JP5100260B2 - Cylindrical substrate manufacturing method and electrophotographic photosensitive member manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a cylindrical substrate and a method for manufacturing an electrophotographic photosensitive member .

  An image forming apparatus employing an electrophotographic system such as a copying machine or a laser beam printer, so-called electrophotographic apparatus, generally includes an electrophotographic photosensitive member, a charging unit, an exposure unit, a developing unit, and a transfer unit. Here, the charging unit is a unit for charging the electrophotographic photosensitive member, and the exposure unit is a unit for forming an electrostatic latent image on the charged electrophotographic photosensitive member. The developing means is a means for developing the electrostatic latent image formed on the electrophotographic photosensitive member with a developer carried on the developer carrying body to form a developed image, and the transfer means is an electrophotographic means. It is a means for transferring the developed image formed on the photoreceptor to a transfer material (paper or the like).

  In the electrophotographic apparatus having the above configuration, in order to obtain a high-quality image, the distance between the electrophotographic photosensitive member and the developer carrier (developing roller, developing sleeve, etc.) must be kept constant. is necessary. In order to keep the distance between the electrophotographic photosensitive member and the developer carrying member constant, the electrophotographic photosensitive member and the developer carrying member must have high accuracy.

  A cylindrical substrate is generally used for an electrophotographic photosensitive member, a developer carrying member, and the like. An end engaging member (gear, flange, etc.) having a shaft or a bearing is engaged with the end of the cylindrical base, and the cylindrical base is held rotatably. Accordingly, a cylindrical substrate used for an electrophotographic photosensitive member, a developer carrier and the like is required to have high outer diameter accuracy (outer diameter dimension, roundness, cylindricity). Also, accuracy related to total runout during rotation (both end concentricity inside the end engaged by the end engaging member, concentricity between the end inner diameter and the outer diameter, perpendicularity between the outer diameter and the end face), etc. Is also required to be highly accurate.

  As one method for improving the accuracy of a cylindrical substrate, there is known a method in which a cylindrical metal base tube cut to a predetermined length through extrusion and drawing is subjected to cutting with a lathe. In the cutting process here, the end surface cutting process that forms an end machining surface substantially perpendicular to the outer peripheral surface at both ends of the cylindrical metal pipe, the outer diameter of the cylindrical metal pipe has a predetermined accuracy, Includes outer diameter cutting to finish the surface roughness.

  In addition, a method of manufacturing a support by cutting the inner peripheral surface and the outer peripheral surface of both ends of a cylindrical metal pipe has been proposed (see Patent Document 1).

  We also propose a method to increase machining accuracy by subjecting the cylindrical metal tube to rough cutting on the outer peripheral surface, then inlaying the inner peripheral surface at both ends, and further cutting the outer peripheral surface. (See Patent Document 2).

In addition, after the centerless polishing process is performed on the outer peripheral surface of the cylindrical metal base tube, the inner surface of both ends is subjected to inlay processing using the outer peripheral surface as a processing reference, and further, the outer peripheral surface is cut using the inlay processing surface as a processing reference. There has also been proposed a method for improving machining accuracy by applying the method (see Patent Document 3).
JP-A-2-110570 Japanese Patent No. 3583272 JP 2003-162078 A

  Conventionally, high accuracy of a cylindrical substrate has been achieved by the method as described above. However, with the conventional technology as described above, it is not possible to sufficiently achieve both high accuracy and reduction in processing cost. That is, in the prior art, a very complicated processing step is required for high accuracy, and a processing device is required for each processing step, resulting in an increase in processing cost.

  It is also possible to simplify the machining process and manufacture a cylindrical substrate, but the cylindrical metal element tube with low accuracy cannot be firmly held by the processing apparatus, and rattling occurs during the processing of the cylindrical metal element tube. appear. Therefore, when the force for holding the cylindrical metal element tube is increased in order to suppress backlash, problems such as deformation of the cylindrical metal element tube occur.

The present invention has been made in view of the above situation , and a method for manufacturing a cylindrical substrate capable of manufacturing a highly accurate cylindrical substrate at low cost with high productivity , and the cylindrical substrate. It is an object of the present invention to provide a method for producing a used electrophotographic photoreceptor .

The method for producing a cylindrical substrate of the present invention is to obtain a cylindrical substrate by cutting the end surface and the outer surface of a cylindrical metal base tube. Specifically, the holding means is pressed against the inner surface of the cylindrical metal element tube to hold the cylindrical metal element pipe, and the end surface of the cylindrical metal element tube held by the holding means is the one end surface. It has a plurality of end surface cutting step a plurality of times cut per, and an outer surface cutting step of cutting the outer surface of the cylindrical metal tube which is held by the holding means. The plurality of end face cutting steps and the outer face cutting step are performed without removing the holding means, and the first end of the plurality of end face cutting steps is the cylindrical metal blank. Is the first cutting process applied to
In addition, the method for producing an electrophotographic photoreceptor of the present invention includes a step of cutting the end face and the outer surface of a cylindrical metal base tube to obtain a cylindrical substrate, and a photoreceptor material on the outer surface of the obtained cylindrical substrate. Forming a layer to obtain an electrophotographic photosensitive member. The step of obtaining the cylindrical substrate is a step of obtaining the cylindrical substrate by the method for producing a cylindrical substrate of the present invention.

According to the present invention, it is possible to perform cutting while the cylindrical metal base tube is stably held and fixed, so that a highly accurate cylindrical substrate can be manufactured at low cost and with high productivity. Further, Ru can be prepared an electrophotographic photosensitive member using the cylindrical substrate.

  Hereinafter, an example of an embodiment of a method for producing a cylindrical substrate of the present invention will be described in detail with reference to the drawings.

  The method for manufacturing a cylindrical substrate according to the present embodiment is to obtain a cylindrical substrate by subjecting a cylindrical metal base tube to a plurality of times of cutting, and FIGS. 1 (a) to 1 (e) show the main steps. FIG. 6 is a schematic cross-sectional view showing a shape change of a cylindrical metal pipe 101. Specifically, FIG. 1A shows the shape of the cylindrical metal base tube 101 before processing. 1B is a first end face cutting process, FIG. 1C is a second end face cutting process, FIG. 1D is an inlay process, and FIG. 1E is an outer face cutting process. The shape change of the cylindrical metal pipe 101 in the process is shown. In addition, the part shown with the oblique line in each figure is a part cut (removed) in each process.

  The material of the cylindrical metal base tube 101 is not limited to a specific material as long as it is a material according to the purpose of use. For example, from the viewpoint of electrical conductivity, suitable materials include copper, aluminum, gold, silver, platinum, lead, nickel, cobalt, iron, chromium, molybdenum, titanium, and stainless steel. Further, considering the workability and manufacturing cost, aluminum is the most suitable material for the cylindrical metal tube 101, and it is desirable to use, for example, an Al—Mg alloy or an Al—Mn alloy.

  The specific method for manufacturing the cylindrical metal pipe 101 is determined in consideration of accuracy, cost, and the like. However, when aluminum or an aluminum alloy is used, a pipe manufactured through processes such as extrusion, drawing, and correction is used. A method of cutting to a predetermined length is common. In the cylindrical metal blank 101 manufactured in this way, some residual stress is generated by processes such as extrusion, drawing, and correction. When the residual stress is released by cutting during the production of the cylindrical substrate, for example by heating during the production of the electrophotographic photosensitive member, the cylindrical substrate as a finished product is deformed. Generally, in order to remove residual stress, heat treatment (annealing) is performed on a pipe material (cylindrical metal base tube 101) cut to a predetermined length, and the treatment is usually performed at a temperature of about 300 to 430 ° C. Is done. When the residual stress is large, when the annealing process is performed, the cylindrical metal element tube 101 is greatly deformed, and when it is small, the deformation is also small. Therefore, in order to manufacture a highly accurate cylindrical base, a cylindrical metal base tube 101 having a small residual stress, that is, a small deformation before and after the annealing process and having a predetermined dimensional accuracy after the annealing process is used. It is preferable to do.

  Next, the manufacturing method of the cylindrical base | substrate which uses the said cylindrical metal raw tube 101 as a starting member is demonstrated concretely. In addition, in the manufacturing method of the cylindrical base | substrate of this invention, several cutting processes are performed with one lathe. Therefore, it has a tool post (turret) to which a plurality of cutting tools (cutting tools) can be attached and a plurality of turrets for enabling simultaneous cutting of both end faces of the cylindrical metal tube 101, and a cylindrical metal A lathe capable of cutting while rotating the raw tube 101 is used.

  First, the cylindrical metal base tube 101 shown in FIG. 1A is set on a lathe (not shown). Here, in order to process the outer surface of the cylindrical metal pipe 101 and the inner surfaces of both ends, it is necessary to hold the cylindrical metal pipe 101 from the inner side. FIG. 2 is a schematic view showing a cross section of a collet chuck 201 as an example of a holding means for holding the cylindrical metal element tube 101 from the inside. The collet chuck 201 includes a support shaft 202, a movable wedge shape portion 203, a fixed wedge shape portion 204, and a holding portion 205.

  When the collet chuck 201 is inserted into the cylindrical metal tube 101 and set on a lathe, the movable wedge 203 is moved toward the fixed wedge 204 via a spring (not shown) in the collet chuck 201 by pushing the center of the lathe. Pressed. Then, the holding portion 205 sandwiched between the movable wedge-shaped portion 203 and the fixed wedge-shaped portion 204 expands outward in the radial direction of the cylindrical metal element tube 101 and presses against the inner surface of the cylindrical metal element tube 101. As described above, the cylindrical metal base tube 101 is held from the inside. At this time, if the force that the holding portion 205 presses against the inner surface of the cylindrical metal element tube 101 is too strong, the cylindrical metal element tube 101 is deformed, and if it is too weak, the holding becomes unstable. It is necessary to press contact with.

  Next, cutting is started with respect to the cylindrical metal element tube 101 set on the lathe, and the entire length of the cylindrical metal element tube 101 (FIG. 1A) before the cutting process is a completed cylinder. 1 to 5 mm longer than the overall length of the substrate. That is, the cylindrical metal base tube 101 includes an extra length portion 106 of about 1 to 5 mm. In FIGS. 1A and 1B, the boundary between the extra length portion 106 and other portions is indicated by a chain line. The extra length portion 106 is provided to ensure a machining allowance for the end face cutting and to prevent an influence during machining even if there is a certain amount of scratches and punching during transportation.

  First, an end face cutting process is performed on the cylindrical metal base tube 101 shown in FIG. The end face cutting process is divided into a first end face cutting process (rough cutting process) shown in FIG. 1 (b) and a second end face cutting process (finish cutting process) shown in FIG. 1 (c). carry out. In the first end face cutting process, only a part 106a of the extra length portion 106 of the cylindrical metal pipe 101 is cut. Therefore, the first end face cutting process is a process that has little influence on the finished size and accuracy of the cylindrical substrate.

  As described above, the cylindrical metal tube 101 is held by the collet chuck 201 before the start of cutting. However, it is not held and fixed in a sufficiently stable state, and is held and fixed with some backlash. Therefore, when the cylindrical metal element tube 101 is cut, the cylindrical metal element tube 101 moves to some extent due to the load caused by the cutting resistance. By moving to some extent, the holding portion 205 of the collet chuck 201 shown in FIG. 2 is further expanded, and rattling between the holding portion 205 and the cylindrical metal element tube 101 is removed, and the cylindrical metal element tube 101 is more stable. Held and fixed. After the rattling has been removed in this way, more accurate cutting can be performed. Therefore, when cutting, it is effective to divide it into multiple times. In the present invention, this backlash removal is performed by the first cutting process for the cylindrical metal pipe 101. More specifically, the backlash removal is performed by a first end face cutting process that has little influence on the finished dimensions and accuracy.

  Similar effects can be obtained not only by the end face cutting process of the cylindrical metal tube 101 but also by the outer face cutting process or the inlay process. However, when the load due to the cutting resistance is applied to a position as far as possible from the holding portion 205 of the collet chuck 201, the effect of removing the backlash is greater. For example, when the holding part 205 is the inner surface of the cylindrical metal element tube 101 and is pressed against the center in the busbar direction, the cutting position at which the end surface of the cylindrical metal element tube 101 is farthest from the holding part 205 is used. It becomes. Therefore, the end face cutting process is the most effective for removing shakiness. Further, since the time required for the end face cutting process is short, rattling can be removed in a short time, and thus productivity is good. From the above, it is most effective to divide the end face cutting process into a plurality of times and remove backlash by the first process.

  The first end face cutting process will be described in more detail with reference to FIG. FIG. 3 is an enlarged view schematically showing an end cross section, a cutting tool bit, and a cutting portion of the cylindrical metal base tube 101. The enlarged portion shown in the figure is a circled portion in FIG.

  As shown in FIG. 3A, in the first end face cutting process, the end face cutting tool 301 is connected to the bus bar of the cylindrical metal base pipe 101 while rotating the cylindrical metal base pipe 101 set on the lathe. Move in the direction. As a result, the end portion of the cylindrical metal base tube 101 (a part 106a of the extra length portion 106) is cut. The rotational speed of the cylindrical metal base tube 101 at this time is, for example, 2000 rpm. Furthermore, if necessary, the end face cutting tool 301 is moved in an oblique direction, and a portion indicated by reference numeral 302 in the drawing is cut to perform chamfering.

  When the first end face cutting process is performed in a plurality of times, the effect of removing the backlash becomes greater. For example, a case where the first end face cutting process is performed in two steps will be described with reference to FIG. First, the end face cutting tool 301 is moved in the generatrix direction of the cylindrical metal base tube 101 to cut a portion 303 corresponding to a half in the radial direction of the portion 106 a of the extra length portion 106. Further, the end face cutting tool 301 is moved in the direction of the generatrix of the cylindrical metal base tube 101 to cut a portion 304 corresponding to the remaining half in the radial direction. Note that the processing order may be reversed, and the portion 304 may be cut after the portion 304 is cut. Further, as shown in FIG. 3C, the end face cutting tool 301 is moved in the direction of the generatrix of the cylindrical metal base tube 101, and a portion 305 corresponding to a half in the generatrix direction of the portion 106 a of the extra length portion 106 is formed. To cut. Next, the end face cutting tool 301 can be further moved in the direction of the generatrix and the portion 306 corresponding to the remaining half can be cut.

  In any case, in the first end face cutting process, by cutting a part 106a of the extra length portion 106 of the cylindrical metal pipe 101, a load due to the cutting resistance is applied to the cylindrical metal pipe 101, and rattling is prevented. Remove.

  Next, with respect to the cylindrical metal base tube 101 that has undergone the first end face cutting process, the second end face cutting process is performed without removing it from the lathe while being held by the collet chuck 201 using the same lathe. Perform the process. The second end face cutting step is a so-called finishing step, in which the remaining portion 106b of the extra length portion 106 is cut and the length of the cylindrical metal base tube 101 is adjusted to the length of the cylindrical base.

  The second end face cutting process will be described in more detail with reference to FIG. As shown in FIG. 4A, as in the first end face cutting step, the end face cutting tool 301 is moved in the direction of the generatrix of the cylindrical metal blank 101, and the remaining part 106b of the extra length part 106 is cut. To do. In the second end face cutting step, as shown in FIG. 4B, the end face cutting tool 301 is moved from the radially outer side to the inner side of the cylindrical metal base tube 101 to cut the remaining portion 106b. It is also possible.

  Next, the cylindrical metal base tube 101 that has undergone the second end face cutting process is subjected to inlay processing without being removed from the lathe while being held by the collet chuck 201 using the same lathe. Specifically, as shown in FIG. 5, while rotating the cylindrical metal element tube 101 at, for example, 2000 rpm, the inlay cutting tool 401 is moved in the direction of the generatrix of the cylindrical metal element tube 101, and the cylindrical metal element The inner end 108 of the tube 101 is cut. However, when the inlay process is unnecessary, the process shown in FIG. 5 is omitted.

  In addition, when processing the edge part of the cylindrical metal raw tube 101, such as end face cutting and inlay processing, it is desirable to process to both ends simultaneously. This is because the machining accuracy is improved by making the cutting resistance to the cylindrical metal pipe 101 symmetrical, the machining time can be shortened, and the like.

  Next, an outer surface cutting process is carried out on the cylindrical metal base tube 101 that has undergone the inlay process without removing it from the lathe while being held by the collet chuck 201 using the same lathe. Specifically, as shown in FIG. 6, the outer surface cutting tool 501 is moved in the generatrix direction of the cylindrical metal base tube 101 while rotating the cylindrical metal base tube 101 at, for example, 2000 rpm, and the outer surface 109 is moved. To cut. In addition, you may give further finishing cutting to an outer surface as needed. Moreover, you may perform finish cutting using another lathe.

  Here, since the cylindrical metal pipe 101 is a metal, it has expansion and contraction due to the processing atmosphere temperature, and particularly, aluminum or aluminum alloy has a large expansion and contraction amount. Therefore, when manufacturing a highly accurate cylindrical substrate, it is ideal that there is no change in the processing atmosphere temperature. Therefore, it is desirable to manage the variation of the ambient temperature during the cutting process within 2 ° C., that is, to be the reference temperature ± 1 ° C.

  An example of use of the cylindrical substrate manufactured as described above will be described. Here, a method for producing an electrophotographic photoreceptor using a cylindrical substrate as a substrate will be described. An electrophotographic photosensitive member is formed by forming a photosensitive material layer on the outer surface of a cylindrical substrate, and an inorganic photosensitive member such as an a-Si (amorphous silicon) photosensitive member formed by a CVD method or the like, a charge generating material and a charge. Examples thereof include organic photoreceptors formed by coating with a transport material. Here, as an example, an outline of a method for manufacturing an a-Si photosensitive member will be described with reference to FIG.

  The a-Si photosensitive member is generally manufactured by a high frequency plasma CVD (Chemical Vapor Deposition) method. The apparatus shown in FIG. 7 is an example of a high-frequency plasma CVD apparatus used for manufacturing an electrophotographic photosensitive member.

  The illustrated high-frequency plasma CVD apparatus includes a reaction vessel 702 that also serves as a cathode electrode in a vertical vacuum vessel, and a plurality of source gas introduction pipes 703 extending in the longitudinal direction of the vessel are provided around the reaction vessel 702. This is arranged. Further, a large number of pores (not shown) are provided on the side surface of the gas introduction pipe 703 along the longitudinal direction. Further, a heater 704 is provided in the center of the reaction vessel 702. The cylindrical substrate 105 serving as the substrate of the electrophotographic photosensitive member is installed in the vertical direction around the heater 704 while being mounted on the substrate holder 705. A lid 706 is provided on the upper portion of the reaction vessel 702. The lid 706 is opened, and the cylindrical substrate 105 is installed as described above.

  A high frequency power source 714 is connected to the side surface of the reaction vessel 702 via a matching box 707. A source gas supply pipe 708 connected to a source gas introduction pipe 703 is attached to the lower part of the reaction vessel 702, and the supply pipe 708 is connected to a gas supply device (not shown) via a supply valve 709. . Further, an exhaust pipe 710 is attached to the lower part of the reaction vessel 702, and the exhaust pipe 710 is connected to an exhaust device (vacuum pump) (not shown) via an exhaust valve 711. In addition, a motor 712 and a vacuum gauge 713 for rotating the substrate holder 705 on which the cylindrical substrate 105 is mounted are attached to the lower portion of the reaction vessel 702.

  The a-Si photosensitive member by the high frequency plasma CVD method using the above apparatus is formed as follows. First, a substrate holder 705 mounted with a cylindrical substrate 105 serving as a substrate of an electrophotographic photosensitive member is set in the reaction vessel 702, the lid 706 is closed, and then the reaction vessel 702 is filled with a predetermined pressure by an exhaust device (not shown). Exhaust until. Thereafter, while continuing the exhaust, the substrate holder 705 on which the cylindrical substrate 105 is mounted is rotated by the motor 712, and the cylindrical substrate 105 is heated from the inside by the heater 704 to control the cylindrical substrate 105 to a predetermined temperature. . When the cylindrical substrate 105 is maintained at a predetermined temperature, a desired source gas is introduced into the reaction vessel 702 through the source gas introduction pipe 703 while being adjusted by respective flow rate controllers (not shown). The introduced source gas fills the inside of the reaction vessel 702 and is then exhausted outside the reaction vessel 702 through the exhaust pipe 710.

  In this way, when it is confirmed by the vacuum gauge 713 that the inside of the reaction vessel 702 filled with the source gas has become a predetermined pressure and stabilized, a high frequency is desired by a high frequency power source 714 (for example, an RF band of 13.56 MHz). Is introduced into the reaction vessel 702 with the amount of input power. Then, glow discharge is generated in the reaction vessel 702. By the energy of this glow discharge, the source gas is decomposed to generate plasma ions, and an a-Si deposited film mainly composed of silicon is formed on the surface of the cylindrical substrate 105. At this time, an a-Si deposited film having various characteristics can be formed by adjusting parameters such as gas type, gas introduction amount, gas introduction ratio, pressure, substrate temperature, input power, and film thickness. Properties can be controlled.

  As described above, when the a-Si deposited film is formed on the surface of the cylindrical substrate 105 with a desired film thickness, the supply of high-frequency power is stopped, the supply valve 709 and the like are closed, and the raw material into the reaction vessel 702 is obtained. The introduction of the gas is stopped, and the formation of the a-Si deposited film for one layer is finished. By repeating the same operation a plurality of times, an a-Si photoreceptor having a desired structure is manufactured.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these Examples. In the following description, the same reference numerals are used for the same or corresponding configurations as those described in the above-described embodiments.

  Further, in the following examples and comparative examples, the cylindrical metal base tube 101 is an Al—Mg alloy drawn tube containing 2.5% by weight of magnesium and subjected to annealing treatment at 380 ° C. for 2 hours. Using.

  The atmospheric temperature during the cutting process was controlled by controlling the reference temperature at 23 ° C. and the fluctuation temperature within 2 ° C., that is, ± 1 ° C.

  The dimensions of the cylindrical metal base tube 101 and the cylindrical base body 105 are shown in Table 1 (unit: mm). The inlay process was performed twice because the cutting amount was as large as 1.5 mm.

Example 1
The cylindrical metal pipe 101 into which the collet chuck 201 was inserted was set on a lathe (trade name: SD550) manufactured by Egro Corporation, and the cylindrical metal pipe 101 was held from the inside. In this state, the cylindrical metal base tube 101 was rotated at 2000 rpm, and was continuously processed without being removed from the lathe under the conditions shown in Table 2, and 100 cylindrical base bodies 105 were manufactured. In the first end face cutting step, the end face cutting tool 301 was fed in the direction of the arrow shown in FIG. 3A, and the entire end face was cut by 0.8 mm. Next, in the second end face cutting step, the end face cutting tool 301 was fed in the direction of the arrow shown in FIG. 4A, and the entire end face was cut by 0.2 mm.

  In the first inlay processing step ("Inlay processing 1" in Table 2) and the second inlay processing step ("Inlay processing 2" in Table 2), the inlay processing bit 401 is placed in the direction of the arrow shown in FIG. Feeding and cutting the end part inner side 108 over 13.0 mm from the end face.

Next, the entire outer surface of the cylindrical metal base tube 101 was cut by performing an outer surface cutting process. Specifically, the outer surface cutting tool 501 was fed in the direction of the arrow shown in FIG. 6 to cut the entire outer surface 109. In addition, about the processing order 1, 2, 3, 4, the both ends simultaneous processing was performed.

  Regarding the cylindrical base body 105 manufactured as described above, “outer diameter dimension”, “outer diameter roundness”, “outer diameter cylindricity”, “outer diameter vs. inner diameter coaxiality”, “both ends of inner diameter coaxiality” Each item of “degree”, “edge perpendicularity”, and “processing time” was evaluated. Note that “outer diameter dimension”, “outer diameter roundness”, and “outer diameter cylindricity” are evaluation items indicating accuracy regarding the outer diameter. In addition, “outer diameter vs. inner diameter coaxiality”, “both ends inner diameter coaxiality” and “end face perpendicularity” are evaluation items indicating the accuracy related to total runout during rotation. “Processing time” is an evaluation item related to productivity.

(Evaluation of outer diameter)
Using a micrometer (manufactured by Mitutoyo Corporation), the dimensions of three points at 20 mm positions from the center and both ends of the cylindrical substrate 105 were measured, and the process capability was calculated from the average value and the variation among the 100 manufactured. The process capability index Cpk is expressed by the following equation.
Cpk = {(UL)-| U + L-2X |} / 6σ
However, U is the standard upper limit value, L is the standard lower limit value, X is the average value, and σ is the standard deviation. The evaluation of the obtained results is carried out by relative evaluation when the result obtained in the comparative example described later is 100. did. In other words, the larger the number, the better the evaluation result.
(Evaluation of outer diameter roundness and outer diameter cylindricity)
Using a roundness cylindrical shape measuring machine (trade name: ROUNDTEST RA-436) manufactured by Mitutoyo Co., Ltd., the roundness was measured for a total of 5 points, 20 mm from both ends and 100 mm from both ends, of the cylindrical base body 105, The cylindricity was calculated from the five points. Evaluation of the calculation result was performed by relative evaluation when the process capability was calculated from the average value and variation among 100 manufactured, and the result obtained in the comparative example described later was taken as 100. In other words, the larger the number, the better the evaluation result.
(Evaluation of outer diameter vs. inner diameter coaxiality, both ends inner diameter coaxiality)
FIG. 8 shows a schematic diagram of the measurement. Both end portions of the cylindrical base body 105 are supported by two V blocks 801, and dial gauges 802 and 803 are applied to the inner surface of the end portion (inner inner diameter portion) subjected to inlay processing. Then, the maximum value and the minimum value of the indication values of the dial gauges 802 and 803 when the cylindrical base body 105 was rotated once were measured, and the difference was defined as the respective outer diameter to inlay inner diameter coaxiality. Further, the maximum value and the minimum value of the difference between the indication values of the dial gauges 802 and 803 when the cylindrical substrate 105 was rotated once were measured, and the difference was defined as the both-end inlay inner diameter coaxiality. Evaluation of the measurement results was carried out by relative evaluation when the process capability was calculated from the average value and variation among the 100 manufactured, and the result obtained in the comparative example described later was taken as 100. In other words, the larger the number, the better the evaluation result.

(Evaluation of perpendicularity of the end face)
Using a roundness cylindrical shape measuring machine (trade name: ROUNDTEST RA-436) manufactured by Mitutoyo Corporation, the inclination of two points at 20 mm positions from both ends of the cylindrical base body 105 with respect to the end face was measured as an end face perpendicularity. Evaluation of the measurement results was carried out by relative evaluation when the process capability was calculated from the average value and variation between 100 manufactured, and the result obtained in the comparative example described later was taken as 100. In other words, the larger the number, the better the evaluation result.

(Evaluation of processing time)
The time required to continuously process 100 cylindrical substrates 105 was measured, and a relative evaluation was performed with the result obtained in the comparative example described later as 100. In other words, the smaller the number, the better the evaluation result.

Further, the outer surface of the obtained cylindrical substrate 105 was subjected to finish cutting. A lathe (trade name: RL550) manufactured by Egro Co., Ltd. was used for the finish cutting. Specifically, the cylindrical substrate 105 was held at the collet chuck from the inside, rotated at 3000 rpm, and processed under the conditions shown in Table 3 on the basis of the inner diameter of the inlay. In addition, the outer surface rough cutting processing and the outer surface finishing cutting processing in Table 3 were performed by arranging the cutting tools side by side. Thereafter, cleaning was performed, and an a-Si photosensitive member was formed on the cylindrical substrate 105 under the conditions shown in Table 4 using the high-frequency plasma CVD apparatus shown in FIG.

  The electrophotographic photoreceptor unit 901 was manufactured by attaching flanges 902 and 903 shown in FIG. 9 to both ends of the obtained a-Si photoreceptor so as to be rotatable. Then, as the evaluation of the electrophotographic photosensitive member characteristics, “runout” and “Vd surface unevenness” were evaluated.

  For evaluation of the characteristics of the electrophotographic photosensitive member, a copying machine (trade name “iR5000” modified machine manufactured by Canon Inc.) was used. FIG. 10 shows an outline of the copying machine. The electrophotographic photoreceptor unit 901 is supported so as to be capable of rotating clockwise in the drawing. Around the electrophotographic photosensitive member unit 901, a pre-exposure device 1008, a main charger 1002, a latent image forming exposure device 1009, and a potential sensor 1003 are sequentially arranged in the clockwise direction. Next, a developing device 1004 for performing development by attaching toner on the electrostatic latent image, a transfer charging device 1005a for transferring the toner image to a recording medium, and a separation charging device 1005b are arranged. Thereafter, a cleaner 1010 including a cleaning roller 1006 and a cleaning blade 1007 for removing residual toner is disposed.

  When measuring the shake, the developing device 1004 and the cleaner 1010 are removed, and instead of the developing device 1004, a displacement sensor (a product made by Keyence Corporation) that can measure the shake at a predetermined position in the bus line direction of the electrophotographic photosensitive member unit 901. Name EX-502 (not shown) was attached. Then, the electrophotographic photosensitive member unit 901 was rotated, the displacement sensor was moved from the end of the unit 901 in the bus direction, and the difference between the maximum value and the minimum value was measured at 9 points at intervals of 40 mm in the bus direction. Furthermore, the maximum value of the measured values at 9 points was regarded as the fluctuation, and the process capability was calculated from the average value and the variation between the 100 samples.

In the measurement of Vd surface unevenness, the developing device 1004 and the cleaner 1010 are removed, and instead of the developing device 1004, a potential probe (Model 344, manufactured by TREK Co., Ltd., which can measure electrophotographic characteristics at a predetermined position in the bus bar direction of the electrophotographic photosensitive member unit 901 is used. (Shown) was attached.
The process speed was 265 mm / sec, and the amount of pre-exposure (LED with a wavelength of 660 nm) was 2.3 μJ / cm ² . Then, the electrophotographic photoreceptor unit 901
The current value of the main charger 1002 was adjusted so that the surface potential at the middle position in the bus line was 450 V (dark potential) as measured with a potential probe. Thereafter, the potential probe was moved in the direction of the bus from the end of the electrophotographic photosensitive member unit 901, and the maximum value and the minimum value were measured at 9 points at intervals of 40 mm in the direction of the bus. The difference between the maximum value and the minimum value of all measured values was regarded as Vd surface unevenness, and the process capability was calculated from the average value and variation of 100 samples. Evaluation of “runout” and “Vd surface unevenness” was carried out by relative evaluation with the result obtained in the comparative example described later as 100. In other words, the larger the number, the better the evaluation result.

(Ranking of each evaluation result)
With respect to each of the evaluation items excluding “processing time”, ranking was performed according to the following criteria.

A: greater than 175 B: greater than 150 and less than 175 C: greater than 125 and less than 150 D: greater than 100 and less than 125 E: 100 (no change)
F ... less than 100

The result of “processing time” was ranked according to the following criteria.
A ... less than 40 B ... 40 or more and less than 60 C ... 60 or more and less than 80 D ... 80 or more and less than 100 E ... 100 (no change)
F ... Greater than 100

(Comprehensive evaluation)
9 items above ("Outer Diameter", "Outer Diameter Roundness", "Outer Diameter Cylindricity", "Outer Diameter vs. Inner Inner Inner Diameter Concentricity", "Both Inner Inner Inner Diameter Concentricity", "End Face Right Angle", "Processing Time", "Runout" The evaluation results of “Vd surface unevenness”) were ranked according to the following criteria. The ranking results are shown in Table 7.
A: B level or higher for each item and 4 or more A levels B ... B level or higher for each item C ... C level or higher for each item D ... D level or higher for each item E ...・ Each item is over E level F ・ ・ ・ Each item has F level

(Example 2)
Compared to Example 1, the first end face cutting process in the processing order 2 in Table 2 was changed to the method shown in FIG. In the first end face cutting step, the portion 303 was cut with a width of 2 mm, and the portion 304 was cut a second time. Otherwise, 100 cylindrical substrates were produced in the same manner as in Example 1. Using the obtained cylindrical substrate, an electrophotographic photosensitive member unit was produced in the same manner as in Example 1, and the same evaluation as in Example 1 was performed, and ranking was performed based on the evaluation result. The ranking results are shown in Table 7.

(Example 3)
The processing order was changed with respect to Example 1. Specifically, the processing order in Table 2 was performed in the order of 1, 2, 5, 3, 4, that is, the inlaying process after the outer surface cutting process. Otherwise, 100 cylindrical substrates were produced in the same manner as in Example 1. Using the obtained cylindrical substrate, an electrophotographic photosensitive member unit was produced in the same manner as in Example 1, and the same evaluation as in Example 1 was performed, and ranking was performed based on the evaluation result. The ranking results are shown in Table 7.

Example 4
The inlay processing step was omitted with respect to Example 1, and the processing order in Table 2 was performed in the order of 1, 2, and 5. Otherwise, a cylindrical substrate was produced in the same manner as in Example 1, and the same evaluation as in Example 1 was performed, and ranking was performed based on the evaluation results. The ranking results are shown in Table 7. In this example, since the inlay process was not performed, each evaluation of “both ends of the inner diameter coaxiality”, “outer diameter vs. inner diameter coaxiality”, “runout”, and “Vd surface unevenness” was omitted.

(Comparative example)
A cylindrical metal tube that has undergone end face processing is held from the inside, set on a lathe made by Egro Co., Ltd. (trade name: SD550), rotated at 2000 rpm, and subjected to inlay processing at both ends simultaneously under the conditions shown in Table 5 It was. Thereafter, the cylindrical metal blank that had been subjected to inlay processing was once removed from the lathe and subjected to outer surface cutting processing based on the inner diameter of the inlay. The outer surface cutting was performed under the conditions shown in Table 6 using a lathe made by Egro Co., Ltd. (trade name: RL550), rotating at 2000 rpm with the inner diameter portion held by the collet chuck. As described above, 100 cylindrical substrates were manufactured. Using the obtained cylindrical substrate, an electrophotographic photoreceptor unit was produced in the same manner as in Example 1, and the same evaluation as in Example 1 was performed, and ranking was performed based on the evaluation result. The ranking results are shown in Table 7.

※項目Ａ〜Ｉは以下を示す
I：外径寸法、II：外径真円度、III：外径円筒度
IV：外径対インロー内径同軸度、V：両端インロー内径同軸度
VI：端面直角度、VII：加工時間、VIII：振れ、IX：Ｖｄ面ムラ
尚、表中の「−」は「評価せず」を示す。

* Items A to I indicate the following
I: Outer diameter dimension, II: Outer diameter roundness, III: Outer diameter cylindricity
IV: Outer diameter vs. inner diameter coaxiality, V: Both ends inner diameter coaxiality
VI: End face perpendicularity, VII: Processing time, VIII: Runout, IX: Vd surface unevenness “-” in the table indicates “not evaluated”.

From Table 7, it can be seen that the accuracy of the cylindrical substrate related to items I to VI was improved by the present invention. In particular, the accuracy (items IV to VI) related to vibration during rotation is improved. This is an effect that the cutting is performed in a state where the cylindrical metal pipe is stably held and fixed by the present invention. Improvements in the accuracy of cylindrical substrates are often seen in items VIII and IX, which are characteristics of products using cylindrical substrates. Item VII
Thus, it can be seen that the processing time is halved by performing a series of processing while holding the cylindrical metal tube.

  In summary, it can be seen that the present invention makes it possible to manufacture a cylindrical substrate with high accuracy and high productivity.

It is a schematic diagram which shows the shape change of the cylindrical metal raw tube in each process of the manufacturing method of the cylindrical base | substrate which concerns on this invention. It is a schematic diagram which shows the cross section of a collet chuck. It is a schematic diagram which shows a 1st end surface cutting process. It is a schematic diagram which shows a 2nd end surface cutting process. It is a schematic diagram which shows an inlay process. It is a schematic diagram which shows an outer surface cutting process. It is a schematic diagram which shows an example of the high frequency plasma CVD apparatus used for manufacture of an electrophotographic photoreceptor. It is the schematic which shows the method of coaxiality evaluation. It is a schematic diagram which shows an electrophotographic photoreceptor unit. FIG. 2 is a schematic view showing a copying machine used for evaluating characteristics of an electrophotographic photosensitive member unit.

Explanation of symbols

DESCRIPTION OF SYMBOLS 101 Cylindrical metal pipe 105 Cylindrical base body 205 Holding | maintenance part 106 Extra length part 106a Part of extra length part 106b The remainder of extra length part

Claims (9)

In the method of manufacturing a cylindrical substrate, the end surface and the outer surface of the cylindrical metal tube are cut to obtain a cylindrical substrate.
The manufacturing method includes a step of holding the cylindrical metal element tube by pressing a holding unit against an inner surface of the cylindrical metal element tube, and an end surface of the cylindrical metal element tube held by the holding unit on one end surface. includes a plurality of end surface cutting step a plurality of times cut per, and an outer surface cutting step of cutting the outer surface of the cylindrical metal tube which is held by said holding means,
The plurality of end face cutting steps and the outer face cutting step are performed without removing the holding means, and
A method for producing a cylindrical substrate, wherein a first round of the plurality of end face cutting steps is a cutting step first applied to the cylindrical metal base tube. The step of holding the cylindrical metal tube is, the manufacturing method of the cylindrical substrate according to claim 1, wherein the step of pressing said holding means to the generatrix direction center of the front Symbol cylindrical metal tube. The method for manufacturing a cylindrical substrate according to claim 1, wherein the holding means is a collet chuck. The plurality of end face cutting steps include a first end face cutting step for cutting a part of the extra length portion of the cylindrical metal base tube with respect to the cylindrical base, and a first step for cutting the remaining portion of the extra length portion. 2 end face cutting process steps,
The method for manufacturing a cylindrical substrate according to any one of claims 1 to 3 , wherein a first round of the plurality of end face cutting steps is the first end face cutting step. The method for manufacturing a cylindrical substrate according to any one of claims 1 to 4, wherein the first end face cutting step is performed in a plurality of times. The method for manufacturing a cylindrical substrate according to any one of claims 1 to 5 , wherein the plurality of end face cutting steps are steps for simultaneously cutting both end faces of the cylindrical metal pipe. The method for manufacturing a cylindrical substrate according to any one of claims 1 to 6 , wherein a material of the cylindrical metal pipe is aluminum or an aluminum alloy. The method for producing a cylindrical substrate according to any one of claims 1 to 7 , wherein a change in the atmospheric temperature during the cutting process is set to 2 ° C or less. A step of cutting the end face and the outer surface of the cylindrical metal base tube to obtain a cylindrical substrate; a step of forming a photosensitive material layer on the outer surface of the obtained cylindrical substrate to obtain an electrophotographic photosensitive member; In a method for producing an electrophotographic photoreceptor having
The method for producing an electrophotographic photoreceptor, wherein the step of obtaining the cylindrical substrate is a step of obtaining the cylindrical substrate by the production method according to any one of claims 1 to 8 .

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