JP6945989B2 - Immersion coating device and method for manufacturing electrophotographic photosensitive member - Google Patents

Description

The present invention is dip coating apparatus for applying a coating solution to the coating object by a dip coating method, and a copying machine, multifunction machine, a printer, an electrophotographic photoreceptor provided in the image forming apparatus of an electrophotographic type facsimile machine, etc. the Rukoto to applying the coating solution to a substrate to a manufacturing process for the method for producing a photoreceptor for producing an electrophotographic photosensitive member.

A dip coating device for applying a coating liquid to an object to be coated by a dip coating method has been conventionally known. For example, the immersion coating apparatus is widely used as an electrophotographic photosensitive member manufacturing apparatus for producing an electrophotographic photosensitive member [specifically, an organic photoconductor (OPC)].

In such a dipping coating device, usually, at least one of the coating object and the coating tank is relative to the coating tank for accommodating the coating liquid for immersing the object to be coated to form a coating film on the surface of the object to be coated. The object to be coated is immersed in the coating liquid in the coating tank and lifted from the coating liquid. The object to be coated is immersed in the coating tank to a predetermined depth, and then the object to be coated is pulled up. Therefore, a coating film (for example, an undercoat layer, a charge generation layer, and a charge transport layer) is formed on the surface of an object to be coated (for example, a substrate constituting an electrophotographic photosensitive member).

Japanese Unexamined Patent Publication No. 9-197689 Japanese Unexamined Patent Publication No. 2010-115641

In such an immersion coating device, when the object to be coated is immersed in the coating liquid in the coating tank and then the object to be coated is pulled up from the coating liquid to form a coating film on the surface of the object to be coated, the vicinity of the coating film is formed. A wind flow is generated in the coating tank, and the solvent vapor concentration from the coating liquid and the coating film in the coating tank can be different. Then, the drying property of the coating film is different, and the film thickness is uneven. This is particularly remarkable when the film thickness is thick (for example, when the film thickness is 28 μm or more) such as the charge transport layer. In recent years, there has been a high demand for higher quality of products manufactured by immersion coating equipment (for example, when the manufactured product is an electrophotographic photosensitive member, the life of the electrophotographic photosensitive member is extended and the image quality is improved). Therefore, it has become a bigger issue than before.

Regarding this point, in Patent Document 1, a tubular windshield having a mesh-like entire wall surface is provided above the coating tank, and in Patent Document 2, the object to be coated immersed in the coating liquid is stretchable. It has been proposed to pull up while covering the sides of the object to be coated with a slide hood.

However, when a mesh-shaped tubular windshield is used as in the configuration described in Patent Document 1, although it is highly effective in preventing wind from the side, at least one of the object to be coated and the coating tank It is not effective in preventing the wind generated when one of them is moved up and down relatively, and vertical streaks-like film thickness unevenness may occur in the coating film, which has a sufficient effect of suppressing the film thickness unevenness of the coating film. There is a problem that it cannot be obtained.

Further, when the telescopic slide hood is used as in the configuration described in Patent Document 2, since the entire object to be coated can be covered, the effect of suppressing the uneven film thickness of the coating film is large, but the telescopic slide When the hood expands and contracts, an air flow is generated step by step, ring-shaped film thickness unevenness is likely to occur in the coating film, and the device configuration is likely to be large, which poses a problem in terms of productivity. Remain.

Therefore, the present invention can suppress uneven film thickness of the coating film caused by the flow of wind due to the relative ascending / descending operation of at least one of the object to be coated and the coating tank, while having a simple apparatus configuration. It is an object of the present invention to provide a coating apparatus and a method for manufacturing an electrophotographic photosensitive member.

As a result of diligent studies to solve the above problems, the present inventors have found the following and have completed the present invention.

That is, the coating tank for accommodating the coating liquid for immersing the object to be coated to form a coating film on the surface of the object to be coated, and at least one of the object to be coated and the coating tank are relatively raised and lowered to be coated. In a dipping coating device equipped with an elevating means for immersing an object in a coating liquid in a coating tank and pulling it up from the coating liquid, for example, when manufacturing an electrophotographic photosensitive member, the film thickness of the coating film (for example, a charge transport layer) is uneven. When a mesh-shaped cylindrical windshield as proposed in Patent Document 1 is installed in order to eliminate the above, it is effective in eliminating random film thickness unevenness and oblique film thickness unevenness of the coating film. However, the film thickness unevenness in the form of vertical streaks occurred in the coating film, resulting in the occurrence of shading streaks on the formed image in the image forming apparatus equipped with the electrophotographic photosensitive member. In response to this result, an electrophotographic photosensitive member was manufactured by changing the size of the cylindrical windshield and the shape of the windshield such as a square columnar, and the same result was obtained.

From the above, the windshield provided above the coating tank over the entire circumference in the circumferential direction prevents wind from the side with respect to the coating film, thereby causing random film thickness unevenness and obliqueness of the coating film. Although it was effective for the uneven film thickness, it is considered that it was not effective for the wind caused by relatively raising and lowering at least one of the object to be coated and the coating tank.

Specifically, in the immersion coating device, after immersing the object to be coated in the coating liquid in the coating tank, when the object to be coated is pulled up from the coating liquid to form a coating film on the surface of the object to be coated, a windshield The air in the vicinity of the outer wall surface of the windshield wraps around from the upper part of the windshield toward the object to be coated along the outer wall surface of the windshield. Then, it is considered that a local difference in solvent vapor concentration occurs, which causes vertical streak-like film thickness unevenness in the coating film.

In order to eliminate such inconvenience, a diligent study was conducted. It was found that it is effective in suppressing vertical streak-shaped film thickness unevenness. This is because after immersing the object to be coated in the coating liquid in the coating tank, when the object to be coated is pulled up from the coating liquid to form a coating film on the surface of the object to be coated, the vicinity of the outer wall surface of the windshield The bent portion can effectively prevent air from wrapping around from the upper part of the windbreak portion toward the object to be coated along the outer wall surface of the windshield portion, thereby reducing the difference in local solvent vapor concentration. It is thought that this is because it can be done.

The present invention is based on such findings, and provides the following first to fourth aspects of the immersion coating apparatus and the method for producing an electrophotographic photosensitive member.

(1 1) dip coating apparatus of the first embodiment according to the dip coating apparatus the present invention of the first aspect, accommodates a coating liquid for forming a coating film on the surface of the coating object by immersing the object to be coated A coating tank to be coated and an elevating means for immersing the object to be coated in the coating liquid in the coating tank and pulling it up from the coating liquid by relatively raising and lowering at least one of the object to be coated and the coating tank. An immersion coating device provided, above the coating tank, a windshield for shielding outside wind is provided over the entire circumference in the circumferential direction, and above the windshield, the windshield is provided. A bent portion bent toward the outside is provided over the entire circumference in the circumferential direction, and the bent portion has a curved portion that bends outward from the outer wall surface of the windshield portion in an arc shape or an elliptical arc shape. It is characterized by being.
(1-2) Immersion coating device of the second aspect
The immersion coating device of the second aspect according to the present invention includes a coating tank for immersing the object to be coated and containing a coating liquid for forming a coating film on the surface of the object to be coated, and the object to be coated and the coating. An immersion coating device including a means for raising and lowering at least one of the tanks so that the object to be coated is immersed in the coating liquid in the coating tank and pulled up from the coating liquid. A windshield for shielding outside wind is provided over the entire circumference of the windshield, and an outwardly bent bent portion is provided in the circumferential direction above the windshield. The bent portion is provided over the entire circumference, and the bent portion has a straight portion that bends linearly outward from the outer wall surface of the windshield portion and a linear portion that is continuously provided at the tip of the straight portion to form an arc shape or an elliptical arc shape. It is characterized by having a curved portion that bends.
(1-3) Immersion coating device of the third aspect
The immersion coating device of the third aspect according to the present invention includes a coating tank for immersing the object to be coated and containing a coating liquid for forming a coating film on the surface of the object to be coated, and the object to be coated and the coating. An immersion coating device including a means for raising and lowering at least one of the tanks so that the object to be coated is immersed in the coating liquid in the coating tank and pulled up from the coating liquid. A windshield for shielding the outside wind is provided above the windshield over the entire circumference in the circumferential direction, and a bent portion bent outward is provided in the upper part of the windshield in the circumferential direction. The bent portion is provided over the entire circumference, and is characterized in that the bent portion bends outward from a position below the upper end of the linear wall surface outside the windshield portion.
(1-4) Immersion coating device of the fourth aspect
The immersion coating device of the fourth aspect according to the present invention includes a coating tank for immersing an object to be coated to form a coating film on the surface of the object to be coated, and the object to be coated and the coating. An immersion coating device including a means for raising and lowering at least one of the tanks so that the object to be coated is immersed in the coating liquid in the coating tank and pulled up from the coating liquid. A windshield for shielding outside wind is provided over the entire circumference of the windshield, and an outwardly bent bent portion is provided in the circumferential direction above the windshield. The bent portion is provided over the entire circumference, and the bent portion is bent at a predetermined bending angle within a predetermined bending angle range with respect to the outer wall surface of the windshield portion. The predetermined bending angle range is 60 ° to 75 °.

(2) The method of producing an electrophotographic photosensitive member according to the production method the present invention of the electrophotographic photosensitive member manufacturing an electrophotographic photosensitive member by Rukoto be coated with the coating solution to a substrate by a dip coating apparatus according to the present invention characterized in that it.

In the present invention, an embodiment in which the bent portion has a straight portion that bends linearly outward from the outer wall surface of the windbreak portion can be exemplified.

In the present invention, an embodiment in which the bent portion is bent with respect to the outer wall surface of the windshield portion at a predetermined bending angle within a predetermined bending angle range can be exemplified.

In the present invention, the embodiment in which the predetermined bending angle range is 45 ° to 150 ° can be exemplified.

In the present invention, an embodiment in which the tip of the bent portion is separated from the outer wall surface of the windshield portion by a predetermined horizontal distance in the horizontal direction can be exemplified.

In the present invention, an embodiment in which the predetermined horizontal distance is 10 mm or more can be exemplified.

In the present invention, an embodiment in which the bent portion is composed of a sheet-shaped member can be exemplified.

In the present invention, the windshield portion has all or a part of the outer wall surface within a predetermined predetermined opening range and within a predetermined opening rate range. An embodiment in which the pores are formed in a porous shape with a predetermined opening rate can be exemplified.

In the present invention, the embodiment in which the predetermined opening range is 50 μm to 100 μm and the predetermined opening rate range is 30% to 50% can be exemplified.

According to the present invention, it is possible to suppress uneven film thickness of the coating film caused by the flow of wind due to the relative ascending / descending operation of at least one of the object to be coated and the coating tank, while having a simple apparatus configuration. ..

It is a front view which shows the schematic structure of the immersion coating apparatus which concerns on embodiment of this invention. It is a schematic disassembled perspective view which shows mainly the windshield part and the bent part part of the immersion coating apparatus which concerns on 1st Embodiment. It is a schematic exploded perspective view which shows mainly the windshield part and the bent part part of the dipping coating apparatus which concerns on 2nd Embodiment. It is a schematic exploded perspective view which shows mainly the windshield part and the bent part part of the dipping coating apparatus which concerns on 3rd Embodiment. It is a schematic disassembled perspective view which shows mainly the windshield part and the bent part part of the immersion coating apparatus which concerns on 4th Embodiment. FIG. 5 is a schematic vertical sectional view showing an enlarged view of a windshield portion and a bent portion of the immersion coating device according to the fifth embodiment. FIG. 5 is a schematic vertical sectional view showing an enlarged view of a windshield portion and a bent portion of the immersion coating device according to the sixth embodiment. FIG. 5 is a schematic vertical sectional view showing an enlarged view of a windshield portion and a bent portion of the immersion coating device according to the seventh embodiment. FIG. 5 is a schematic vertical sectional view showing an enlarged view of a windshield portion and a bent portion of the immersion coating device according to the eighth embodiment. FIG. 5 is a vertical cross-sectional view showing a schematic configuration of an example of an electrophotographic photosensitive member manufactured by applying a coating liquid to a substrate by the immersion coating apparatus shown in FIG. FIG. 5 is an enlarged partial cross-sectional view of a surface portion of an example of an electrophotographic photosensitive member shown in FIG. FIG. 5 is a cross-sectional view schematically showing a schematic configuration of an image forming apparatus including an electrophotographic photosensitive member manufactured by the immersion coating apparatus shown in FIG. 1.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.

(Immersion coating device)
First, the immersion coating apparatus 100 according to the embodiment of the present invention will be described below with reference to FIG.

FIG. 1 is a front view showing a schematic configuration of an immersion coating device 100 according to an embodiment of the present invention. In FIG. 1, the arrow indicates the flow direction of the coating liquid L.

As shown in FIG. 1, the immersion coating apparatus 100 (in this example, the electrophotographic photosensitive member manufacturing apparatus) is a coating liquid L for immersing the object to be coated E to form a coating film on the surface Ea of the object to be coated E. The coated object E and at least one of the coated object E and the coated object 10 (in this example, the coated object E) are relatively moved up and down to put the coated object E into the coating liquid L in the coating tank 10. It is provided with an elevating portion 20 (an example of elevating means) (specifically, an elevating mechanism portion) for immersing and pulling up from the coating liquid L.

The immersion coating device 100 immerses the object to be coated E in the coating tank 10 to a predetermined depth, and then pulls up the object to be coated E to form a coating film on the surface Ea of the object to be coated E. There is. Thereby, the coated product can be manufactured by applying the coating liquid L to the surface Ea of the object to be coated E.

In this example, the object to be coated E is a long object to be coated (for example, a cylindrical object to be coated) that is long in the vertical direction V. Specifically, the object to be coated E is a substrate F1 (specifically, a conductive substrate) (see FIGS. 10 and 11) constituting the electrophotographic photosensitive member F (see FIGS. 10 and 11 described later). The coating film formed on the surface Ea of the object to be coated E is formed into a plurality of layers (for example, an interference prevention layer, an undercoat layer, a charge generation layer, and a charge transport layer), and the coating liquid L is formed on the surface Ea of the object to be coated E. The product obtained by coating the coating film is an electrophotographic photosensitive member F (for example, a laminated organic photosensitive member).

<Applying tank>
The coating tank 10 has an opening 10a with an open upper surface, and the object to be coated E is inserted through the opening 10a. The coating tank 10 has a size capable of accommodating the object to be coated E. Further, the coating tank 10 is a coating tank (specifically, a single coating tank) capable of simultaneously (simultaneously or substantially simultaneously) coating the coating liquid L on a plurality of objects E to E from the viewpoint of improving productivity. (A plurality of coating tanks for applying the coating liquid L to each of the plurality of objects E to E to be coated) may be used.

<Elevating part>
The elevating portion 20 includes a support mechanism 21 that supports the object to be coated E and a drive device 22 that elevates and elevates the support mechanism 21. In this example, the elevating part 20 moves up and down the object to be coated E by a ball screw mechanism.

The support mechanism 21 is connected to the support portion 211 (specifically, the support plate) connected to the drive device 22 and the lower surface 211a on the tip end side of the support portion 211, and is connected to the object to be coated E (for example, the object to be coated E). It is provided with a holding portion 212 that detachably holds the upper end surface Eb).

The holding portion 212 may have any structure as long as the object to be coated E can be detachably held, and is not particularly limited. For example, the holding portion 212 may be provided with a chuck claw mechanism that detachably grips the protrusion provided on the upper end surface Eb of the object to be coated E. Alternatively, the holding portion 212 may be provided with a hook portion that can be engaged with and disengaged from the loop portion provided on the upper end surface Eb of the object to be coated E.

The drive device 22 includes a locking member 221 (screw shaft having a male screw portion in this example) and an elevating drive unit 222 (motor in this example) that drives the locking member 221 (rotational drive in this example). ing.

The support portion 211 of the support mechanism 21 is provided with an engaging portion 211b (female screw hole in this example) that engages (screws in this example) with the locking member 221 (male screw portion in this example). ..

In the elevating unit 20 having such a configuration, the locking member 221 is driven in one direction or the other direction (in this example, forward rotation drive or reverse rotation drive) by the elevating drive unit 222 to be coated together with the support portion 211. The object E can be moved up and down in the vertical direction V or substantially the vertical direction V. As the elevating drive unit 222, a drive unit whose drive speed can be adjusted, for example, a servomotor can be used. By doing so, the ascending / descending speed of the support portion 211 can be easily adjusted.

Specifically, the locking member 221 extends in the vertical direction V or the substantially vertical direction V. The support portion 211 extends in the horizontal direction H or a substantially horizontal direction H. The support portion 211 is engaged with the locking member 221 along the horizontal direction H or the substantially horizontal direction H. The object to be coated E is detachably attached to the holding portion 212 in a state of extending in the vertical direction V or substantially the vertical direction V.

The support mechanism 21 rotatably supports the guide member 223 (guide shaft in this example) that guides the support portion 211 along the vertical direction V or the substantially vertical direction V, and the lower end 221a of the locking member 221 around the axis. An upper support base 224 that supports the lower end 223a of the guide member 223 and an upper support base 224 that rotatably supports the upper end 221b of the locking member 221 and supports the upper end 223b of the guide member 223. It also has 225.

The support portion 211 of the support mechanism 21 is provided with an insertion portion 211c (specifically, a guide hole) through which the guide member 223 is inserted. The guide member 223 extends in the vertical direction V or the substantially vertical direction V. The locking member 221 and the guide member 223 are supported by the lower support base 224 and the upper support base 225 so as to be parallel to or substantially parallel to each other. An elevating drive unit 222 is provided on either one of the lower support base 224 and the upper support base 225 (upper support base 225 in this example).

In the elevating portion 20 having such a configuration, the guide member 223 guides the support portion 211 in the support mechanism 21 along the vertical direction V or the substantially vertical direction V, so that the locking member 221 supports the support mechanism 21. The portion 211 can be reliably moved up and down together with the object to be coated E in the vertical direction V or substantially the vertical direction V.

In this example, the elevating part 20 raises and lowers the object to be coated E by a ball screw mechanism, but another elevating mechanism, for example, a cylinder mechanism, a ball screw mechanism, or a link mechanism combined with a cylinder mechanism is used. You may.

In the present embodiment, the immersion coating device 100 is located between the coating liquid supply unit 30 for supplying the coating liquid L to the coating tank 10 and overflowing from the coating tank 10, and the coating liquid supply unit 30 and the coating liquid supply unit 30. It is further provided with a circulation unit 40 (an example of a circulation means) for circulating the coating liquid L.

In this example, the case where the elevating part 20 raises and lowers while holding a single object E to be coated is illustrated, but from the viewpoint of improving productivity, a plurality of objects E to be coated E to be applied by the elevating part 20. It may be configured to move up and down so as to hold E, and to apply a plurality of objects E to E to be coated simultaneously (simultaneously or substantially simultaneously) in one immersion. In this case, the coating tank 10 and the coating liquid recovery section 41 described later can be formed in a size capable of immersing a plurality of objects E to E to be coated.

<Coating liquid supply unit>
The coating liquid supply unit 30 includes a storage unit 31 (specifically, a storage tank) for storing the coating liquid L and a supply path 32 (specifically) for guiding the coating liquid L stored in the storage unit 31 to the coating tank 10. Is provided with a supply pipe) and a supply drive unit 33 (specifically, a pump) provided in the supply path 32 to supply the coating liquid L from the storage unit 31 to the coating tank 10.

The storage unit 31 may have a volume capable of accommodating the minimum amount of the coating liquid L required for circulation and the coating liquid L corresponding to the volume of the object to be coated E. Further, a lid portion 31a that can be opened and closed is provided above the storage portion 31 so that the coating liquid L can be charged and the coating liquid L and the solvent in the coating liquid L can be added. Further, the storage unit 31 is provided with a stirrer (not shown) for stirring and mixing the coating liquid L in the storage unit 31, a viscometer (not shown) for measuring the viscosity of the coating liquid L, and the like, and the coating liquid L is provided. The liquid physical properties of the above may be adjusted.

Further, an outlet 31b for flowing out the coating liquid L is provided at the bottom of the storage unit 31. The bottom of the coating tank 10 is provided with an inflow port 10b into which the coating liquid L flows. In the supply path 32, one end 32a is connected to the outflow port 31b in the storage section 31, and the other end 32b is connected to the inflow port 10b in the coating tank 10.

As the supply drive unit 33, for example, a pump having relatively little pulsation, such as a sine pump, a magnet pump, or a gear pump, can be preferably used.

<Circulation part>
The circulation unit 40 includes a coating liquid recovery unit 41 that collects the coating liquid L that overflows from the coating tank 10, and a circulation path 42 (specifically, a circulation pipe) that guides the coating liquid L that overflows from the coating tank 10 to the storage unit 31. And have.

The coating liquid collecting unit 41 is for suppressing evaporation of the coating liquid L in the receiving portion 411 having an L-shaped cross section and the receiving portion 411, which is liquid-tightly integrated with the upper end portion of the outer peripheral wall surface 11 of the coating tank 10. It is provided with a lid portion 412. The lid portion 412 is provided at the upper end of the receiving portion 411. In this example, the lid portion 412 is placed on the upper end surface of the receiving portion 411. Further, the lid portion 412 is provided with an opening 412a for moving the object to be coated E in and out of the coating tank 10.

An outlet 411a through which the coating liquid L flows out is provided on the side wall of the receiving portion 411. An inflow port 31c through which the coating liquid L flows is provided on the side wall of the storage portion 31. In the circulation path 42, one end 42a is connected to the outflow port 411a in the receiving portion 411, and the other end 42b is connected to the inflow port 31c in the storage portion 31.

Here, the outflow port 411a in the receiving portion 411 is arranged at a position higher than the inflow port 31c in the storage portion 31. Therefore, the coating liquid L collected by the coating liquid collecting unit 41 can flow into the storage unit 31 from the outflow port 411a through the circulation path 42 and the inflow port 31c. As a result, the coating liquid L can be circulated between the coating tank 10 and the storage portion 31.

<Windshield>
Above the coating tank 10, a windshield portion 50 for shielding the outside wind is provided over the entire circumference in the circumferential direction.

The windshield portion 50 may have any shape as long as it can shield the outside wind. In this example, the windshield portion 50 has a cylindrical shape. The windshield portion 50 is provided integrally with the lid portion 412.

As the material that can form the windbreak portion 50, any material may be used as long as it is a material that is not or hardly deteriorated by solvent vapor, and for example, a resin material such as stainless steel, polypropylene, or polyethylene terephthalate, or aluminum. , Metallic materials such as stainless steel, natural materials such as paper materials, and among these, stainless steel is preferably used from the viewpoint of improving the strength of the windbreak portion 50.

<Bending part>
The upper portion 50a of the windshield portion 50 is provided with a bent portion 60 bent outward over the entire circumference in the circumferential direction. Here, the upper portion 50a is a portion of a predetermined range determined in advance in the circumferential direction downward from the upper end 50b of the windshield portion 50.

According to the present embodiment, since the windshield portion 50 is provided above the coating tank 10 over the entire circumference in the circumferential direction, after the object to be coated E is immersed in the coating liquid L in the coating tank 10. When the object E to be coated is pulled up from the coating liquid L to form a coating film on the surface Ea of the object E to be coated, the windshield portion 50 can suppress the wind from the side to the object E to be coated. As a result, random film thickness unevenness and oblique film thickness unevenness of the coating film can be suppressed.

Moreover, since the bent portion 60 is provided on the upper portion 50a of the windshield portion 50 over the entire circumference in the circumferential direction, the apparatus configuration can be simplified and the object to be coated E is coated in the coating tank 10. After being immersed in the liquid L, when the object to be coated E is pulled up from the coating liquid L to form a coating film on the surface Ea of the object to be coated E, the air in the vicinity of the outer wall surface 51 of the windshield portion 50 is blown by the bent portion 60. Therefore, it is possible to effectively prevent the windshield portion 50 from wrapping around from the upper portion 50a of the windshield portion 50 toward the object to be coated E along the outer wall surface 51 of the windshield portion 50, whereby the object to be coated E and the coating tank 10 can be prevented. It is possible to effectively prevent wind due to the relative ascending / descending motion of at least one of them (in this example, the object to be coated E). As a result, it is possible to reduce the local difference in solvent vapor concentration, and therefore, it is possible to suppress the vertical streak-like film thickness unevenness of the coating film, and as a result, the film thickness difference at each part of the coating film is possible. Can be reduced.

Further, by applying the coating liquid L to the substrate F1 (see FIGS. 10 and 11) with the immersion coating apparatus 100, a stable electrophotographic photosensitive member in which the difference in film thickness at each part of the coating film is as small as possible. F (see FIGS. 10 and 11) can be obtained.

In the immersion coating apparatus 100 according to the present embodiment, in order to improve productivity, a plurality of objects E to E to be coated may be simultaneously (simultaneously or substantially simultaneously) coated in one immersion. In that case, the bent portion 60 may be provided in one windshield portion 50 that surrounds all of the plurality of objects E to E to be coated, or a plurality of windshield portions that surround the plurality of objects E to E to be coated. Bending portions 60 may be provided at 50 to 50, respectively. When a plurality of objects E to E to be coated are applied simultaneously (simultaneously or substantially simultaneously) in one immersion, the difference in vapor concentration between the inside and the outside of the windshield 50 becomes large, so that the bent portion 60 is provided. Therefore, the effect of suppressing the vertical streak-like film thickness unevenness of the coating film can be increased.

Further, in the immersion coating apparatus 100 according to the present embodiment, only the object to be coated E is raised or lowered among the object to be coated E and the coating tank 10, but only the coating tank 10 is raised or lowered, or the subject is coated. Both the coated object E and the coated tank 10 may be raised and lowered.

Here, the relative immersion speed of the object to be coated E can be exemplified by about 5 mm / sec to 20 mm / sec, and the relative pulling speed of the object to be coated E can be exemplified by about 1 mm / sec to 3 mm / sec.

Further, in the immersion coating device 100 according to the present embodiment, the windshield portion 50 may be integrated with the coating tank 10. In that case, the windshield 50 is connected to the upper part of the coating tank 10.

[About the first to tenth embodiments]
Next, the details of the windshield portion 50 and the bent portion 60 in the immersion coating device 100 according to the present embodiment will be described below with reference to FIGS. 2 to 9 in addition to FIG.

The windbreak portion 50 may be, for example, a cylindrical one or a square tubular one (a hollow square columnar whose upper surface and bottom surface are open).

(1st embodiment and 2nd embodiment)
2 and 3 are schematic exploded perspective views showing mainly the windshield portion 50 and the bent portion 60 portion of the immersion coating device 100 according to the first embodiment and the second embodiment, respectively.

The windshield portion 50 in the immersion coating device 100 according to the first embodiment shown in FIG. 2 has a cylindrical shape. The windshield portion 50 in the immersion coating device 100 according to the second embodiment shown in FIG. 3 has a square cylinder shape.

Then, in the immersion coating apparatus 100 according to the first embodiment and the second embodiment, the bent portion 60 has a straight portion 61 that bends linearly outward from the outer wall surface 51 of the windshield portion 50. That is, the bent portion 60 is formed linearly outward from the outer wall surface 51 of the windshield portion 50.

By doing so, the air AR in the vicinity of the outer wall surface 51 of the windbreak portion 50 is bent linearly by the straight portion 61, and the object to be coated is applied from the upper portion 50a of the windshield portion 50 along the outer wall surface 51 of the windshield portion 50. It is possible to surely prevent wraparound toward E.

(Third and Fourth Embodiments)
4 and 5 are schematic exploded perspective views showing mainly the windshield portion 50 and the bent portion 60 portion of the immersion coating device 100 according to the third embodiment and the fourth embodiment, respectively.

By the way, if the windshield 50 is formed in a shape that does not allow wind (air AR) to pass through at all, the windshield 50 can effectively prevent the wind from the side, and the random film thickness of the coating film is increased accordingly. It is possible to suppress thickness unevenness and oblique film thickness unevenness. However, on the other hand, if the windshield portion 50 is formed in a shape that does not allow air to pass through at all, the solvent vapor concentration of the coating liquid L tends to increase, and then the coating liquid L is applied to the object to be coated E. The difference in film thickness between the coating film on the upper part of the surface Ea and the coating film on the lower part tends to be large.

The windshield 50 in the immersion coating device 100 according to the third embodiment and the fourth embodiment shown in FIGS. 4 and 5 is the outer wall surface 51 of the windshield 50 in the immersion coating device 100 according to the first embodiment. All (entire surface) (see FIG. 4) or part (partial surface) (see FIG. 5) have a predetermined predetermined opening within a predetermined predetermined opening range, and a predetermined predetermined opening. It is formed into a porous M (mesh shape) having a predetermined hole opening rate within the hole opening rate range. Of course, such a mesh structure may be formed in the windshield portion 50 of the dipping coating device 100 according to the second embodiment.

Here, the "opening" is the size of the "opening (opening)". For example, if the opening is circular, the diameter of the opening is large, and if the opening is square, the opening is square. If the length of one side is long, the length in the longitudinal direction of the opening can be set.

Further, the "opening ratio (opening ratio)" is the ratio of the area of the open portion to the total area of the porous portion, and the open ratio = ("total opening area" / "total porous portion". Area ") x 100 [%] can be calculated.

In the windshield portion 50 of the immersion coating device 100 according to the fourth embodiment, the ratio of the area of the porous M portion to the total area of the outer wall surface 51 and the position where the porous M portion is provided are the windshield portions. It can be appropriately set according to various conditions related to the solvent vapor concentration of the coating liquid L, such as the shape of 50 and the type and amount of the solvent of the coating liquid L. In this example, the porous M is formed in a portion about the lower half of the outer wall surface 51 over the entire circumference in the circumferential direction.

In the immersion coating apparatus 100 according to the third embodiment and the fourth embodiment, all or a part of the outer wall surface 51 has a predetermined opening within a predetermined opening range, and a predetermined opening rate range is provided. Since it is formed in a porous M (mesh shape) with a pore-opening ratio of, the difference in film thickness between the coating film on the upper part and the coating film on the lower part of the surface Ea of the object to be coated E coated with the coating liquid L can be obtained. It can be made smaller. This is because in the windbreak portion 50 in which the porous M is formed, the solvent vapor concentration inside the windshield portion 50 can be appropriately lowered, so that the coating liquid L drips when the coating film is formed. It is considered that this is because it is possible to suppress.

The predetermined opening and the predetermined opening ratio should be appropriately set according to various conditions related to the solvent vapor concentration of the coating liquid L, such as the shape of the windshield 50 and the type and amount of the solvent of the coating liquid L. Can be done.

By the way, if the predetermined opening is smaller than the lower limit of the predetermined opening range or the predetermined opening rate is smaller than the lower limit of the predetermined opening rate range, it is difficult to obtain the effect of lowering the solvent vapor concentration. On the other hand, when the predetermined opening is larger than the upper limit of the predetermined opening range or the predetermined opening rate is larger than the upper limit of the predetermined opening rate range, the object to be coated E passes through the windshield 50. This makes it easier to receive wind from the side, which makes it easier for random film thickness unevenness and oblique film thickness unevenness to occur in the coating film.

In this respect, in the dip coating apparatus 100 according to the third embodiment and the fourth embodiment, the effect of lowering the solvent vapor concentration can be obtained by keeping the predetermined opening within the predetermined opening range, while the effect of lowering the solvent vapor concentration can be obtained. When the predetermined opening rate is within the predetermined opening rate range, the object to be coated E can be made less likely to receive the wind from the side through the windshield 50, and the coating film is more effectively random. It is possible to suppress various film thickness unevenness and oblique film thickness unevenness.

In the dipping coating apparatus 100 according to the third embodiment and the fourth embodiment, the predetermined opening range can be exemplified by about 50 μm to 100 μm, and the predetermined opening ratio range can be exemplified by about 30% to 50%. can.

As described above, when the predetermined opening range is about 50 μm to 100 μm and the predetermined opening ratio range is about 30% to 50%, the upper portion of the object to be coated E coated with the coating liquid L The difference in film thickness between the coating film and the coating film at the bottom can be reliably reduced.

(Fifth Embodiment)
FIG. 6 is a schematic vertical cross-sectional view showing an enlarged portion of a windshield portion 50 and a bent portion 60 portion of the immersion coating device 100 according to the fifth embodiment.

As shown in FIG. 6, in the immersion coating device 100 according to the fifth embodiment, in the windshield portion 50 of the immersion coating device 100 shown in FIGS. 2 to 5, the straight portion 61 constituting the bent portion 60 is a windshield. The outer wall surface 51 of the portion 50 is bent at a predetermined bending angle θ within a predetermined bending angle range. Here, the predetermined bending angle θ of the straight portion 61 is referred to as an angle formed by the portion of the outer wall surface 51 of the windshield portion 50 below the straight portion 61 and the straight portion 61. Further, the predetermined bending angle range is a bending angle range that can surely prevent the air AR that wraps around from the upper portion 50a of the windbreak portion 50 toward the object to be coated E along the outer wall surface 51 of the windbreak portion 50. ..

By the way, when the bending angle θ is below the lower limit value or the upper limit value of the predetermined bending angle range, the air AR toward the upper portion 50a of the windshield portion 50 along the outer wall surface 51 of the windshield portion 50 is generated by the windshield portion 50. It is not possible to effectively prevent the wraparound from the upper portion 50a toward the object to be coated E.

In this respect, in the immersion coating device 100 according to the fifth embodiment, when the bending angle θ is within a predetermined bending angle range, the bending angle θ is directed toward the upper portion 50a of the windshield portion 50 along the outer wall surface 51 of the windshield portion 50. It is possible to effectively prevent the air AR from wrapping around from the upper portion 50a of the windshield portion 50 toward the object to be coated E, and it is possible to effectively suppress uneven film thickness of the coating film.

In the immersion coating apparatus 100 according to the fifth embodiment, the predetermined bending angle range can be exemplified by about 45 ° to 150 °, and more preferably about 60 ° to 75 °.

In this way, when the predetermined bending angle range is about 45 ° to 150 °, the air AR directed to the upper portion 50a of the windbreak portion 50 along the outer wall surface 51 of the windshield portion 50 is provided by the windshield portion 50. It is possible to reliably prevent the upper portion 50a from wrapping around toward the object to be coated E. Moreover, when the predetermined bending angle range is about 60 ° to 75 °, the air AR directed to the upper portion 50a of the windshield 50 along the outer wall surface 51 of the windshield 50 is blown by the bending portion 60. The air AR can be directed diagonally downward by the bending angle θ of the bent portion 60 from the outer wall surface 51 of the 50, thereby causing the air AR toward the upper portion 50a of the windbreak portion 50 along the outer wall surface 51 of the windshield portion 50. It is possible to more reliably prevent the windshield portion 50 from wrapping around from the upper portion 50a toward the object to be coated E, and it is possible to effectively suppress uneven film thickness of the coating film.

(Sixth Embodiment)
FIG. 7 is a schematic vertical cross-sectional view showing an enlarged portion of a windshield portion 50 and a bent portion 60 portion of the immersion coating device 100 according to the sixth embodiment.

As shown in FIG. 7, in the immersion coating device 100 according to the sixth embodiment, in the windshield portion 50 of the immersion coating device 100 shown in FIGS. 2 to 5, the bent portion 60 is the outer wall surface 51 of the windshield portion 50. It has a curved portion 62 that bends outward in a curved shape. That is, the bent portion 60 is formed in a curved shape from the outer wall surface 51 of the windshield portion 50 toward the outside. Here, as the curved shape, an arc shape and an elliptical arc shape can be exemplified. The direction of the curved shape is as follows: a curved shape that is convex upward, a curved shape that the tip points diagonally upward, a curved shape that the tip points in the horizontal direction H or substantially horizontal direction H, a curved shape that the tip points diagonally downward, and a curved shape that the tip blocks. An example of a curved shape toward the outer wall surface 51 of the wind portion 50 can be illustrated.

By doing so, the air AR in the vicinity of the outer wall surface 51 of the windbreak portion 50 is bent in a curved shape by the curved portion 62, and the object to be coated is applied from the upper portion 50a of the windshield portion 50 along the outer wall surface 51 of the windshield portion 50. It is possible to surely prevent wraparound toward E.

(7th Embodiment)
FIG. 8 is a schematic vertical cross-sectional view showing an enlarged portion of a windshield portion 50 and a bent portion 60 portion of the immersion coating device 100 according to the seventh embodiment.

As shown in FIG. 8, in the dipping coating device 100 according to the seventh embodiment, in the windshield portion 50 of the dipping coating device 100 shown in FIGS. 2 to 5, the bent portion 60 is a straight portion 61 that bends linearly. And a curved portion 62 which is connected to the tip of the straight portion 61 and bends in a curved shape. Here, as the curved shape, an arc shape and an elliptical arc shape can be exemplified. The direction of the curved shape is as follows: a curved shape that is convex upward, a curved shape that the tip points diagonally upward, a curved shape that the tip points in the horizontal direction H or substantially horizontal direction H, a curved shape that the tip points diagonally downward, and a curved shape that the tip blocks. An example of a curved shape toward the outer wall surface 51 of the wind portion 50 can be illustrated.

The straight line portion 61 constituting the bent portion 60 is bent with respect to the outer wall surface 51 of the windshield portion 50 at a predetermined bending angle θ within a predetermined bending angle range. The predetermined bending angle range and the predetermined bending angle θ are the same as those described in the fifth embodiment, and the description thereof will be omitted here.

By doing so, the air AR in the vicinity of the outer wall surface 51 of the windbreak portion 50 is formed by the bent portion 60 having the straight portion 61 and the curved portion 62, and the upper portion 50a of the windbreak portion 50 is formed along the outer wall surface 51 of the windshield portion 50. It is possible to more reliably prevent the vehicle from wrapping around toward the object to be coated E.

Moreover, even if the predetermined bending angle θ of the straight portion 61 exceeds the upper limit value of the predetermined bending angle range, the air AR toward the upper portion 50a of the windshield portion 50 along the outer wall surface 51 of the windshield portion 50 is provided. The curved portion 62 can be directed diagonally upward, laterally, diagonally downward, or the like, whereby the air AR directed toward the upper portion 50a of the windshield portion 50 along the outer wall surface 51 of the windshield portion 50 is directed to the windshield portion 50. It is possible to make it difficult to wrap around from the upper portion 50a toward the object to be coated E, and it is possible to effectively suppress uneven film thickness of the coating film.

In this example, the straight portion 61 and the curved portion 62 constituting the bent portion 60 are integrally formed.

Although not shown, the bent portion 60 has a curved portion that bends in a curved shape from the outer wall surface 51 of the windshield portion 50, and a straight portion that is connected to the tip of the curved portion and bends in a straight line. That is, the structure may be formed in a curved shape outward from the outer wall surface 51 of the windshield portion 50, and further formed in a straight line.

(8th Embodiment)
FIG. 9 is a schematic vertical cross-sectional view showing an enlarged portion of a windshield portion 50 and a bent portion 60 portion of the immersion coating device 100 according to the eighth embodiment.

In the fifth to seventh embodiments, the bent portion 60 is provided at the upper end 50b (see FIGS. 6 to 8) of the windshield portion 50, but as shown in FIG. 9, in the eighth embodiment. In the dipping coating device 100, the windshield portion 50 of the dipping coating apparatus 100 shown in FIGS. 2 to 5 is below the upper end 50b of the windshield portion 50 by a predetermined vertical distance h (for example, 5 mm). It is provided at the position. Note that FIG. 9 shows an example of the fifth embodiment. Here, the predetermined distance range is a distance range that can surely prevent the air AR that wraps around from the upper portion 50a of the windshield portion 50 toward the object to be coated E along the outer wall surface 51 of the windshield portion 50.

By doing so, when the bent portion 60 cannot be provided at the upper end 50b of the windbreak portion 50, even if the bent portion 60 is provided below the upper end 50b of the windshield portion 50 by a predetermined vertical distance h, the windshield portion It is possible to reliably prevent the air AR wrapping around from the upper portion 50a of the windshield portion 50 toward the object to be coated E along the outer wall surface 51 of the 50.

(9th Embodiment)
In the dipping coating device 100 according to the ninth embodiment, in the dipping coating device 100 according to the fifth to eighth embodiments, the bent portion 60 has a tip 60a (see FIGS. 6 to 9) of the windshield portion 50. It is separated from the outer wall surface 51 by a predetermined horizontal distance d (see FIGS. 6 to 9) in the horizontal direction H. Here, the predetermined horizontal distance d is the distance between the tip 60a of the bent portion 60 of the virtual straight line (not shown) along the horizontal direction H and the outer wall surface 51 of the windshield portion 50. Further, the predetermined horizontal distance d is a horizontal distance that can surely prevent the air AR that wraps around from the upper portion 50a of the windshield portion 50 toward the object to be coated E along the outer wall surface 51 of the windshield portion 50.

By the way, when the tip 60a of the bent portion 60 is located closer to the outer wall surface 51 of the windshield portion 50 than the horizontal distance d in the predetermined horizontal direction H, the coating liquid L is applied to the object to be coated E. Due to the difference in coating speed and / or the difference in the coating environment of the coating liquid L on the object to be coated E and / or the continuous coating on the object to be coated E, the effect of suppressing uneven film thickness of the coating film is reduced. In some cases, this results in the instability of the manufactured product. In particular, when the coating speed is high or the solid content concentration of the coating liquid L is low, uneven film thickness of the coating film is likely to occur.

In this respect, in the immersion coating device 100 according to the ninth embodiment, the tip 60a of the bent portion 60 is separated from the outer wall surface 51 of the windshield portion 50 by a predetermined horizontal distance d in the horizontal direction H, so that the coating is applied. Due to the difference in speed and / or the difference in coating environment and / or continuous coating, it is possible to avoid a decrease in the effect of suppressing uneven film thickness of the coating film, thereby improving the stability of the manufactured product. Can be done.

In the dipping coating device 100 according to the ninth embodiment, the predetermined horizontal distance d may be about 10 mm or more.

In this way, when the predetermined horizontal distance d is about 10 mm or more, uneven coating film thickness can be suppressed by the difference in coating speed and / or the difference in coating environment and / or continuous coating. As a result, the stability of the manufactured product can be reliably improved.

(10th Embodiment)
By the way, the bent portion 60 may be provided on the upper portion 50a of the windbreak portion 50 by integrating the bent portion 60 with the windshield portion 50, for example, by processing the windshield portion 50 itself. It takes time and effort to process, and the processing cost is high. Moreover, it is not possible to substantially correspond to the existing windshield portion 50.

In this regard, in the immersion coating device 100 according to the tenth embodiment, the bent portion 60 is composed of a sheet-shaped member. As a result, the bent portion 60 can be detachably provided with respect to the windshield portion 50. For example, the bent portion 60 made of a sheet-shaped member can be attached to the upper portion 50a of the windshield portion 50 with an adhesive sheet (for example, an adhesive tape).

By doing so, it is not necessary to process the windshield 50 itself, so that the labor for processing can be reduced, and a sheet-like member is provided on the upper portion 50a of the windshield 50, which is a simpler configuration. However, uneven film thickness of the coating film can be suppressed. Moreover, it can easily correspond to the existing windbreak portion 50.

[Electrophotophotoreceptor]
Next, the electrophotographic photosensitive member F manufactured by the immersion coating apparatus 100 shown in FIG. 1 will be described below with reference to FIGS. 10 and 11.

FIG. 10 is a vertical cross-sectional view showing a schematic configuration of an example of an electrophotographic photosensitive member F manufactured by applying a coating liquid L to a substrate F1 by the immersion coating apparatus 100 shown in FIG. Further, FIG. 11 is an enlarged partial cross-sectional view of the surface portion of an example of the electrophotographic photosensitive member F shown in FIG.

In the dipping coating by the dipping coating device 100 according to the present embodiment, the electrophotographic photosensitive member is manufactured by using the conventional dipping coating device, except that the windshield portion 50 provided with the bent portion 60 described above is used. It can be carried out under the same conditions as.

The electrophotographic photosensitive member F to be manufactured is roughly classified into a single-layer type and a laminated type, and the immersion coating apparatus 100 according to the present embodiment has image characteristics particularly in either type. The excellent electrophotographic photosensitive member F can be produced.

As shown in FIG. 10, the electrophotographic photosensitive member F (in this example, the electrophotographic photosensitive member drum) is a cylindrical substrate F1 (specifically, a conductive substrate) as an object to be coated E and an outer peripheral surface of the substrate F1. A photoconductor body F3 (photoreceptor drum body) composed of a plurality of layers including the photosensitive layer F2 formed in the above, and a pair of flanges F4 that support the photoconductor body F3 while closing the openings at both ends in the direction of the rotation axis. It is equipped with F4.

As shown in FIG. 11, the electrophotographic photosensitive member F has a substrate F1 (E) and a photosensitive layer F2. The photosensitive layer F2 is formed on the outer peripheral surface of the substrate F1.

In this example, the electrophotographic photosensitive member F is a laminated type, and the photosensitive layer F2 is a charge generating layer F21 (specifically, a charge generating substance-containing layer) (see FIG. 11) and a charge transporting layer F22 (specifically). It includes a charge-transporting substance-containing layer) (see FIG. 11). Such a laminated electrophotographic photosensitive member F is widely used in the field of electrophotographic technology.

The charge generating layer F21 contains a charge generating substance that generates an electric charge. The charge generation layer F21 is laminated on the substrate F1. The charge transport layer F22 contains a charge transport material that transports the charges generated in the charge generation layer F21. The charge transport layer F22 is laminated on the charge generation layer F21.

The immersion coating apparatus 100 according to the present embodiment can also be used for producing layers other than each layer in the above-mentioned electrophotographic photosensitive member F.

For example, the dip coating device 100 according to the present embodiment is also applied to the interference prevention layer, the undercoat layer, and the protective layer provided on the uppermost layer provided between the substrate F1 and the charge generation layer F21 for the purpose of preventing charge injection. Can be formed using.

Next, the substrate F1 constituting the electrophotographic photosensitive member F manufactured by using the immersion coating apparatus 100 according to the present embodiment and each layer provided on the substrate F1 will be described below.

<Hpokeimenon>
The substrate F1 (specifically, the conductive substrate) has a function as an electrode of the electrophotographic photosensitive member F and a function as a support member. The constituent material of the substrate F1 is not particularly limited as long as it is a material used in the technical field.

Specifically, as a constituent material of the substrate F1, for example, a metal material such as aluminum, aluminum alloy, copper, zinc, stainless steel, and titanium, a polymer material such as polyethylene terephthalate, polyamide, polyester, polyoxymethylene, and polystyrene, Hard paper material, a support made of non-conductive material such as glass laminated with a conductive film such as metal foil, a metal material or conductive polymer on the surface of the support made of non-conductive material such as glass , Tin oxide, indium oxide and other conductive compound layers are vapor-deposited or coated. Among these, aluminum alloys such as JIS3003 series, JIS5000 series and JIS6000 series are particularly preferable.

Further, the shape of the substrate F1 can be exemplified by a cylindrical shape, the diameter of the substrate F1 can be exemplified by about 10 mm to 300 mm, and the length of the substrate F1 can be exemplified by about 200 mm to 1000 mm.

If necessary, the surface of the substrate F1 is subjected to diffuse reflection treatment such as anodic oxide film treatment, surface treatment with chemicals, hot water, coloring treatment, and roughening of the surface within a range that does not affect the image quality. You may be.

<Underlay layer>
For the undercoat layer, for example, a resin material is dissolved or dispersed in an appropriate solvent to prepare a coating liquid for the undercoat layer, the coating liquid for the undercoat layer is applied to the surface of the substrate F1, and the organic solvent is dried by drying. It can be formed by removing it.

Examples of the resin material that can be used for the undercoat layer include natural binder resins such as casein, gelatin, polyvinyl alcohol, and ethyl cellulose, in addition to binder resins (such as polyamide resins) similar to those contained in the photosensitive layer F2 described later. Polymer materials and the like can be mentioned, and one or more of these can be used. Among these resin materials, a polyamide resin is preferable, and a polyamide resin containing an alcohol-soluble nylon resin and a piperazine-based compound is particularly preferable.

Examples of the solvent for dissolving or dispersing the resin material that can be used for the undercoat layer include water, alcohols such as methanol, ethanol and butanol, glime such as methylcarbitol and butylcarbitol, dichloroethane, chloroform or trichloroethane. Examples thereof include chlorine-based solvents such as, acetone, dioxolane, and mixed solvents obtained by mixing two or more of these solvents. Among these solvents, for example, non-halogen organic solvents can be preferably used in consideration of the global environment.

Further, the coating liquid for the undercoat layer may contain metal oxide particles. The metal oxide particles can easily adjust the volume resistance value of the intermediate layer, further suppress the injection of electric charge into the photosensitive layer F2, and have the electrical characteristics of the electrophotographic photosensitive member F under various environments. Can be maintained. Examples of the material that can be used for the metal oxide particles include materials such as titanium oxide, aluminum oxide, aluminum hydroxide, and tin oxide.

The ratio (C / D) of the total weight C of the binder resin and the metal oxide particles to the weight D of the solvent in the coating liquid for the undercoat layer is preferably about 1/99 to 40/60, for example, 2 /. About 98 to 30/70 is particularly preferable.

The ratio (E / F) of the weight E of the binder resin to the weight F of the metal oxide particles is preferably, for example, about 90/10 to 1/99, and particularly preferably about 70/30 to 5/95. ..

The temperature in the drying step of the coating film of the undercoat layer is not particularly limited as long as it can remove the organic solvent used, but for example, about 50 ° C. to 140 ° C. is appropriate, and 80 ° C. ~ 130 ° C. is particularly preferable.

If the drying temperature of the coating film of the undercoat layer is less than about 50 ° C., the drying time may be long. Further, if the drying temperature of the coating film of the undercoat layer exceeds about 140 ° C., the electrical characteristics of the electrophotographic photosensitive member F during repeated use may deteriorate, and the obtained image may deteriorate.

Such temperature conditions are common not only in the undercoat layer but also in layer formation such as the photosensitive layer F2 described later and other treatments.

The film thickness of the undercoat layer is not particularly limited, but is preferably about 0.01 μm to 20 μm, and particularly preferably about 0.05 μm to 10 μm.

<Charge generation layer>
The charge generation layer F21 has a function of generating electric charges by absorbing light emitted by a light emitting device that emits light such as a light beam (specifically, a semiconductor laser) in an electrophotographic device such as an image forming device. It has a charge generating substance as a main component, and contains a binder resin and additives as needed. As the charge generating substance, a compound used in the art can be used.

Specifically, as the charge generating substance, for example, azo pigments such as monoazo pigments, bisazo pigments and trisazo pigments, indigo pigments such as indigo and thioindigo, and perylene pigments such as peryleneimide and perylene anhydride, Polycyclic quinone pigments such as anthraquinone and pyrenequinone, metallic phthalocyanines such as oxotitanium phthalocyanine and phthalocyanine pigments such as non-metallic phthalocyanine, organic photoconductive materials such as squarylium pigments, pyrylium salts, thiopyrilium salts and triphenylmethane pigments, In addition, inorganic photoconductive materials such as selenium and amorphous silicon can be mentioned, and those having sensitivity in the exposure wavelength range can be appropriately selected and used. These charge generating substances may be used alone or in combination of two or more.

The charge generation layer F21 may contain a binder resin for the purpose of improving the binding property. As the binder resin that can be used for the charge generating layer F21, a resin having binding properties used in the art can be used, and one having excellent compatibility with the charge generating substance is preferable.

Specifically, examples of the binder resin that can be used for the charge generation layer F21 include polyester, polystyrene, polyurethane, phenol resin, alkyd resin, melamine resin, epoxy resin, silicone resin, acrylic resin, methacrylic resin, polycarbonate, and poly. Examples thereof include allylate, phenoxy resin, polyvinyl butyral, polyvinyl formal, and a copolymer resin containing two or more of the repeating units constituting these resins. Examples of the copolymer resin include insulating resins such as vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-maleic anhydride copolymer resin and acrylonitrile-styrene copolymer resin. can. The binder resin that can be used for the charge generation layer F21 is not limited to these, and a resin that is generally used in the art can be used as the binder resin. These binder resins may be used alone or in combination of two or more.

Examples of the solvent that can be used for the charge generation layer F21 include halogenated hydrocarbons such as dichloromethane and dichloroethane, ketones such as acetone, methyl ethyl ketone and cyclohexanone, and esters such as ethyl acetate and butyl acetate; tetrahydrofuran (THF). , Ethers such as dioxane, alkyl ethers of ethylene glycol such as 1,2-dimethoxyethane, aromatic hydrocarbons such as benzene, toluene and xylene; such as N, N-dimethylformamide and N, N-dimethylacetamide. Examples thereof include an aprotic polar solvent. Among these solvents, for example, non-halogen organic solvents can be preferably used in consideration of the global environment. These solvents may be used alone or in combination of two or more.

Dispersers such as paint shakers, ball mills and sand mills can be used to dissolve or disperse the charge generating material in the binder resin solution. At this time, it is preferable to appropriately set the dispersion conditions so that impurities are not generated from the container and the members constituting the disperser due to wear or the like and are not mixed in the coating liquid.

Other steps and conditions thereof are the same as those for forming the undercoat layer, and description thereof will be omitted here.

The film thickness of the charge generation layer F21 is not particularly limited, but preferably about 0.05 μm to 5 μm, and more preferably about 0.1 μm to 1 μm.

<Charge transport layer>
The charge transport layer F22 has a function of receiving the charge generated by the charge generating substance and transporting it to the surface Fa (see FIGS. 10 and 11) of the electrophotographic photosensitive member F, and the charge transport material and the binder resin, if necessary. Contains additives. As the charge transporting substance, a compound used in the art can be used.

Specifically, as the charge transporting substance, for example, carbazole derivative, pyrene derivative, oxazole derivative, oxaziazole derivative, thiazole derivative, thiazazole derivative, triazole derivative, imidazole derivative, imidazolone derivative, imidazolidine derivative, bisimidazolidine derivative, Styryl compounds, hydrazone compounds, polycyclic aromatic compounds, indol derivatives, pyrazoline derivatives, oxazolone derivatives, benzimidazole derivatives, quinazoline derivatives, benzofuran derivatives, acrydin derivatives, phenazine derivatives, aminostilben derivatives, triarylamine derivatives, triarylmethane derivatives , Phenylene diamine derivatives, stillben derivatives, enamine derivatives, benzidine derivatives, polymers having a group derived from these compounds in the main chain or side chains (poly-N-vinylcarbazole, poly-1-vinylpyrene, ethylcarbazole-formaldehyde resin) , Triphenylmethane polymer, poly-9-vinylanthracene, etc.), polysilane, and the like. These charge transporting substances may be used alone or in combination of two or more.

As the binder resin that can be used for the charge transport layer F22, a resin having binding properties used in the art can be used, and one having excellent compatibility with the charge transport substance is preferable.

Specifically, as the binder resin that can be used for the charge transport layer F22, for example, vinyl polymer resins such as polymethylmethacrylate, polystyrene, and polyvinyl chloride, copolymer resins thereof, and polycarbonate, polyester, and polyester. Resins such as carbonate, polysulfone, phenoxy, epoxy resin, silicone resin, polyarylate, polyamide, polyether, polyurethane, polyacrylamide, phenol resin, polyphenylene oxide, and heat-curable resin obtained by partially cross-linking these resins. be able to. These binder resins may be used alone or in combination of two or more.

Among these, polystyrene, polycarbonate, polyarylate and polyphenylene oxide are ^{preferable because they have a volume resistance value of 10 13} Ω or more, are excellent in electrical insulation, and are also excellent in film forming property and potential characteristics. , Polycarbonate is particularly preferable.

The ratio A / B of the charge transporting substance and the binder resin is preferably about 10/12 to 10/30.

Examples of the solvent that can be used for the charge transport layer F22 include aromatic hydrocarbons such as benzene, toluene, xylene and monochlorobenzene, halogenated hydrocarbons such as dichloromethane and dichloroethane, THF (tetrahydrofuran), dioxane and dimethoxymethyl ether. Ethers such as, and aprotic polar solvents such as N, N-dimethylformamide can be mentioned. Further, if necessary, a solvent such as alcohols, acetonitrile or methyl ethyl ketone can be further added and used. Among these solvents, for example, non-halogen organic solvents can be preferably used in consideration of the global environment. These solvents may be used alone or in combination of two or more.

The film thickness of the charge transport layer F22 is not particularly limited, but preferably about 5 μm to 50 μm, and more preferably about 10 μm to 40 μm.

Further, the coating liquid for producing the single-layer electrophotographic photosensitive member F can be prepared by mixing (dispersing) the above-mentioned charge generating substance, charge transporting substance, binder resin and solvent.

[Image forming device]
Next, the image forming apparatus 700 including the electrophotographic photosensitive member F manufactured by the immersion coating apparatus 100 shown in FIG. 1 will be described below with reference to FIG. The image forming apparatus 700 and its operation are not limited to the following items.

<Structure of image forming apparatus>
FIG. 12 is a cross-sectional view schematically showing a schematic configuration of an image forming apparatus 700 including an electrophotographic photosensitive member F manufactured by the dipping coating apparatus 100 shown in FIG.

As shown in FIG. 12, the image forming apparatus 700 is charged by the electrophotographic photosensitive member F, the charging means for charging the surface Fa of the electrophotographic photosensitive member F (specifically, the charger 710), and the charger 710. An exposure means (specifically, an exposure apparatus 720) that exposes the electrophotographic photosensitive member F to form an electrostatic latent image and an electrostatic latent image formed by the exposure apparatus 720 are developed to form a toner image. A developing means (specifically, a developing device 730), a transfer means (specifically, a transfer charging device 740) for transferring a toner image formed by the developing device 730 onto a recording medium P such as a recording paper, and an electrophotographic photograph. A cleaning means (specifically, a cleaner device 750) that removes and recovers the toner remaining on the photoconductor F, and a fixing means that fixes the toner image transferred by the transfer charger 740 on the recording medium P to form an image. (Specifically, a fuser 760) is provided. In this example, the image forming apparatus 700 is a monochrome printer (specifically, a laser printer).

The image forming apparatus 700 is a monochrome image forming apparatus in this example, but may be, for example, an intermediate transfer type color image forming apparatus capable of forming a color image. Specifically, it is a so-called tandem full-color image forming apparatus in which a plurality of electrophotographic photosensitive members F to F on which toner images are formed are arranged side by side in a predetermined direction (for example, horizontal direction H or substantially horizontal direction H). There may be. Further, the image forming apparatus 700 may be another color image forming apparatus. Further, although the image forming apparatus 700 is a printer in this example, it may be, for example, a copying machine, a multifunction device, or a facsimile apparatus.

The electrophotographic photosensitive member F is rotatably supported by a main body frame (not shown) of the image forming apparatus 700, and is rotatably supported by a driving means (not shown) in a predetermined rotation direction R (clockwise in the figure) around the rotation axis α1. It is driven to rotate. The driving means includes, for example, an electric motor and a reduction gear, and transmits the rotational driving force to the substrate F1 of the electrophotographic photosensitive member F so as to rotationally drive the electrophotographic photosensitive member F at a predetermined peripheral speed. It has become.

A charger 710, an exposure device 720, a developing device 730, a transfer charger 740, and a cleaner device 750 are provided around the electrophotographic photosensitive member F from the upstream side to the downstream side in the rotation direction R in this order. There is.

The charger 710 is a charging means that uniformly charges the surface Fa of the electrophotographic photosensitive member F to a predetermined potential by a high voltage applying means (specifically, a high voltage applying device 711). Examples of the charging means include a non-contact charging method and a contact charging method. Examples of the non-contact charging method include a corona charging method using a charging charger, and examples of the contact charging method include a charging roller or a charging brush method. In this example, the charger 710 includes a charging roller.

By the way, in a conventional image forming apparatus, when the surface of an electrophotographic photosensitive member is charged only with a DC voltage by a contact charging method, it is excellent in that it reduces the generation of ozone and damage to the electrophotographic photosensitive member. However, the chargeability changes in various places due to a slight difference in the thickness of the coating film, and each layer (for example, a charge generation layer or a charge transport layer) formed on the electrophotographic photosensitive member on an image such as a halftone formed. It is known that image density unevenness (specifically, shading streaks) due to the difference in film thickness is likely to occur.

In this regard, even if the image forming apparatus 700 according to the present embodiment uses a contact charging type charging means (specifically, a charger 710) that charges the surface Fa of the electrophotographic photosensitive member F only with a DC voltage. , Image density unevenness (specifically, shading streaks) due to the difference in film thickness of each layer (for example, charge generating layer F21 and charge transporting layer F22) formed on the electrophotographic photosensitive member F on an image such as a halftone formed. ) Can be eliminated or almost eliminated.

The exposure apparatus 720 is an exposure means that emits light modulated based on image information. In this example, the exposure apparatus 720 includes, for example, a light source (not shown) including a semiconductor laser or a light emitting diode (LED), and the light output from the light source is combined with the charger 710 and the developer 730. By irradiating the surface Fa of the electrophotographic photosensitive member F between them, an electrostatic latent image corresponding to the image information is formed on the surface Fa of the uniformly charged electrophotographic photosensitive member F. The exposure apparatus 720 repeatedly scans the light modulated based on the image information on the surface Fa of the electrophotographic photosensitive member F driven by rotation in the rotation axis α1 direction of the electrophotographic photosensitive member F, which is the main scanning direction. As a result, an electrostatic latent image can be formed on the surface Fa of the electrophotographic photosensitive member F.

The developer 730 accommodates the developer D (for example, toner and carrier for a two-component developer) and an electrostatic latent image formed on the surface Fa of the electrophotographic photosensitive member F by the exposure apparatus 720. Is a developing means for developing with the developer D. In this example, the developing device 730 accommodates a developing roller 730a, which is provided so as to face the surface Fa of the electrophotographic photosensitive member F and supplies the developing agent D to the surface Fa of the electrophotographic photosensitive member F, and the developing agent D. It is provided with a developing tank 730b (specifically, a casing). The developing tank 730b rotatably supports the developing roller 730a around the rotation axis α2 which is parallel to or substantially parallel to the rotation axis α1 of the electrophotographic photosensitive member F.

The transfer charger 740 is a recording medium P in which a toner image, which is a visible image formed on the surface Fa of the electrophotographic photosensitive member F by the developing device 730, is conveyed in a predetermined conveying direction W by a conveying means (not shown). It is a transfer means to be transferred onto. The transfer means applies a predetermined high voltage to the transfer nip portion TN formed between the electrophotographic photosensitive member F and the transfer charger 740 by the high voltage application means 741 (specifically, the high voltage application device). .. The transfer means can be configured in the same manner as the charging means described above. In this example, the contact-type transfer means for transferring the toner image onto the recording medium P by applying a charge having the opposite polarity to the toner to the recording medium P. It is said that.

The cleaner device 750 is a cleaning means for removing and recovering the toner remaining on the surface Fa of the electrophotographic photosensitive member F after the transfer operation by the transfer charger 740. In this example, the cleaner device 750 includes a cleaning blade 750a for removing the toner remaining on the surface Fa of the electrophotographic photosensitive member F, and a recovery casing 750b for accommodating the toner removed by the cleaning blade 750a. Further, the cleaner device 750 is provided together with a static elimination means (specifically, a static elimination lamp) which is not shown.

The fixing device 760 is a fixing means for fixing the toner image transferred to the recording medium P by the transfer charger 740 to the recording medium P. The fuser 760 is provided on the downstream side of the transfer nip portion TN between the electrophotographic photosensitive member F and the transfer charger 740 in the transport direction W. In this example, the fixing device 760 includes a heating means (specifically, a heating roller 760a) and a pressurizing means (specifically, a pressurizing roller 760b) provided so as to face the heating roller 760a. The pressure roller 760b is pressed by the heating roller 760a to form a fixing nip portion FN.

Further, the image forming apparatus 700 includes a separating means (specifically, a separating claw 770) for separating the recording medium P from the electrophotographic photosensitive member F, and a casing (specifically) for accommodating each component constituting the image forming apparatus 700. In particular, the casing 780) is further provided.

<Operation of image forming device>
In the image forming apparatus 700 described above, first, when the electrophotographic photosensitive member F is rotationally driven in a predetermined rotational direction R by the driving means, the surface Fa of the electrophotographic photosensitive member F is brought to a predetermined potential by the charger 710. It is uniformly charged.

Next, the exposure apparatus 720 irradiates the surface Fa of the electrophotographic photosensitive member F uniformly charged with light according to the image information. An electrostatic latent image is formed on the surface Fa of the electrophotographic photosensitive member F by irradiating the surface Fa with light by the exposure apparatus 720.

The electrostatic latent image formed on the surface Fa of the electrophotographic photosensitive member F is developed by the developing device 730, and a toner image is formed on the surface Fa of the electrophotographic photosensitive member F.

The recording medium P sent from the upstream side of the electrophotographic photosensitive member F in the transport direction W is transferred to the electrophotographic photosensitive member F in synchronization with the toner image formed on the surface Fa of the electrophotographic photosensitive member F. It is supplied to the transfer nip portion TN between the charger and the 740.

The toner image on the surface Fa of the electrophotographic photosensitive member F is given a charge having a polarity opposite to the charging polarity of the toner image by the transfer charger 740 via the recording medium P supplied to the transfer nip portion TN. It is transferred onto the recording medium P.

The recording medium P on which the toner image is transferred is further conveyed to the fixing device 760, and the toner image is heated and applied when passing through the fixing nip portion FN between the heating roller 760a and the pressure roller 760b in the fixing device 760. It is pressed and further discharged to the outside of the image forming apparatus 700.

On the other hand, the toner remaining on the surface Fa of the electrophotographic photosensitive member F after the transfer of the toner image by the transfer charger 740 is removed from the surface Fa of the electrophotographic photosensitive member F by the cleaner device 750 and recovered.

Then, when an image is continuously formed on a plurality of recording media P, the series of operations described above is repeated.

According to the image forming apparatus 700 provided with the electrophotographic photosensitive member F and the electrophotographic photosensitive member F, each layer (for example, the charge generating layer F21 and the electric charge) formed on the electrophotographic photosensitive member F on the image such as the halftone formed. Image density unevenness (specifically, shading streaks) caused by the difference in film thickness of the transport layer F22) can be eliminated or almost eliminated.

[Example]
Next, specific Examples 1 to 11 of the immersion coating apparatus 100 according to the present embodiment will be described below together with Comparative Examples 1 to 4. However, the immersion coating device 100 according to the present embodiment is not limited to these Examples 1 to 11.

In Examples 1 to 11 and Comparative Examples 1 to 4, as the coating liquid L, the coating liquid for the undercoat layer, the coating liquid for the charge generating layer, and the coating liquid for the charge transport layer are used, and the coating liquid is drawn onto the substrate F1. An electrophotographic photosensitive member F (a layer coating liquid, a charge generation layer coating liquid, and a charge transport layer coating liquid) are applied in this order to form an undercoat layer, a charge generation layer F21, and a charge transport layer F22 on a substrate F1. Hereinafter, a photoconductor F) was produced.

(Preparation of coating liquid)
<Coating liquid for undercoat layer>
Add 3 parts by weight of titanium oxide (manufactured by Showa Denko KK, trade name: TS-043) and 2 parts by weight of copolymerized polyamide (nylon) (manufactured by Toray Industries, Inc., trade name: CM8000) to 25 parts by weight of methyl alcohol. A coating liquid for the undercoat layer was prepared by dispersion treatment with a paint shaker (dispersor) for 8 hours.

<Coating liquid for charge generation layer>
First, a charge generating substance represented by the following structural formula was prepared as follows.

29.2 g of diiminoisoindoline and 200 ml of sulfolane were mixed, 17.0 g of titanium tetraisopropoxide was further added, and the mixture was reacted at 140 ° C. for 2 hours under a nitrogen atmosphere. After allowing the obtained reaction mixture to cool, the precipitate was collected by filtration, washed successively with chloroform and a 2% aqueous hydrochloric acid solution, washed successively with water and methanol, and dried to obtain 25.5 g of bluish-purple crystals. Got

As a result of chemical analysis of the obtained compound, it was confirmed that it was oxotitanyl phthalocyanine represented by the above structural formula (yield 88.5%).

1 part by weight of the obtained titanyl phthalocyanine and 1 part by weight of butyral resin (manufactured by Denki Kagaku Kogyo Co., Ltd., trade name: BM-2) were added to 98 parts by weight of methyl ethyl ketone and dispersed for 2 hours with a paint shaker to generate electric charges. A coating solution for layers was prepared.

<Coating liquid for charge transport layer>
2 parts by weight of triphenylamine compound (TPD) (manufactured by Tokyo Kasei Kogyo Co., Ltd., trade name: D2448) represented by the following structural formula as a charge transporting substance, Z-type polycarbonate (manufactured by Teijin Chemicals Ltd., trade name) : TS2050) 3 parts by weight and 24 parts by weight of tetrahydrofuran were added to prepare a coating liquid for a charge transport layer.

(Example 1)
The coating liquid for the undercoat layer, the coating liquid for the charge generation layer, and the coating liquid for the charge transport layer prepared as described above, and the cylindrical windshield portion 50 having the structure shown in FIG. 2 (material: SUS304, diameter: 80 mmφ, (Height: 100 mm) and a bent portion 60 (material: SUS304, shape: linear, bending angle θ: 90 °, horizontal distance d from the windshield portion 50: 15 mm) having the structure shown in FIG. 6 are provided in FIG. Photoreceptor F was produced using the immersion coating device 100 having the structure shown. The bent portion 60 is integrated with the windshield portion 50.

The coating liquid for the undercoat layer is pulled up to a dry film thickness of 1.0 μm on a cylindrical aluminum substrate of 30 mm (diameter) × 357 mm (length) having a ten-point average roughness Rz of 0.90. It was applied at a rate and allowed to air dry. Next, the coating liquid for the charge generation layer was applied at a pulling speed so that the dry film thickness was 0.2 μm, and the mixture was naturally dried. Further, the coating liquid for the charge transport layer was applied at a pulling speed so that the drying film thickness became 34 μm, and dried at a drying temperature of 130 ° C. for 60 minutes. In this way, the photoconductor F was produced.

(Example 2)
A square cylindrical windshield (material: SUS304, width: 80 mm, depth: 80 mm, height: 100 mm) having the structure shown in FIG. 3 and a bent portion 60 (bent portion 60) at the upper portion 50a of the windshield 50 having the structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the material: SUS304, the shape: linear, the bending angle θ: 90 °, and the horizontal distance d from the windshield 50) were provided.

(Example 3)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. 6 The bent portion 60 at the upper portion 50a of the windshield portion 50 (material: SUS304, shape: linear, bending angle θ: 70 °, windshield portion 50 Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from d: 13 mm).

(Example 4)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from d: 13 mm).

(Example 5)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. 6 The bent portion 60 at the upper portion 50a of the windshield portion 50 (material: SUS304, shape: linear, bending angle θ: 150 °, windshield portion 50 Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from d: 13 mm).

(Example 6)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from 10 mm).

(Example 7)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 is the bent portion 60 at the upper portion 50a of the windshield portion 50 having the structure shown in FIG. ) Was changed, and the photoconductor F was prepared in the same manner as in Example 1.

(Example 8)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 is the bent portion 60 at the upper portion 50a of the windshield portion 50 having the structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance from the wind portion 50 was changed to d: 15 mm).

(Example 9)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. 9. The bent portion 60 at the upper portion 50a of the windshield portion 50 (material: SUS304, shape: linear, bending angle θ: 90 °, The photoconductor F was produced in the same manner as in Example 1 except that the photoconductor F was arranged 5 mm below the upper end 50b and changed to a horizontal distance d: 15 mm from the windshield 50).

(Example 10)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance from 50 was changed to d: 10 mm, which was affixed with an adhesive tape).

(Example 11)
Photoreceptor F was produced in the same manner as in Example 1 except that the entire surface of the windshield 50 was changed to a mesh shape (material: SUS304, opening 74 μm and pore opening rate 34%) having the structure shown in FIG. ..

(Comparative Example 1)
The photoconductor F was produced in the same manner as in Example 1 except that the bent portion 60 at the upper portion 50a of the windshield portion 50 was not provided.

(Comparative Example 2)
The bent portion 60 in the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from d: 13 mm).

(Comparative Example 3)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. 6 The bent portion 60 at the upper portion 50a of the windshield portion 50 (material: SUS304, shape: linear, bending angle θ: 160 °, windshield portion 50 Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from d: 13 mm).

(Comparative Example 4)
The bent portion 60 at the upper portion 50a of the windbreak portion 50 has a structure shown in FIG. Photoreceptor F was produced in the same manner as in Example 1 except that the horizontal distance was changed from d: 5 mm).

[evaluation]
The film thickness of each photoconductor F produced in Examples 1 to 11 and Comparative Examples 1 to 4 was measured with a film thickness measuring device (manufactured by Philmetrics, model: F-20-EXR) to measure the film thickness. The uniformity was evaluated.

For each of the photoconductors F to F, 36 points were measured at positions of 78.5 mm, 127.5 mm, and 278.5 mm downward from the upper end of the coating at 10 ° intervals in the circumferential direction, and the average value of these values was measured. , And the difference Δ between the maximum value and the minimum value was obtained.

Further, the black photoconductor unit of a digital copying machine (manufactured by Sharp Co., Ltd., model: MX-5140FN) modified to a contact charging method (charging roller) to which only a DC voltage is applied is compared with Examples 1 to 11. Halftone images (without image processing) in which the photoconductors F to F produced in Comparative Examples 1 to 4 are mounted, and image processing that makes image unevenness such as error diffusion inconspicuous is not performed on A4 paper in monochrome. And 5 halftone images (with image processing) subjected to error diffusion image processing were output, and image evaluation was performed.

The above evaluation results are shown in Table 1. In [Image evaluation] of Table 1, when both the image of [with image processing] and the image of [without image processing] have a shading streak of the period of the photoconductor F, it is evaluated as "A" and [with image processing]. In the image of [B], there is no shading streak of the cycle of the photoconductor F, and in the image of [No image processing], a shading streak of the cycle of the photoconductor F is slightly generated at the portion corresponding to the lower end portion of the coating of the photoconductor F. The evaluation was made as "C" when the light and shade streaks of the period of the photoconductor F were generated from the upper end to the lower end of the coating of the photoconductor F. Then, in [Judgment], the case where there is no problem in actual use is judged as "⊚", the case where it is acceptable in actual use is judged as "○", and the case where it is not acceptable in actual use is judged as "x".

As shown in Table 1, in Comparative Example 1, by not providing the bent portion 60 in the upper portion 50a of the windshield portion 50, shading streaks of the period of the photoconductor F were generated from the upper end to the lower end of the coating of the photoconductor F. On the other hand, in Examples 1 to 11, by using the immersion coating device 100 according to the present embodiment, the difference in film thickness (thickness distribution) at various points of the coating film in the circumferential direction of the photoconductor F can be obtained. There was no big difference, and no shading streaks occurred on the halftone image with image processing that was image-processed in actual use, and good results were obtained.

Further, in Comparative Example 2 and Comparative Example 3, the shading streaks were generated at the bending angles θ of the bent portion 60 at 30 ° and 160 °, whereas the shading streaks were generated in Examples 1 to 6 and 8 to 11 in Examples. Then, when the bending angle θ of the bending portion 60 was 45 ° to 150 °, the effect of suppressing the shading streaks could be exhibited. Above all, in Example 3, since the bending angle θ of the bent portion 60 was 70 °, no shading streaks were generated even in [without image processing], which was very good.

Further, in Comparative Example 4, a light and shade streak was generated when the horizontal distance d of the tip 60a of the bent portion 60 from the outer wall surface 51 of the windshield portion 50 was 5 mm, whereas in Examples 1 to 11, the shield was shielded. When the horizontal distance d of the tip 60a of the bent portion 60 from the outer wall surface 51 of the wind portion 50 is 10 mm or more, the effect of suppressing uneven film thickness of the coating film can be exhibited.

Further, in Examples 7 to 9, the effect of suppressing the shading streaks was large even in the shapes shown in FIGS. 7 to 9. In particular, the structures of Example 7 in which the bent portion 60 in the upper portion 50a of the windshield portion 50 is arcuate, and the structure of Example 8 in which the bent portion 60 in the upper portion 50a of the windshield portion 50 is linear and arcuate. Even with [No image processing], no shading streaks occurred, which was very good.

Further, in Example 10, even if polyethylene terephthalate was used instead of the SUS of Examples 1 to 9 and 11 as the material of the bent portion 60, a sufficient effect could be exhibited.

Further, in the eleventh embodiment, by forming the windshield portion 50 itself into a mesh structure, the film thickness difference of the portion 78.5 mm, 127.5 mm, and 278.5 mm from the upper end of the coating of the photoconductor F and the photoconductor F The film thickness difference in the circumferential direction of the portion 78.5 mm and 278.5 mm from the upper end of the coating was reduced, and the photoconductor F having a small film thickness difference could be produced.

In the present embodiment, an electrophotographic photosensitive member manufacturing apparatus for producing an electrophotographic photosensitive member is given as an example, but in the immersion coating apparatus according to the present invention, an object to be coated is used as a substrate of the electrophotographic photosensitive member. It is not limited to those for producing electrophotographic photosensitive members, but all technical fields such as those produced by a dip coating method, for example, those for producing a photocatalyst thin film and those for producing a zinc oxide thin film for electrodes. Applicable to

The present invention is not limited to the embodiments described above, and can be implemented in various other forms. Therefore, such embodiments are merely exemplary in all respects and should not be construed in a limited way. The scope of the present invention is shown by the claims and is not bound by the text of the specification. Furthermore, all modifications and modifications that fall within the equivalent scope of the claims are within the scope of the present invention.

10 Coating tank 11 Outer wall surface 20 Lifting section 21 Support mechanism 22 Driving device 30 Coating liquid supply section 31 Storage section 32 Supply path 33 Supply drive section 40 Circulation section 41 Coating solution recovery section 42 Circulation path 50 Windshield 50a Upper 50b Upper end 51 Outer wall surface 60 Bent part 60a Tip 61 Straight part 62 Curved part 100 Immersion coating device 700 Image forming device AR Air E Object to be coated Ea Surface Eb Upper end surface F Electrophotographic photosensitive member F1 Base material F2 Photosensitive layer F21 Charge generation layer F22 Charge transport layer Fa Surface H Horizontal direction L Coating liquid M Porous V Vertical direction d Horizontal distance h Vertical distance θ Bending angle

Claims (11)

The coating tank for immersing the object to be coated and containing a coating liquid for forming a coating film on the surface of the object to be coated, and at least one of the object to be coated and the coating tank are relatively moved up and down. An immersion coating device provided with an elevating means for immersing an object to be coated in the coating liquid in the coating tank and pulling it up from the coating liquid.
Above the coating tank, a windshield portion for shielding the outside wind is provided over the entire circumference in the circumferential direction.
At the upper part of the windshield, a bent portion bent outward is provided over the entire circumference in the circumferential direction.
The immersion coating device is characterized in that the bent portion has a curved portion that bends outward from the outer wall surface of the windshield portion in an arc shape or an elliptical arc shape. The coating tank for immersing the object to be coated and containing a coating liquid for forming a coating film on the surface of the object to be coated, and at least one of the object to be coated and the coating tank are relatively moved up and down. An immersion coating device provided with an elevating means for immersing an object to be coated in the coating liquid in the coating tank and pulling it up from the coating liquid.
Above the coating tank, a windshield portion for shielding the outside wind is provided over the entire circumference in the circumferential direction.
At the upper part of the windshield, a bent portion bent outward is provided over the entire circumference in the circumferential direction.
The bent portion has a straight portion that bends linearly outward from the outer wall surface of the windshield portion, and a curved portion that is continuously provided at the tip of the straight portion and bends in an arc shape or an elliptical arc shape. An immersion coating device characterized by the fact that. The coating tank for immersing the object to be coated and containing a coating liquid for forming a coating film on the surface of the object to be coated, and at least one of the object to be coated and the coating tank are relatively moved up and down. An immersion coating device provided with an elevating means for immersing an object to be coated in the coating liquid in the coating tank and pulling it up from the coating liquid.
Above the coating tank, a windshield portion for shielding the outside wind is provided over the entire circumference in the circumferential direction.
At the upper part of the windshield, a bent portion bent outward is provided over the entire circumference in the circumferential direction.
The immersion coating device is characterized in that the bent portion bends outward from a position below the upper end of the linear wall surface outside the windshield portion. The immersion coating apparatus according to claim 2 or 3.
The bent portion is bent at a predetermined bending angle within a predetermined bending angle range with respect to the outer wall surface of the windbreak portion.
The immersion coating apparatus, wherein the predetermined bending angle range is 45 ° to 150 °. The coating tank for immersing the object to be coated and containing a coating liquid for forming a coating film on the surface of the object to be coated, and at least one of the object to be coated and the coating tank are relatively moved up and down. An immersion coating device provided with an elevating means for immersing an object to be coated in the coating liquid in the coating tank and pulling it up from the coating liquid.
Above the coating tank, a windshield portion for shielding the outside wind is provided over the entire circumference in the circumferential direction.
At the upper part of the windshield, a bent portion bent outward is provided over the entire circumference in the circumferential direction.
The bent portion is bent at a predetermined bending angle within a predetermined bending angle range with respect to the outer wall surface of the windbreak portion.
The immersion coating apparatus, wherein the predetermined bending angle range is 60 ° to 75 °. The dipping coating device according to any one of claims 3 to 5.
The immersion coating device is characterized in that the bent portion has a straight portion that bends linearly outward from the outer wall surface of the windshield portion. The dipping coating device according to any one of claims 1 to 6.
The tip of the bent portion is separated from the outer wall surface of the windshield portion by a predetermined horizontal distance in the horizontal direction.
A dipping coating device having a predetermined horizontal distance of 10 mm or more. The dipping coating device according to any one of claims 1 to 7.
The immersion coating device, wherein the bent portion is composed of a sheet-shaped member. The immersion coating apparatus according to any one of claims 1 to 8.
The windbreak portion has a predetermined predetermined opening within a predetermined predetermined opening range in which all or a part of the outer wall surface is within a predetermined opening range, and is within a predetermined predetermined opening rate range. An immersion coating device characterized in that it is formed in a porous shape with an opening rate of. The dipping coating device according to claim 9.
The immersion coating apparatus, wherein the predetermined opening range is 50 μm to 100 μm, and the predetermined opening ratio range is 30% to 50%. Manufacturing of the electrophotographic photosensitive member, characterized in that to produce the electrophotographic photosensitive member by Rukoto be coated with the coating solution to a substrate by a dip coating apparatus according to any one of claims 1 to 10 Method .

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