JP5015449B2 - Bending method of electrophotographic blade - Google Patents

Bending method of electrophotographic blade Download PDF

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JP5015449B2
JP5015449B2 JP2005343052A JP2005343052A JP5015449B2 JP 5015449 B2 JP5015449 B2 JP 5015449B2 JP 2005343052 A JP2005343052 A JP 2005343052A JP 2005343052 A JP2005343052 A JP 2005343052A JP 5015449 B2 JP5015449 B2 JP 5015449B2
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metal plate
bending
composite metal
die
punch
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JP2007144469A (en
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治彦 上野
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Canon Chemicals Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/04—Bending sheet metal along straight lines, e.g. to form simple curves on brakes making use of clamping means on one side of the work
    • B21D5/045—With a wiping movement of the bending blade

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  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Description

本発明は、複写機やプリンタに用いられるブレードを製造するための電子写真用ブレードの曲げ加工方法に関するものである。 The present invention relates to a method for bending an electrophotographic blade for manufacturing a blade used in a copying machine or a printer.

電子写真に用いられる高精度のブレードを製造するための、パンチとダイを用いた従来の曲げ加工装置による曲げ加工方法は以下のように行われていた。   A bending method by a conventional bending apparatus using a punch and a die for manufacturing a high-accuracy blade used in electrophotography has been performed as follows.

（１）被加工材のスプリングバックを想定し、パンチ先端角とダイ溝角を最終製品角に合わせて加工を行うヤゲン曲げにおいては、９０度のＶ字形溝を有する下型に対して、上型を、略８８度に加工し、金属板を９０度より小さな角度で曲げる方法がある。   (1) Assuming a springback of the workpiece, the bevel bending, in which the punch tip angle and die groove angle are adjusted to the final product angle, is compared to the lower die with a 90-degree V-shaped groove. There is a method in which the mold is processed to approximately 88 degrees and the metal plate is bent at an angle smaller than 90 degrees.

しかし、金属板に樹脂層を積層した複合金属板の場合は、ヤゲン曲げ加工で成形すると、下死点位置でダイ肩部に相当する箇所に打痕（ショックマーク）が生じてしまう。   However, in the case of a composite metal plate in which a resin layer is laminated on a metal plate, if it is formed by a bevel bending process, a dent (shock mark) is generated at a position corresponding to the die shoulder at the bottom dead center position.

（２）パンチとダイからなる曲げ加工用の型を使用して金属板をＬ字曲げする場合は、被加工材である金属板の厚み以上のクリアランスを設けた型で曲げ加工を行う。しかし、この加工方法では、被加工材の材質によるスプリングバックが生じ、安定した角度の曲げ加工が困難である。そこで、ダイの肩に曲げる金属板の板厚の１／１０程度突出した幅１ｍｍ程度の小さな縁を設け、このダイの中にパンチにより金属板を押し込んで、金属板の曲げ部に強い圧縮力を加えて打ち込み部を形成し、スプリングバックの影響を小さくする。あるいは、ポンチ側に種々の工夫をこらしたりしている。   (2) When a metal plate is bent in an L shape using a bending die composed of a punch and a die, the bending is performed with a die having a clearance equal to or greater than the thickness of the metal plate as the workpiece. However, in this processing method, a spring back occurs due to the material of the workpiece, and it is difficult to bend at a stable angle. Therefore, a small edge with a width of about 1 mm that protrudes about 1/10 of the thickness of the metal plate to be bent on the shoulder of the die is provided, and the metal plate is pushed into the die by a punch, and a strong compressive force is applied to the bent portion of the metal plate. Is added to form a driving portion to reduce the influence of springback. Alternatively, various ideas are given to the punch side.

しかし、この方法では、曲げ部近くにショックマークを付けなければならない。また被加工材を曲げるためにパンチと被加工材を摺擦しなければならず、製品に若干でも摺働傷が生じてしまう。そのため電子写真に用いられるブレードの曲げ加工に用いるのは困難である。   However, in this method, a shock mark must be put near the bent portion. Further, in order to bend the work material, the punch and the work material must be rubbed, and the product may be slightly rubbed. For this reason, it is difficult to use for bending a blade used in electrophotography.

（３）断面がＵ字型の曲げ加工用工具を用いて金属板をハット型断面形状に成形する方法において、金属板のパンチ側片面またはパンチ側およびダイス側の両面に、充分に軟質で高延性の樹脂シートを１枚または複数枚重ねて加工する方法がある。この場合は、パンチとダイのクリアランスを、樹脂シートの厚さの合計に被加工材である金属板の厚さの８０ないし９８％を加えた値にクリアランスを設定する（特許文献１参照）。
特開平７−１７８４６２号公報 (3) In a method of forming a metal plate into a hat-shaped cross-section using a U-shaped bending tool, the metal plate is sufficiently soft and high on one side of the punch side or both the punch side and the die side. There is a method of processing one or a plurality of ductile resin sheets. In this case, the clearance between the punch and the die is set to a value obtained by adding 80 to 98% of the thickness of the metal plate as the workpiece to the total thickness of the resin sheet (see Patent Document 1).
JP 7-178462 A

しかしながら上記従来の技術では、いずれの加工方法を用いても、電子写真用のブレードを充分な精度で加工するのは難しい。   However, with the above-described conventional technique, it is difficult to process an electrophotographic blade with sufficient accuracy by any processing method.

本発明は、上記従来の技術の有する未解決の課題に鑑みてなされたものであり、高速、高精細の画像を形成するための機能部材として用いられる高精度な電子写真用ブレードを安定して製造することのできる電子写真用ブレードの曲げ加工方法を提供することを目的とするものである。 The present invention has been made in view of the above-mentioned unsolved problems of the prior art, and stably provides a high-precision electrophotographic blade used as a functional member for forming a high-speed, high-definition image. An object of the present invention is to provide an electrophotographic blade bending method that can be manufactured.

上記目的を達成するため、本発明の電子写真用ブレードの曲げ加工方法は、パンチとダイとを備えた曲げ加工装置を用いて、厚み２μｍ以上３００μｍ以下の面転写シート上に樹脂材料を押し出して厚み１μｍ以上２００μｍ以下の樹脂シートを一体成形し、その樹脂シート側に接着剤によってスプリングバックの大きな金属板を接合して一体化させた複合金属板をＬ字形に曲げる曲げ加工工程を有し、前記パンチと前記ダイのクリアランスを、前記複合金属板の総厚みの８０ないし９８％に設定して曲げ加工を行うことを特徴とする。 In order to achieve the above object, the method of bending an electrophotographic blade of the present invention uses a bending apparatus equipped with a punch and a die to extrude a resin material onto a surface transfer sheet having a thickness of 2 μm to 300 μm. A resin sheet having a thickness of 1 μm or more and 200 μm or less is integrally formed, and a metal plate having a large spring back is joined to the resin sheet side by an adhesive, and the combined metal plate is bent into an L shape, Bending is performed by setting the clearance between the punch and the die to 80 to 98% of the total thickness of the composite metal plate.

金属板と樹脂層が一体成形された複合金属板を、複合金属板の総厚みよりも小さいクリアランスでＬ字曲げ加工することで、金属板のスプリングバック量をコントロールすると同時に、傷や打痕等の発生を防ぐ。これによって、高品質な電子写真用ブレードを製造することができる。 The metal plate and the resin layer are integrally molded, and the composite metal plate is bent in an L shape with a clearance smaller than the total thickness of the composite metal plate to control the springback amount of the metal plate, and at the same time, scratches, dents, etc. Prevent the occurrence of Thereby, it is possible to manufacture a high-quality electrophotographic blade.

また、製品保護を兼ねる面転写用シートを一体に成形した複合金属板を用いて上記の曲げ加工を行えば、オイルレス成形を可能とするため、加工後の洗浄工程を必要としない。   In addition, if the above bending process is performed using a composite metal plate integrally molded with a surface transfer sheet that also serves as product protection, oilless molding is possible, so that a cleaning step after the process is not required.

本発明を実施するための最良の形態を図面に基づいて説明する。   The best mode for carrying out the present invention will be described with reference to the drawings.

図１に示すように、パンチ１と、ストリッパープレート２と、ダイ３とによってＬ字曲げ加工を行う曲げ加工装置を用いて、樹脂層である樹脂シート１１と金属板１２が一体に形成された複合金属板１０の曲げ加工を行う。この工程で、図２に示すように、パンチ１とダイ３のクリアランスＣを、複合金属板１０の総厚みの８０ないし９８％に設定する。   As shown in FIG. 1, a resin sheet 11 and a metal plate 12, which are resin layers, are integrally formed using a bending apparatus that performs L-shaped bending with a punch 1, a stripper plate 2, and a die 3. The composite metal plate 10 is bent. In this step, as shown in FIG. 2, the clearance C between the punch 1 and the die 3 is set to 80 to 98% of the total thickness of the composite metal plate 10.

パンチ１の肩部１ａの曲率半径Ｒ１は０．２〜５ｍｍが望ましく、特にＲ１＝０．３ｍｍが好ましい。ダイ３の肩部３ａの曲率半径Ｒ２は０．２〜５ｍｍが望ましく、特にＲ２＝０．５ｍｍが好ましい。   The radius of curvature R1 of the shoulder 1a of the punch 1 is preferably 0.2 to 5 mm, and particularly preferably R1 = 0.3 mm. The radius of curvature R2 of the shoulder 3a of the die 3 is preferably 0.2 to 5 mm, particularly preferably R2 = 0.5 mm.

複合金属板１０の金属板１２は、少なくとも銅および亜鉛を含有するとよい。   The metal plate 12 of the composite metal plate 10 may contain at least copper and zinc.

また、金属板１２は、スズ青銅またはリン青銅を用いた板材によって作られているとよい。   The metal plate 12 is preferably made of a plate material using tin bronze or phosphor bronze.

金属板１２と一体成形される樹脂シート１１は、金属板１２の片面または両面に１層以上の樹脂層を積層したものであるとよい。   The resin sheet 11 integrally formed with the metal plate 12 is preferably one in which one or more resin layers are laminated on one side or both sides of the metal plate 12.

樹脂シート１１は、面転写用シート１３上に樹脂材料を押出し固化させて樹脂層を形成したものである。この方法により製作した樹脂シート１１は、接着層１１ａを介して金属板１２に積層し接合される。面転写用シート１３を有する複合金属板１０を樹脂シート１１の押出し方向に平行に切断し、さらに、所定の形状に切断する。切断した複合金属板１０を上記の曲げ加工装置を用いてＬ字形に曲げて、最終形状に加工を施した後、面転写用シート１３を剥離する。   The resin sheet 11 is formed by extruding and solidifying a resin material on the surface transfer sheet 13 to form a resin layer. The resin sheet 11 manufactured by this method is laminated and bonded to the metal plate 12 via the adhesive layer 11a. The composite metal plate 10 having the surface transfer sheet 13 is cut in parallel to the extrusion direction of the resin sheet 11 and further cut into a predetermined shape. The cut composite metal plate 10 is bent into an L shape using the bending apparatus described above and processed into a final shape, and then the surface transfer sheet 13 is peeled off.

面転写用シート１３となる樹脂材料は、ポリエステル系樹脂、ポリアミド系樹脂、ポリオレフィン系樹脂、これらの共重合体、およびこれらのアロイからなる群より選ばれる１種以上の樹脂を含んでなるものである。前記ポリエステル系樹脂においては、ポリエチレンテレフタレート、ポリエチレン−２、６−ナフタレート、これらの共重合体、および複合体からなる群より選ばれる１種以上の樹脂等を用いることができる。   The resin material used as the surface transfer sheet 13 comprises one or more resins selected from the group consisting of polyester resins, polyamide resins, polyolefin resins, copolymers thereof, and alloys thereof. is there. In the polyester resin, one or more resins selected from the group consisting of polyethylene terephthalate, polyethylene-2, 6-naphthalate, copolymers thereof, and composites can be used.

樹脂シート１１となる樹脂材料には、ウレタンゴム、ポリアミド樹脂、ポリアミドエラストマー、シリコンゴム、シリコン樹脂等を用いることができる。   As the resin material used as the resin sheet 11, urethane rubber, polyamide resin, polyamide elastomer, silicon rubber, silicon resin, or the like can be used.

面転写用シート１３上に樹脂材料を均一な膜厚に押出し固化させて樹脂シート１１を形成し、複合金属板１０の曲げ加工後の面転写用シート１３は剥離される。従って、面転写用シート１３と樹脂シート１１の剥離性は良好であることが望ましい。このような観点から、面転写用シート１３は極性基を含まない厚さ２μｍ以上３００μｍ以下である直鎖状高分子であることが望ましく、特にオレフィン系高分子が好ましい。また樹脂シート１１は厚さ１μｍ以上２００μｍ以下である極性基を含む高分子であることが望ましく、特にポリアミド系高分子が好ましい。   A resin material is extruded and solidified on the surface transfer sheet 13 to a uniform film thickness to form the resin sheet 11, and the surface transfer sheet 13 after the bending of the composite metal plate 10 is peeled off. Therefore, it is desirable that the peelability between the surface transfer sheet 13 and the resin sheet 11 is good. From such a viewpoint, the surface transfer sheet 13 is desirably a linear polymer having a thickness of 2 μm or more and 300 μm or less that does not include a polar group, and an olefin polymer is particularly preferable. The resin sheet 11 is desirably a polymer containing a polar group having a thickness of 1 μm to 200 μm, and a polyamide-based polymer is particularly preferable.

金属板１２は、スズ青銅またはリン青銅、ステンレススチール、アルミ板等スプリングバックの大きな材質を用いることができ、特にリン青銅を用いることが好ましい。   The metal plate 12 can be made of a material having a large spring back such as tin bronze, phosphor bronze, stainless steel, or aluminum plate, and it is particularly preferable to use phosphor bronze.

また、金属板１２と樹脂シート１１とを接合する接着層１１ａは、例えば、ウレタン系の接着剤を用いる。   Moreover, the adhesive layer 11a which joins the metal plate 12 and the resin sheet 11 uses a urethane type adhesive agent, for example.

上記材料と成形方法により成形された複合金属板１０は、打抜き加工によってブレード形状に加工される。打抜き加工により成形された複合金属板１０は、複合金属板１０の総厚みよりもクリアランスＣを小さく設定したパンチ１とダイ３によって、厚さ方向に圧縮変形を受けながらＬ字曲げ加工される。   The composite metal plate 10 formed by the above material and forming method is processed into a blade shape by punching. The composite metal plate 10 formed by punching is bent in an L shape while being subjected to compressive deformation in the thickness direction by the punch 1 and the die 3 in which the clearance C is set smaller than the total thickness of the composite metal plate 10.

複合金属板１０の厚み方向に圧縮変形を与えながら曲げ加工を行うことは、金属板１２のスプリングバックの防止に効果的であるが、工具のクリアランスを小さくすることにより、樹脂シート１１に傷が生じたり、厚みを損なったりしてしまうことが考えられる。そこで上記のクリアランスＣを複合金属板１０の総厚みの８０ないし９８％の範囲に設定する。   Bending while compressing and deforming in the thickness direction of the composite metal plate 10 is effective in preventing spring back of the metal plate 12, but the resin sheet 11 is damaged by reducing the tool clearance. It may occur or the thickness may be impaired. Therefore, the clearance C is set in the range of 80 to 98% of the total thickness of the composite metal plate 10.

また、製品保護を兼ねる面転写用シート１３と金属板１２と樹脂シート１１からなる多層構成の複合金属板１０を用いて加工を行うことで、パンチ１またはダイ３と摺擦する箇所は樹脂シート１１によって摩擦抵抗を低減し、オイルレス成形を可能とする。加えて、面転写用シート１３が潤滑作用を持つことで、加工後の洗浄工程を必要としない。   Further, by performing processing using the composite metal plate 10 having a multi-layer structure composed of the surface transfer sheet 13 which also serves as product protection, the metal plate 12 and the resin sheet 11, the portion rubbed with the punch 1 or the die 3 is a resin sheet. 11 reduces frictional resistance and enables oilless molding. In addition, since the surface transfer sheet 13 has a lubricating action, a cleaning step after processing is not required.

曲げ加工が完了した複合金属板１０は、使用面である樹脂シート１１を残し、加工の保護シート、潤滑シート、スプリングバック量のコントロールを併せ持つ面転写用シート１３を剥離する。このようにして、電子写真として使用可能なブレードとする。   The composite metal plate 10 that has been subjected to the bending process leaves the resin sheet 11 that is the use surface, and peels off the protective sheet, the lubrication sheet, and the surface transfer sheet 13 that also has control of the springback amount. In this way, a blade that can be used for electrophotography is obtained.

樹脂シートの原料であるポリアミドエラストマー（ダイセル・ヒュルス社製、商品名：ダイアミド ＰＡＥ Ｅ４０−Ｓ３）を２５０℃で溶融した。この溶融材料を、面転写用シートとして押出成形によって製作された、厚さが０．１ｍｍのポリエチレンテレフタレート（ＰＥＴ）フィルムに、固化後の厚さが０．０３ｍｍとなるように押出して、厚さ０．１３ｍｍのシートをロールコーター法にて作製した。   Polyamide elastomer (trade name: Daiamide PAE E40-S3, manufactured by Daicel Huls Co., Ltd.) as a raw material for the resin sheet was melted at 250 ° C. This molten material was extruded as a surface transfer sheet by extrusion molding into a polyethylene terephthalate (PET) film having a thickness of 0.1 mm so that the thickness after solidification was 0.03 mm. A 0.13 mm sheet was produced by a roll coater method.

このシートと、金属板である板厚０．１２ｍｍのリン青銅シートとの間に、接着剤（東洋モートン社製、商品名：アドコート ＡＤ−７６Ｐ１）を設けて貼合し、所定の形状にプレス切断することで長さ２００ｍｍ、幅２３ｍｍのブレード形状の複合金属板とした。   Between this sheet and a phosphor bronze sheet with a thickness of 0.12 mm, which is a metal plate, an adhesive (manufactured by Toyo Morton Co., Ltd., trade name: ADCOAT AD-76P1) is bonded and pressed into a predetermined shape. By cutting, a blade-shaped composite metal plate having a length of 200 mm and a width of 23 mm was obtained.

打抜き加工により成形された複合金属板は、パンチ、ストリッパープレート、ダイを有する曲げ加工装置を用いて、複合金属板の総厚み０．２６ｍｍに対し８０ないし９８％（０．２２ｍｍ〜０．２５ｍｍ）に設定したクリアランスでＬ字曲げ加工を行った。工具肩部の形状は、パンチの肩部のＲ１＝０．３ｍｍ、ダイの肩部のＲ２＝０．５ｍｍとした。Ｌ字曲げ加工時の材料押え圧力は、金型下死点時で２６５ｋｇに設定した。   The composite metal plate formed by punching is 80 to 98% (0.22 mm to 0.25 mm) with respect to the total thickness of 0.26 mm of the composite metal plate using a bending apparatus having a punch, a stripper plate, and a die. L-shaped bending was performed with the clearance set to. The shape of the tool shoulder was R1 = 0.3 mm of the punch shoulder and R2 = 0.5 mm of the die shoulder. The material presser pressure during the L-shaped bending process was set to 265 kg at the bottom dead center of the mold.

プレス加工により抜き切断された形状の複合金属板は、幅２３ｍｍのうち１ｍｍをダイからの突出し量としてダイにセットし曲げ加工を行った。   The composite metal plate having a shape cut and cut by press working was bent by setting 1 mm out of the width of 23 mm to the die as a protruding amount from the die.

曲げ加工した複合金属板から、面転写用シートであるポリエチレンテレフタレートフィルムを剥離した。このようにして、電子写真用のブレードを製作した。   The polyethylene terephthalate film, which is a sheet for surface transfer, was peeled from the bent composite metal plate. Thus, an electrophotographic blade was produced.

製作された複合金属板のブレードは、ポリアミドエラストマーに傷や剥れがないものであった。   The manufactured composite metal plate blade had no damage or peeling to the polyamide elastomer.

比較のために、ＰＰの面転写用シートと樹脂シートを一体成形した複合金属板（サンプル１）と、ＰＥＴの樹脂シートに面転写用シートを貼合せた複合金属板（サンプル２）を製作した。また、ＰＰの樹脂シートに面転写用シートを貼合せた複合金属板（サンプル３）と、面転写用シートなしの複合金属板（サンプル４）を製作した。   For comparison, a composite metal plate (sample 1) in which a PP surface transfer sheet and a resin sheet were integrally formed and a composite metal plate (sample 2) in which a surface transfer sheet was bonded to a PET resin sheet were manufactured. . In addition, a composite metal plate (sample 3) in which a surface transfer sheet was bonded to a PP resin sheet and a composite metal plate (sample 4) without a surface transfer sheet were manufactured.

本実施例およびサンプル１〜４の加工評価を行った結果を表１に示す。   Table 1 shows the results of processing evaluation of this example and samples 1 to 4.

Figure 0005015449
Figure 0005015449

本実施例や、サンプル１のように樹脂シートと面転写用シートを一体で成形した複合金属板に関しては、曲げ加工後、複合金属板から面転写用シートを剥がしても樹脂シートに不良要因は確認できない。しかし、サンプル２およびサンプル３のように、金属板と樹脂シートを接着層により貼合した後に、面転写用シートを積載して曲げ加工を行うと、樹脂シートに傷や剥れといった問題が生じる。また、面転写用シートを使用せずに曲げ加工を行うと、樹脂シートと工具間の摩擦力が増大し、樹脂シートを剥がしてしまう問題が生じた。   Regarding the composite metal plate in which the resin sheet and the surface transfer sheet are integrally formed as in this example and sample 1, even if the surface transfer sheet is peeled off from the composite metal plate after bending, I can't confirm. However, as in sample 2 and sample 3, if the sheet for surface transfer is stacked and bent after bonding the metal plate and the resin sheet with the adhesive layer, the resin sheet has a problem such as scratches or peeling. . In addition, when bending is performed without using the surface transfer sheet, the frictional force between the resin sheet and the tool increases, causing a problem that the resin sheet is peeled off.

プリンタや複写機のブレードのみならず、樹脂層を積層した複合金属板の曲げ加工に広く適用できる。   It can be widely applied not only to the blades of printers and copiers, but also to bending of composite metal plates with resin layers laminated.

一実施例による曲げ加工に用いる曲げ加工装置および被加工材である複合金属板の構成を示す図である。It is a figure which shows the structure of the bending apparatus used for the bending process by one Example, and the composite metal plate which is a workpiece. パンチとダイのクリアランスを説明する図である。It is a figure explaining the clearance between a punch and a die.

符号の説明Explanation of symbols

１ パンチ
２ ストリッパープレート
３ ダイ
１０ 複合金属板
１１ 樹脂シート
１１ａ 接着層
１２ 金属板
１３ 面転写用シート 1 Punch 2 Stripper Plate 3 Die 10 Composite Metal Plate 11 Resin Sheet 11a Adhesive Layer 12 Metal Plate 13 Surface Transfer Sheet

Claims (1)

パンチとダイとを備えた曲げ加工装置を用いて、厚み２μｍ以上３００μｍ以下の面転写シート上に樹脂材料を押し出して厚み１μｍ以上２００μｍ以下の樹脂シートを一体成形し、その樹脂シート側に接着剤によってスプリングバックの大きな金属板を接合して一体化させた複合金属板をＬ字形に曲げる曲げ加工工程を有し、前記パンチと前記ダイのクリアランスを、前記複合金属板の総厚みの８０ないし９８％に設定して曲げ加工を行うことを特徴とする電子写真用ブレードの曲げ加工方法。 Using a bending apparatus equipped with a punch and a die , a resin material is extruded onto a surface transfer sheet having a thickness of 2 μm or more and 300 μm or less, and a resin sheet having a thickness of 1 μm or more and 200 μm or less is integrally formed, and an adhesive is formed on the resin sheet side. And bending the composite metal plate obtained by joining and integrating the metal plates having a large spring back into an L shape, and the clearance between the punch and the die is set to 80 to 98 of the total thickness of the composite metal plate. A bending method for an electrophotographic blade , characterized in that bending is performed with the setting of%.
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