a thin film having a thickness of 20 to 50 μm, the end is peeled and cut, and the whole is released by blowing compressed air or the like to the thin film that is in close contact therewith. In this method, an end portion of the deposited film is formed by providing a U-shaped electrical insulating portion so as to be easily peeled off, and peeling of the deposited film is started from this end portion.
[0003]
The U-shaped electrical insulating portion needs to be formed smoothly so that it does not get caught on the outer peripheral surface of the metal matrix in order to facilitate the mold release operation of the portion that becomes a seamless endless member after separation. For this reason, a groove is formed by machining or the like, and an electric insulating material is embedded in the groove.
[0004]
However, after machining the groove shape by machining or the like, the ridge line portion of the groove must be finished to be a mirror surface in order to facilitate the separation of the deposited film, which requires work time and labor. If the contour ridge line portion of the peeling start portion is poorly polished, it is difficult to peel off easily, and if the metal matrix material of the groove contour ridge portion is rough, polishing time is required. In addition, if slight scratches remain, the deposited film will be caught here and the peeling work will become difficult, and it will be forcibly peeled over time, causing damage to the metal matrix and the peeling time. It becomes a problem in terms of productivity. In order to eliminate such problems, it is easy to peel off by providing a peeling start portion without forming a groove by machining, and as a result, it is possible to prevent damage over time of the metal matrix. Productivity needs to be maintained.
[0005]
By the way, a seamless endless flexible member for an image forming apparatus includes (A) a belt-like organic photosensitive member and a conveying belt as a belt-like member, and (B) a sleeve-like developing portion (developing member as a roller-like member). There is a photosensitive drum (drum-shaped photosensitive member) as a cylindrical member.
[0006]
Regarding the image forming photoreceptor substrate (photoreceptor substrate), the following techniques (1) to (3) (manufacturing method of seamless endless flexible member) are currently being studied.
(1) In the present technology, a U-shaped electrical insulating portion is provided at both ends of the metal mold for electroforming, and the endless member deposition end portion surrounded by the electrical insulating portion is peeled and cut as a peeling start portion. A groove is formed by machining, and an electric insulating material resin is embedded therein, a one-component silicone rubber is filled therein, or an acid resistant paint is filled therein.
(2) In this technique, a groove is formed by machining, and a peeling start part is formed by filling a ceramic by a thermal spraying method, and the surface of the peeling start part is coated with a scratch-resistant film, and then the tip of the surface The range of 1 to 5 mm is used as a mirror surface to facilitate peeling of the deposited film.
(3) In this technology, the outline of the groove for forming the peeling start part is coated with a sealing agent and a thermosetting fluoroelastomer to form a pointed shape, and peeling starts with an adhesive tape. The contour line of the part forming groove is formed by machining.
[0007]
However, in the technique (1), there is a difficulty in that productivity is lowered due to the time and effort required for machining and polishing at the time of groove formation, and deterioration and damage of the electrical insulating material due to repeated use of electroforming. Also, in the technique (2), it takes time for machining and polishing, and the ceramic end of the filler is slightly deteriorated and damaged due to repeated use of the electroforming process. There is a problem of reducing productivity. Furthermore, in the technique of (3), the peeling start portion forming groove is caused by the time and labor required for machining and polishing, and the deterioration or damage of the electrical insulating material at the peeling start portion due to repeated use of the electroforming process. There is a problem in that the deposited film is caught on the outline portion of the film and the peelability is deteriorated to lower the productivity.
[0008]
[Problems to be solved by the invention]
The present invention has been made in view of the above problems, and a first object thereof is a metal capable of producing a seamless flexible endless member such as a photoreceptor substrate for an image forming apparatus with high productivity by electroforming. To provide a mother mold.
A second object of the present invention is to provide a method capable of producing a seamless endless flexible member with high productivity by electroforming by using the metal matrix.
[0009]
[Means for Solving the Problems]
According to claim 1 invention, the reduced diameter portion an outer peripheral surface which is an end portion of the cylindrical portion outer peripheral surface of a cylindrical metal master mold having a mirror-like hard chromium thin follows the surface roughness Rz0.2Myuemu, said mirror surface-like Deposition film peeling start comprising an insulating part made of an adhesive tape having a pointed cut-out part on a hard chrome thin film, and comprising a deposited film formed on the cut-out part and a dendrite formed on the deposited film It is the metal mother mold for electroforming characterized by having a part.
[0012]
The invention according to claim 2 is the pressure sensitive adhesive tape according to claim 1, wherein the base material is a polyester resin and the adhesive is an acrylic adhesive, or the base material is a fluororesin and the adhesive is a silicone adhesive. Or a metal matrix for electroforming, wherein the base material is acetate and the adhesive is an acrylic adhesive.
[0013]
The invention according to claim 3 is the metal matrix for electroforming according to any one of claims 1 and 2 , wherein the deposited film peeling start portion has a thickness of 50 μm to 200 μm.
[0014]
The invention according to claim 4 is characterized in that a seamless flexible endless member is manufactured by electroforming using the cylindrical metal matrix according to claims 1 to 3. It is a manufacturing method of an endless member.
[0015]
According to a fifth aspect of the present invention, there is provided a method for producing a seamless flexible endless member characterized in that the seamless endless flexible member produced in the fourth aspect is a photosensitive substrate for an image forming apparatus. It is.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows a configuration example of an image forming apparatus (copier) using a Carlson process, which is configured by using seamless endless members such as belts and sleeves formed by electroforming (electroforming). It is explanatory drawing shown.
[0017]
This image forming apparatus includes a belt-shaped organic photoreceptor 1 having a seamless endless member as a base, a charging unit 2, an exposure unit 3, a sleeve-like developing unit 4 as a seamless endless member, a transfer unit, and a transfer unit. 5, a belt-like conveyance unit (conveying belt) 6 that is a seamless endless flexible member, and a sleeve-like fixing unit 7 that uses the seamless seamless endless member as a base. In FIG. 1, reference numeral 1a is a belt running roller, 7a is a fixing roller, and 7b is a pressure roller.
[0018]
The use of a belt-like organic photoconductor or a transport mechanism having a seamless endless flexible member as described above provides the flexibility of arrangement of the image forming system and the advantage that the apparatus can be made compact. There is. Further, in the sleeve-like fixing mechanism using the seamless endless member as a base, since the heat capacity can be reduced, advantages such as shortening the rise time and standby time can be obtained.
[0019]
FIG. 2 is a perspective view showing the shape of a seamless endless flexible member formed by electroforming (electroforming), where (a) shows a belt and (b) shows a sleeve. A detent guide 9 is bonded and formed on the belt-shaped organic photoreceptor 1 of FIG. 1 and the transport belt 8 (or belt-shaped organic photoreceptor) of FIG. In the sleeve-like seamless endless flexible member 10 used as the sleeve-like developing part 4 and the sleeve-like fixing part 7, flanges 11 are press-fitted or bonded to both ends.
[0020]
FIG. 3 is a perspective view showing the appearance of a cylindrical metal matrix for electroforming. When manufacturing a seamless endless member having no seam by this metal mold, that is, a cylindrical photoreceptor substrate (photoreceptor drum substrate) 12 for an image forming apparatus, the central portion in the longitudinal direction shown in FIG. After a thin film having a thickness of 20 to 50 μm is deposited on the outer peripheral surface of the cylindrical portion of the conical metal mother die 30 by plating, the plated film is peeled off (released) from the mother die. Usually, this plating film is made of nickel.
[0021]
In the present invention, the metal matrix is configured as follows so that the mold release operation can be easily performed. A U-shaped groove is formed on the upper end portion 13 and the lower end portion 14 of the metal mother die 30, and an insulating material (electrical insulating material) 15 a is embedded in the groove to form peeling start portions 15 and 16. The plating film (deposited film) is peeled off from the peeling start portion and cut along dotted lines 17 and 18 which are appropriate portions of the plating film thickness (the cylindrical plating film between these dotted lines is a cylindrical photoreceptor. It becomes the product of the base.)
[0022]
The cutting from the dotted lines 17 and 18 is generally performed by mounting a cutting jig or putting a marking line in advance in a metal matrix. In the seamless endless flexible member 12 whose upper and lower ends of the cylindrical plating film are cut, compressed air is blown between the metal matrix and drops downward when the entire surface is released. Electroforming conditions are adopted. That is, electroforming is performed with a plating solution in which a compressive stress is generated in the deposited film so that a gap is formed between the outer peripheral surface of the metal matrix and the inner peripheral surface of the deposited film.
[0023]
Usually, when electroforming with nickel sulfamate solution, saccharin is added as a compressive stress generator, and the amount of addition is adjusted by the outer diameter size and surface property of the metal matrix, the nickel solution temperature and the current density. In the image forming photoreceptor substrate having a deposited film thickness of about 30 μm, the outer diameter of the metal matrix is 60 to 200 mm, and the compressive stress generator is added in the range of about 10 to 100 ppm. In a metal mold having an outer diameter of 30 to 60 mm for producing a fixing sleeve and the like, the deposited film thickness is as thick as about 50 μm, and therefore it is somewhat difficult to release the entire surface from the mold unless a compressive stress generator is added in an amount of 100 ppm or more. It becomes.
[0024]
4 (a) to 4 (c) relate to a manufacturing procedure of a metal mold for electroforming, that is, a formation procedure of a deposition film peeling start portion which is a main section of the metal mold, and (c) is manufactured. (D) is the sectional view on the aa line of (c). In this embodiment, as shown in FIG. 3, the U-shaped groove is not formed to form the peeling start portions 15 and 16 in which the insulating material is embedded, but the outer peripheral surface and the reduced diameter portion of the metal matrix are formed. After forming a mirror-like hard chrome thin film on the outer peripheral surface, a peeling start portion having a pointed shape is formed with an adhesive tape.
[0025]
More specifically, as shown in FIG. 4A, first, as shown in FIG. 4A, the outer peripheral surface of the cylindrical portion of the metal mother die (metal mother die body) and the outer peripheral surface of the reduced diameter portion 19 (this reduced diameter portion is the metal mother In the cylindrical portion of the mold, it is formed in the vicinity of the end portion on the conical portion side), and a square and specular scratch-resistant metal hard chrome surface 20 is formed. The hard chrome surface has a surface roughness Rz of 0.2 μm or less. Next, as shown in FIG. 4 (b), after adhering an adhesive tape 21 based on Teflon (fluorine resin), polyester resin or acetate having a thickness of 50 to 200 μm in this mirror surface, a pointed shape 22 Then, the insulating portion 24 is formed by cutting with a knife (in this case, a notch of the pointed shape 22 is formed), or a seal formed with the insulating portion is attached. The angle of the pointed tip 26 is, for example, 30 to 90 °. Next, as shown in FIG. 4C, the periphery 25 of the insulating portion 24 excluding the range of the pointed shape 22 is roughened with sandpaper to improve the adhesion of the deposited film. Prevents the peeling of the deposited film in the plating solution. In this way, a metal matrix is produced.
[0026]
By electroforming, a deposited film 22 a and a dendrite (dendritic protrusion) 27 having a film thickness corresponding to the area of the pointed shape 22 are formed at the tip 26 of the pointed shape 22. In the vicinity of the tip 26, the deposition temperature rises to cause a large difference in linear expansion, and the height of the dendrite 27 becomes higher than the thickness of the insulating part 50 to 200 μm, so that the deposited film 22a of the dendrite forming part adheres. The tape can be easily peeled off. For example, if a gauze is used for the peeling operation, the cloth thread is caught on the dendrite 27, so that it can be easily peeled off without using a knife or the like. Will not hurt.
[0027]
Another preferred method is as follows. That is, instead of forming the peeling start portions 15 and 16 embedded with an insulating material by performing U-shaped groove processing as shown in FIG. 3, on the outer peripheral surface of the metal matrix and the outer peripheral surface of the reduced diameter portion, A mirror-like hard chrome thin film having a surface roughness Rz of 0.2 μm or less is formed. Next, an adhesive tape with a thickness of 50 to 200 μm is applied, and a pointed shape 22 is formed by providing a notch with a predetermined shape on the adhesive tape, and the one-part RTV silicone rubber sealing agent or heat curing is formed on the pointed shape 22. An insulating part is formed by applying a type fluorine elastomer. Then, if the adhesive tape is removed and left standing or heat-treated, a peeling start portion (insulating portion) having a pointed shape in close contact with the scratch-resistant metal hard chrome mirror surface can be formed. By using this cylindrical metal mother mold, a photosensitive substrate for an image forming apparatus that is seamless and endless can be produced with high productivity by electroforming.
[0028]
【The invention's effect】
As is apparent from the above description, the present invention provides the following effects.
(1) Inventions according to claims 1, 4 and 5 When a metal matrix having a predetermined structure is produced, a deposition film peeling start portion having a pointed shape is formed on the mirror-finished surface without groove processing by an adhesive tape. If this is done, the machining cost can be reduced and the time required for polishing the deposition film peeling start portion can be reduced, and there is no difficulty in peeling the deposited film due to rough machining due to machining of the peeling start portion forming groove contour. Therefore, the scratch-resistant metal treatment is easy, the subsequent mirror polishing can be easily performed by buffing, and the film can be easily peeled off without being caught by the deposited film. Further, if the adhesive tape is brought into close contact with the mirror-finished surface, air remaining on the close contact surface can be easily eliminated, and it is difficult to peel off in the plating solution, so that it can be used with good durability. If this cylindrical metal matrix is used, a seamless endless flexible member such as a photoreceptor substrate for an image forming apparatus can be manufactured with high productivity by electroforming.
(2) Inventions according to claims 2, 4 and 5
When producing a metal matrix with a predetermined structure, the base of the adhesive tape is a polyester resin, fluororesin or acetate, and an acrylic adhesive or silicone adhesive is used as the adhesive to form the deposited film peeling start part. It is strong against contact with the electroforming liquid and can be used with good durability. By using this cylindrical metal matrix, a seamless endless member such as a photoreceptor substrate for an image forming apparatus can be used for electroforming. And can be manufactured with high productivity.
(3) Inventions according to claims 3, 4 and 5
When a metal matrix having a predetermined structure is prepared, if the film thickness of the deposited film peeling start portion formed of an adhesive tape, a one-component RTV silicone rubber, or a thermosetting fluorine-based elastomer is 50 to 200 μm, the deposited film is peeled off. It can be instantly adhered and peeled off with an adhesive tape, and by using this cylindrical metal matrix, seamless flexible endless members such as photoreceptor substrates for image forming apparatuses can be produced by electroforming. It can be manufactured with good performance.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram showing a configuration example of an image forming apparatus using a Carlson process, which is configured using a seamless endless member such as a belt and a sleeve formed by electroforming.
FIGS. 2A and 2B are perspective views showing a shape of a seamless endless flexible member formed by electroforming, where FIG. 2A shows a belt and FIG. 2B shows a sleeve.
FIG. 3 is a perspective view showing an appearance of a metal mold for electroforming according to the present invention.
4 (a) to 4 (c) are explanatory views showing a procedure for forming a deposited film peeling start portion of an electroforming metal mother die according to the present invention, and FIG. 4 (d) is an explanation of aa in FIG. 4 (c). It is sectional drawing.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Belt-shaped organic photoreceptor 1a Belt running roller 2 Charging part 3 Exposure part 4 Sleeve-shaped image development part 5 Transfer part 6 Belt-shaped conveyance part (conveyance belt)
7 Sleeve-shaped fixing portion 7a Fixing roller 7b Pressure roller 8 Conveying belt 9 Detent guide 10 Seamless endless member 11 Flange 12 Cylindrical photosensitive substrate (photosensitive drum substrate)
13 Upper end portion 14 Lower end portion 15 Peeling start portion 15a Insulating material (electrical insulating material)
16 Peeling start part 17 Dotted line 18 Dotted line 19 Reduced diameter part 20 Scratch resistant metal hard chrome surface 21 Adhesive tape 22 Pointed shape 22a Precipitation film (plating film)
23 Outline 24 Insulating part 25 Perimeter 26 Pointed tip 27 Dendrite 30 Metal matrix

Claims (5)

  A cylindrical hard matrix has a mirror-like hard chrome thin film with a surface roughness of Rz 0.2 μm or less on the outer peripheral surface of the reduced diameter portion, which is the end of the cylindrical outer peripheral surface of the cylindrical metal matrix, and a pointed shape on the mirror-like hard chrome thin film And having an insulating portion made of an adhesive tape having a cutout portion, and having a deposited film peeling start portion made of a deposited film formed on the cutout portion and a dendrite formed on the deposited film. Metal mold for electroforming. The pressure-sensitive adhesive tape has a polyester resin and a pressure-sensitive adhesive that is an acrylic adhesive, a base material that is a fluororesin and a pressure-sensitive adhesive that is a silicone-based adhesive, or a base material that is acetate and the pressure-sensitive adhesive is acrylic. The metal mold for electroforming according to claim 1, wherein the metal matrix is for electrocasting. The thickness of the said depositing film peeling start part is 50 micrometers-200 micrometers, The metal mother die for electrocasting in any one of Claims 1-2 characterized by the above-mentioned. A seamless flexible endless member is produced by electroforming using the cylindrical metal matrix according to any one of claims 1 to 3. Method. 5. The method for producing a seamless endless flexible member according to claim 4, wherein the seamless endless flexible member is a photosensitive substrate for an image forming apparatus.

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