JP4433597B2 - Method for manufacturing substrate for photosensitive drum - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a substrate for a photosensitive drum and a substrate for a photosensitive drum, and more particularly to a substrate for a photosensitive drum suitable for a photosensitive drum for preventing interference fringes, the surface of which is obtained by cutting. In particular, the present invention relates to a method for producing a photosensitive drum substrate capable of forming fine stripes more uniformly and without generating burrs, and a photosensitive drum substrate capable of producing a higher-quality photosensitive drum.
[0002]
[Prior art]
As is well known, a photosensitive drum (cylindrical electrophotographic photosensitive member) is formed by forming a photosensitive film as a photosensitive layer on the surface of a cylindrical substrate (substrate for photosensitive drum) made of aluminum or an aluminum alloy. In addition, the surface of the photosensitive drum base is usually smoothed (mirror-finished) by precision cutting with a diamond tool (bite) after cutting the surface of the drawn tube and finishing it with high shape accuracy. Or it is manufactured by applying a predetermined rough surface treatment).
[0003]
FIG. 5 is a schematic view showing a form of a cutting edge of a diamond tool used for manufacturing a conventional photosensitive drum substrate, and is a view seen from the front flank side of the chip. FIGS. 6 and 7 are enlarged photographs showing the surface state of the photoreceptor drum substrate cut by a conventional diamond cutting tool. That is, in manufacturing the above-described photosensitive drum substrate, a cutting tool with a cutting edge as shown in FIG. 5 is used, and the surface of the substrate is entirely smoothed as shown in FIGS. ing.
[0004]
For example, Japanese Patent Laid-Open No. 6-194857 discloses a “photosensitive drum substrate manufacturing method” that uses a diamond tool to finish the surface of the substrate to a surface roughness of about 0.2 to 1 μm. The cutting tool has a main cutting edge formed by a rake face and a side flank face, and a minor cutting edge formed by intersecting the rake face and the front flank face. , It is constituted by an aggregate of diamond particles. In addition, the front flank surface is formed by a polished surface having no polishing mark, and the edge of the auxiliary cutting edge is formed by cutting large irregularities of diamond particles by grinding with a grindstone.
[0005]
On the other hand, in order to improve the quality of the photosensitive drum, smoothing treatment on the surface of the substrate is extremely important. However, if the smoothness is too high, when the photosensitive drum is scanned with laser light, Interference fringes (moire) occur in the layer. Therefore, cutting is performed with a cutting tool provided with serrated irregularities on the cutting edge, and by forming fine streaks on the surface of the substrate, irregular reflection occurs on the surface of the photosensitive layer of the photosensitive drum, and interference fringes are generated. Techniques for preventing the occurrence are being studied.
[0006]
[Problems to be solved by the invention]
By the way, according to the manufacturing method as described above, the surface of the substrate obtained by cutting as shown in the circled parts in FIGS. Wrinkle-like burrs may occur. Also, if saw-shaped irregularities are provided on the cutting blade made of the aggregate of diamond particles as described above to form streaks on the surface of the substrate, variations in the depth of the streaks occur. Such variations in the streak or the occurrence of burrs in the above-described cutting work are considered to be problems peculiar to the bite constituted by the diamond particles as described above.
[0007]
That is, the cutting blade made of diamond particles as described above is obtained by sintering a large number of diamond particles and then flattening them by polishing, as shown in FIG. Particles are exposed in an irregular arrangement. Therefore, even if unevenness is imparted to the cutting edge constituted by diamond particles, the shape thereof is non-uniform, and in particular, the recesses formed between the particles vary in depth. As a result, in the manufactured photosensitive drum, interference fringes may not be sufficiently suppressed. In particular, burrs on the surface of the substrate become defects when forming the photosensitive layer and appear as image defects in the photosensitive drum.
[0008]
The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a photosensitive drum substrate suitable for a photosensitive drum that prevents interference fringes, and smoothes the surface of the raw tube by cutting. In this case, a method for producing a substrate for a photosensitive drum capable of forming fine streaks on the surface more uniformly and without generating burrs, and a uniform streak free of burrs on the surface, which is of higher quality. It is an object of the present invention to provide a photoreceptor drum substrate capable of producing a photoreceptor drum.
[0009]
[Means for Solving the Problems]
In order to solve the above-described problems, the method for manufacturing a substrate for a photosensitive drum according to the present invention has a large number of striations along a substantially circumferential direction by cutting the surface of a cylindrical base tube with a cutting tool. A method for producing a formed cylindrical substrate for a photosensitive drum , wherein the cutting blade includes a saw-shaped blade ridge composed of single crystal diamond and having continuous concavities and convexities as a cutting tool, and a convex portion of the blade ridge. The above-mentioned streak is formed by using a cutting tool having an average depth of the concave portion of 0.5 to 5 μm based on the average peak height .
[0010]
That is, in the above manufacturing method, a cylindrical substrate for a photosensitive drum on which a large number of streaks are formed is manufactured by cutting with a cutting tool. At that time, the cutting edge of the specific bite is made of single crystal diamond, has a smoother edge, and has been given a sharper predetermined uneven shape in advance, which is excellent. The sharpness can be exhibited, and fine streaks can be formed uniformly on the surface without generating burrs.
[0011]
Further, in the above manufacturing method, it is preferable that the unevenness of the cutting edge is formed from the cutting edge to the flank, and by using such a cutting tool bite, a minute amount generated during cutting is obtained. The cutting waste can be smoothly discharged by the concave portion continuous with the cutting edge flank, and the generation of burrs can be more reliably prevented.
[0012]
Furthermore, the more preferable aspect in said each manufacturing method is the range whose difference of the peak height of the convex part in a cutting blade of a bit is 0-1 micrometer, and the difference of the minimum point height of a recessed part is the range of 0-1 micrometer. Oh Ru. By setting the convex part and the concave part in the cutting edge of the cutting tool as described above, it is possible to make the cutting forces in the convex part and the concave part uniform, and to further prevent the occurrence of burrs. And the density of the convex part in the cutting edge of a cutting tool is 10-350 pieces / mm, and the striation of the arrangement | sequence which can prevent the interference fringe of a photosensitive layer more effectively can be formed in the surface of a base | substrate.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a schematic view showing the shape of a cutting edge of a diamond cutting tool used in the present invention, as viewed from the rake face side of a chip. FIG. 2 is an enlarged photograph showing irregularities formed on the flank face of the diamond cutting tool of FIG. 3 and 4 are enlarged photographs showing the surface state of the photosensitive drum substrate cut by the diamond cutting tool of FIG. In the description of the embodiments, the photoreceptor drum substrate is abbreviated as “substrate” as appropriate.
[0016]
First, a method for producing a photoreceptor drum substrate according to the present invention will be described. The production method of the present invention is a method of producing a cylindrical substrate for a photosensitive drum having a surface roughness of 0.5 to 5 μm by cutting the surface of a cylindrical base tube with a cutting tool. In the manufacturing method, a large number of striations are formed along a substantially circumferential direction by using a specific cutting tool.
[0017]
A photosensitive drum (cylindrical electrophotographic photosensitive member) is a drum having a photosensitive film formed on the surface of a substrate (cylindrical substrate), and has an outer diameter of about 15 to 300 mm depending on the electrophotographic apparatus to be applied. Is designed to be about 200 to 1100 mm. As a raw tube for manufacturing the substrate, a drawn tube made of aluminum or aluminum alloy is usually used. The thickness of the tube before finishing, which will be described later, is about 0.7 to 5 mm based on the relationship between the outer diameter and length of the photosensitive drum and the rigidity.
[0018]
In the present invention, as the cutting tool, a cutting tool is used which is made of single crystal diamond and has unevenness along the blade length. That is, a cutting tool is used in which the tip is formed in a specific shape by single crystal diamond. As a result, the surface roughness of the substrate is adjusted to 0.5 to 5 μm as described above, and a large number of striations are formed along the substantially circumferential direction. That is, a large number of striations are formed on the surface of the base so that all the streaks obtained are substantially along the circumferential direction. In the present invention, the surface roughness of the substrate is a concept including the average height difference of the uneven portions described later in the above-mentioned streak. In order to form a practical photosensitive layer, the surface roughness of the substrate is It is necessary to adjust to 5 μm or less.
[0019]
As is well known, in the case of a finishing bite, the tip is constituted by a cutting edge (main cutting edge) constituted by a rake face and a flank face (main flank face), and a main cutting edge constituted by a rake face and a front flank face. Although the cutting edge of the cutting tool tip used in the present invention is provided with a saw-shaped edge, as shown in FIG. is important.
[0020]
The irregularities of the cutting edge are provided by polishing with a polishing tool having fine grooves after forming a basic shape in the manufacture of a chip. Further, the unevenness of the cutting edge may be formed from the cutting edge to the upper rake face, but the unevenness of the cutting edge is for smoothly discharging minute cutting waste generated in the cutting process. As shown in FIG. 2, it is preferably formed from the cutting edge to the flank. In addition, the cutting edge of the chip requires the above surface roughness in order to make the surface of the substrate smooth as a whole, but in order to form uniform streaks and prevent the occurrence of burrs. It is preferable that the concave portion and the convex portion have a predetermined height and depth.
[0021]
Specifically, as shown in FIG. 1, in order to form uniform streaks on the substrate surface, the peak height difference (difference in height between peaks) (Δh) of the cutting edge is 0. The difference between the lowest point heights of the recesses (the difference between the heights of the ridges) (Δk) is set in the range of 0 to 1 μm. Moreover, in order to reliably prevent the occurrence of the above-mentioned burrs, assuming that the average peak height of the convex portion is (H) and the average minimum point height of the concave portion is (K), the average peak height (H) of the convex portion. The average depth (d) of the recesses (ie, the difference between the average peak height (H) of the protrusions and the average lowest point height (K) of the recesses) is 0.5 to 5 μm. Is done. The peak height of the convex part and the lowest point height of the concave part refer to a height based on a predetermined point on the blade surface of the cutting edge. The unevenness formed continuously on the flank is also set in the same manner.
[0022]
Furthermore, in order to more effectively prevent interference fringes in the photosensitive layer, it is preferable to form streaks on the surface of the substrate with a constant density. Therefore, in the present invention, the density of the protrusions on the cutting edge of the cutting tool (the number of protrusions per unit length) is 10 to 350 / mm, preferably 50 to 350 / mm. In other words, the distance between the apexes of adjacent convex portions is 2.8 to 100 μm, preferably 2.8 to 20.0 μm. Moreover, the shape of the convex part of a cutting blade is a substantially isosceles triangle, The vertex angle is 30-175 degrees, Preferably it is 100-170 degrees.
[0023]
In the production of the substrate according to the present invention, from the viewpoint of reducing the consumption cost of the tool and increasing the machining efficiency, the surface of the raw tube is usually subjected to primary cutting to finish with high shape accuracy and then secondary cutting. Perform the above finishing process. When performing the primary cutting process, first, the raw pipe is cut using a normal R bite, and the surface is smoothed so that the surface roughness (Rmax.) Becomes 5 to 15 μm. Next, a secondary cutting process as a finishing process is performed on the element tube as an intermediate obtained by the primary cutting process by using the above-described specific single crystal diamond tip tool.
[0024]
In the secondary cutting process, the workpiece (intermediate body) is rotated at 2000 to 10000 rpm and 0.05 to 0.5 mm / rev. Send in at a speed of. Then, by such secondary cutting, a substrate having a surface roughness of 0.5 to 5 μm as described above and having predetermined fine streaks formed on the surface is obtained. Depending on the shape accuracy and surface roughness of the raw tube used as the material, it is also possible to directly finish using the above-mentioned specific tool.
[0025]
In the manufacturing method of the present invention, as described above, when cutting is performed as a finishing process, a cutting tool having a single-crystal diamond cutting blade is used, and such a cutting blade is like a conventional diamond cutting tool. Compared to a spilled blade ridge due to exposure of diamond particles, it has a smoother ridge, and given a sharper irregular shape in advance, so it exhibits excellent sharpness, and the surface In addition, fine streaks can be formed uniformly and without generating burrs. As a result, it is possible to manufacture a higher-quality photosensitive drum free from defects in the photosensitive layer.
[0026]
Further, in the manufacturing method of the present invention, by using a cutting tool in which irregularities are formed from the cutting edge to the flank, fine cutting waste generated during cutting is caused by a recess continuous to the cutting flank. Since it can be discharged smoothly, the generation of burrs can be prevented more reliably.
[0027]
Furthermore, in the manufacturing method of the present invention, the difference in peak height of the convex portion and the depth of the concave portion in the cutting edge of the cutting tool are set as described above, so that each cutting force in the convex portion and the concave portion is made uniform. And the occurrence of burrs can be more reliably prevented. Then, by setting the density of the convex portions on the cutting edge of the cutting tool to the above predetermined density, it is possible to form an array of streaks on the surface of the substrate that can more effectively prevent the interference fringes of the photosensitive layer.
[0028]
The surface state of the substrate obtained by the manufacturing method of the present invention is shown in FIGS. The surface of the substrate shown in the figure is formed by cutting a large number of striations along a substantially circumferential direction by cutting with the above-mentioned specific cutting tool having a cutting edge made of single crystal diamond. As the raw tube, an aluminum drawn tube having an outer diameter of 30.3 mm, an inner diameter of 28.5 mm, and a length of 340 mm is subjected to primary processing, and the primary processing is performed from an aggregate of diamond particles. This was done with an R bite having a conventional diamond cutting edge. The above-mentioned cutting tool used for finishing is a flat cutting tool whose cutting edge has a peak height difference of 0.1 μm, a concave point height difference of 0.1 μm, and a convex peak average peak height. The average depth of the concave portion with respect to the thickness was designed to be 1.3 μm, and the apex angle of the convex portion was designed to be 160 °.
[0029]
In the above finishing process, the front rake angle of the cutting tool tip is set to 0 °, the side rake angle is set to 10 °, the flank angle (front flank angle) is set to 3 °, and the rotational speed of the workpiece is 4000 rpm. The feed rate is 0.2 mm / rev. The removal allowance was set to 0.015 mm. As a result, as shown in FIG. 3 and FIG. 4, no burrs were observed, and uniform streaks could be formed. When a photoreceptor drum was manufactured using the obtained substrate, no interference fringes were generated.
[0030]
That is, the substrate of the present invention obtained by the above-described manufacturing method has a surface roughness of 0.5 to 5 μm and a large number of streaks free from burrs by cutting with the above-mentioned specific cutting tool. Is formed on the surface substantially along the circumferential direction. In the substrate of the present invention, the structure in which the surface roughness is in the above-mentioned range and a large number of burrs are formed on the surface along the substantially circumferential direction can prevent defects in the photosensitive layer and interfere. It is possible to manufacture a photosensitive drum free from stripes.
[0031]
Moreover, in the base | substrate of this invention obtained by the manufacturing method of said preferable aspect, the difference of the peak height of the convex part of a streak is the range of 0-1 micrometer, and the difference of the lowest point height of a recessed part is 0 The average depth of the recesses is in the range of 1 μm and the average peak height of the protrusions is 0.5 to 5 μm. Furthermore, in a more preferable aspect, the density of the convex portions of the streak is 10 to 350 / mm, preferably 50 to 350 / mm. In the substrate of these aspects, the generation of interference fringes can be prevented more reliably, and a higher-quality photoconductor drum can be manufactured.
[0032]
【The invention's effect】
As described above, according to the method for manufacturing a substrate for a photosensitive drum according to the present invention, a fine streak can be formed on the surface more uniformly and without generating burrs, and no photosensitive fringe is generated. A substrate for a photosensitive drum suitable for a drum is obtained. Further, according to the photoreceptor drum substrate of the present invention obtained by the above production method, it is possible to produce a higher-quality photoreceptor drum that can prevent defects in the photoreceptor layer and that does not generate interference fringes.
[Brief description of the drawings]
FIG. 1 is a schematic view showing the form of a cutting edge of a diamond cutting tool used in the present invention. FIG. 2 is an enlarged photograph showing irregularities formed on the flank of the cutting tool of FIG. FIG. 4 is an enlarged photograph showing the surface state of a photoreceptor drum substrate cut by a cutting edge diamond bit. FIG. 4 is an enlarged view showing the surface state of a photoreceptor drum substrate cut by a cutting edge diamond bit of FIG. FIG. 5 is a schematic diagram showing the form of a cutting edge of a diamond tool used for manufacturing a conventional photosensitive drum substrate. FIG. 6 shows the surface state of the photosensitive drum substrate cut by a conventional diamond tool. It is an enlarged photograph shown.
FIG. 7 is an enlarged photograph showing a surface state of a substrate for a photosensitive drum cut by a conventional diamond tool.
[Explanation of symbols]
Δh: Difference in peak height of the convex part of the cutting edge H: Average peak height of the convex part of the cutting edge Δk: Difference in minimum point height of the concave part of the cutting edge K: Average minimum point height of the concave part of the cutting edge d: Average depth of the recess of the cutting blade

Claims (4)

A method of manufacturing a cylindrical substrate for a photosensitive drum in which a large number of streaks are formed along a substantially circumferential direction by cutting the surface of a cylindrical raw tube with a cutting tool, The cutting edge is provided with a saw-like edge that is composed of single crystal diamond and has continuous irregularities , and the average depth of the recess when the average peak height of the protrusion of the edge is used as a reference is 0.5 to 5 μm. A method for producing a substrate for a photosensitive drum, wherein the above-mentioned streak is formed by using a cutting tool.   The method for producing a photoreceptor drum substrate according to claim 1, wherein the unevenness of the cutting edge is formed from the cutting edge to the flank. In the range difference between the peak height of the projections is 0~1μm in bytes of the cutting blade, the photosensitive drum according difference in the lowest point height of recesses to claim 1 or 2 area by der of 0~1μm Manufacturing method for a substrate.   The method for producing a substrate for a photosensitive drum according to any one of claims 1 to 3, wherein the density of the convex portions on the cutting edge of the cutting tool is 10 to 350 pieces / mm.

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