JP2010075828A - Coating apparatus and method of manufacturing electrophotographic photoreceptor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coating apparatus which is used for simultaneously dip-coating a plurality of bodies to be coated, and in which the sagging of a coated film, caused by vapor of a solvent or a surrounding wind, is hardly generated and unevenness of film thickness among the bodies to be coated is hardly generated due to the arrayed positions of the bodies to be coated, and to provide a method for manufacturing an electrophotographic photoreceptor by using the coating apparatus. <P>SOLUTION: The coating apparatus is provided with: a plurality of dip-coating tanks corresponding to the plurality of bodies to be coated, respectively; and a covering lid for covering the plurality of dip-coating tanks from above. A plurality of through-holes corresponding to the plurality of bodies to be coated, respectively, are arranged on the covering lid. The coating apparatus is further provided with: a plurality of hoods arranged above the plurality of through-holes, respectively; and a sucking machine for sucking the gas in the inter-hood space surrounded by the hood and the upper surface of the covering lid. The amount of the gas to be sucked from the inter-hood space can be adjusted individually in each inter-hood space. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a coating apparatus suitably used for manufacturing an electrophotographic photosensitive member, and a method for manufacturing an electrophotographic photosensitive member using the coating apparatus.

  An electrophotographic photoreceptor generally has a support and a photosensitive layer formed on the support. In addition, a conductive layer, an intermediate layer (undercoat layer) or the like may be provided between the support and the photosensitive layer, and a protective layer or the like may be provided on the photosensitive layer.

  In producing such an electrophotographic photoreceptor, examples of a method for forming a layer such as a photosensitive layer on a support include a dip coating method, a roll coater method, a spray method, and an electrostatic coating method. Among these, the dip coating method is an advantageous method when the coated body has a three-dimensional shape such as a cylindrical shape or a seamless belt shape. Furthermore, the dip coating method is widely used for mass production because it can be applied simultaneously to a plurality of objects to be coated with one coating device (dip coating device).

FIG. 1 shows an example of a conventional coating apparatus (dip coating apparatus).
In the coating apparatus shown in FIG. 1, the coating liquid 20 is fed to the lower part of the coating tank 9 via the recovery tank 2 and the filter 4 by the liquid feeding means 3 such as a pump, and the coating liquid exceeds the capacity of the coating tank 9. The liquid 20 falls into the overflow tank 10 and is then circulated to the recovery tank 2 via a pipe. In addition, the cover lid 7 provided with the through-hole 8 for allowing the substrate 1 to pass through covers the top of the coating tank 9, so that foreign matter is mixed into the coating solution 20 and the solvent from the coating solution 20 is removed. Volatilization is suppressed. Part of the cylindrical object 1 is gripped by an elevating means (not shown), dipped in the coating liquid 20 in the coating tank 9, and then pulled up to form a wet coating film on the surface. Is done. In addition, a hood 5 is installed above the through-hole 8 of the cover lid 7 so as to prevent the wet paint film immediately after being pulled up from being affected by the surrounding wind. In FIG. 1, 6 is an overflow surface.

  FIG. 2 shows the positional relationship of the coating lid 7, the hood 5, and the coated body 1 provided with the through-holes 8 as viewed from above in a coating apparatus that performs dip coating simultaneously on a plurality of coated bodies. FIG.

  However, in the conventional coating apparatus as described above, when the object to be coated immediately after the lifting is present inside the hood, the vapor of the solvent evaporating from the wet paint film is inside the hood (the space inside the hood). Easy to stay. Then, since the concentration of the solvent vapor is high, the drying of the coating film is delayed, and as a result, the coating film sags, that is, the film thickness at the top of the coating film becomes thin, and the film thickness at the bottom of the coating film becomes thick. There was a tendency to become.

  In order to improve such drawbacks, Patent Document 1 discloses a coating apparatus having a configuration in which a gap for discharging the vapor of the solvent is provided in the lower portion of the hood as shown in FIG.

  FIG. 3 is a diagram illustrating a configuration in which a gap 11 is provided in the lower portion of the hood 5 in a coating apparatus that performs dip coating simultaneously on a plurality of coated objects. In FIG. 3, 1-1, 1-2, and 1-3 are objects to be coated, 7 is a cover lid, 8-1, 8-2, and 8-3 are through-holes, 9 is A coating tank, 10 is an overflow tank, and 20 is a coating solution.

  Further, in Patent Document 2, the hoods 5-1, 5-2, and 5-3 are formed in a mesh shape that is permeable to the outside, and as shown in FIG. A coating apparatus having a configuration arranged around 1-2, 1-3 is disclosed. In FIG. 4, 7 is a cover lid, 8-1, 8-2, and 8-3 are through-holes, 9-1, 9-2, and 9-3 are application tanks, and 10 is an overflow. A tank, 20 is a coating solution.

According to the coating apparatus having these configurations, since the concentration of the solvent vapor inside the hood is reduced to some extent, there is a certain effect in suppressing coating sag.
Japanese Patent No. 2889513 JP 10-337514 A

  However, as a result of the study by the present inventors, when dip coating is simultaneously performed on a plurality of objects to be coated by these coating apparatuses, compared to the objects to be coated located at the end in the arrangement position of the objects to be coated, It was found that the concentration of the solvent vapor in the surrounding area was less likely to decrease as the coated body located in the center, and the coating sagging was likely to occur. As a result, the degree of coating sagging between the coated bodies varies, resulting in uneven film thickness between the coated bodies. It has also been found that this tendency becomes more prominent as the number of objects to be coated increases and as the distance between the objects to be coated is closer.

  It is an object of the present invention to provide a coating apparatus for performing dip coating simultaneously on a plurality of coated objects, coating sagging generated by solvent vapor or ambient wind, and a coated object depending on the arrangement position of the coated objects. An object of the present invention is to provide a coating apparatus that is less likely to cause film thickness unevenness.

  Another object of the present invention is to provide a method for producing an electrophotographic photosensitive member using the coating apparatus.

The present invention, in a coating apparatus for forming a coating film on each surface of the plurality of coated bodies by pulling up after immersing a plurality of coated bodies in a coating solution in a coating tank,
The coating apparatus includes a plurality of coating tanks corresponding to the plurality of objects to be coated, and a cover lid for covering the plurality of coating tanks from above,
The cover lid is provided with a plurality of through holes corresponding to each of the plurality of coated objects,
The applicator further includes a plurality of hoods disposed above each of the plurality of through-holes, and a suction device for sucking a gas in the hood inner space surrounded by the hood and the upper surface of the cover lid; With
An amount of gas sucked from the space in the hood can be individually adjusted for each space in the hood.

Further, the present invention provides a method for producing an electrophotographic photosensitive member for producing a plurality of electrophotographic photosensitive members,
The manufacturing method includes a coating step of forming a coating film on each surface of the plurality of coated bodies by pulling up after immersing the plurality of coated bodies in a coating solution in a coating tank,
The coating process is performed by using the above-described coating apparatus.

  According to the present invention, in a coating apparatus for performing dip coating simultaneously on a plurality of coated objects, a coating film sag generated by solvent vapor or ambient wind, or a coated object depending on the arrangement position of the coated objects. It is possible to provide a coating apparatus that is less likely to cause film thickness unevenness.

  In addition, according to the present invention, a method for producing an electrophotographic photoreceptor using the coating apparatus can be provided.

An example of the coating apparatus of the present invention is shown in FIG.
In the coating apparatus shown in FIG. 5, the cover lid 7 that covers the coating tanks 9-1, 9-2, and 9-3 containing the coating solution 20 from above has through holes 8-1, 8-2, and 8-3. Is provided. The hole diameters of these through holes are preferably smaller than the inner diameter of the coating tank. And the opening parts 12-1, 12-2, and 12-3 are provided in the lower part of food | hood 5-1, 5-2, and 5-3, respectively. Pipes are connected to the openings 12-1, 12-2, 12-3, respectively, and each pipe is connected to a suction machine (not shown). The gas in the hood inner space surrounded by the hood and the upper surface of the cover lid is discharged to the outside through the pipe. The amount of gas sucked from the space in the hood (also referred to as suction amount) can be individually adjusted for each space in the hood by the valves 13-1, 13-2, and 13-3. Even if there is a difference in the suction force of the gas sucked in each space in the hood because the distance between the suction machine and the hood is different for each hood, a balance can be achieved depending on the opening amount of each valve. Although the number of openings may be one or plural for one space in the hood, a plurality of openings are preferable in order to uniformly control the concentration of the solvent vapor over the entire circumference of the coated body. In FIG. 5, reference numerals 1-1, 1-2, and 1-3 are objects to be coated, and 10 is an overflow tank.

  Further, in the present invention, "a plurality of application tanks corresponding to each of a plurality of objects to be applied" includes, for example, a plurality of objects to be applied and application tanks as shown in FIG. 5, FIG. 6 and FIG. And it means that there is one application tank for one object to be applied. Further, in the present invention, “a plurality of through-holes corresponding to each of a plurality of coated bodies” means that there are a plurality of coated bodies and through-holes as shown in FIG. 5 and FIGS. And it means that there is one through-hole for one object to be coated.

Another example of the coating apparatus of the present invention is shown in FIG.
In the coating apparatus shown in FIG. 6, the inside of the cover lid 7 is provided with a flow passage through which gas can flow (the inside of the cover lid 7 is hollow). Further, openings 14-1, 14-2 and 14-3 are provided on the upper surface of the cover lid 7. The gas in the hood space flows out of the openings 14-1, 14-2 and 14-3 by suction by a suction machine (not shown), passes through the flow path inside the cover lid 7, and passes through the pipe 15. And sucked by a suction machine (not shown). In this configuration, the suction of the solvent vapor generated from the coating solution 20 in the coating tanks 9-1, 9-2, and 9-3 located on the lower side of the cover lid 7 is small, and the volatilization of the coating solution 20 is promoted. There is nothing to do. Furthermore, since the solvent vapor suction direction is not perpendicular to the substrate, adverse effects such as locally sucking the solvent vapor from the wet coating immediately after being applied to the surface of the substrate. There is no effect. Furthermore, since no piping is used in the vicinity of the hood, a space for piping is not required between the hoods, and maintenance such as cleaning becomes easy. In FIG. 6, 1-1, 1-2, and 1-3 are objects to be coated, 5-1, 5-2, and 5-3 are hoods, and 8-1, 8-2, and 8- 3 is a through-hole and 10 is an overflow tank.

  It is preferable that a plurality of openings are provided per one space in the hood, and the plurality of openings are preferably arranged so as to surround the through-hole. The arrangement is preferably uniform. Thereby, it is possible to more uniformly control the concentration of the solvent vapor in the circumferential direction of the coated body.

  Examples of the arrangement of the openings when a plurality of openings are provided on the upper surface of the cover lid are shown in FIGS.

  In FIG. 7, three openings 14 are arranged around the through-hole 8 provided in the cover lid 7. In FIG. 8, twelve openings 14 are arranged around the through-hole 8 provided in the cover lid 7. In FIG. 9, the opening part 14 arrange | positioned around the through-hole 8 provided in the cover lid 7 is a slit shape. 7, 8, and 9, 1 is an object to be coated and 5 is a hood.

  An example of a method for adjusting the amount of gas sucked from the space in the hood (suction amount) when a plurality of openings are provided on the upper surface of the cover lid will be described with reference to FIG.

  In FIG. 10, the plurality of openings 14 are all processed as screw holes, and the screws 16 can be used as a lid for the openings 14. The concentration of the solvent vapor between the hoods can be balanced by adjusting the opening amounts of the openings 14 according to the degree of opening / closing or closing of the screws 16. Furthermore, it is possible to optimize the balance of the solvent vapor in the circumferential direction in the hood space.

  In FIG. 10, the gas in the hood space flows out from the opening 14 by suction of a suction machine (not shown), passes through a flow path (cavity) inside the cover lid 7, and is connected to a suction machine (not shown). It is configured to pass through the pipe 15 and sucked by a suction machine (not shown). Since the opening force closer to the pipe 15 tends to be stronger, the balance between the hoods and in the hood space is adjusted by adjusting the opening amount of each opening. In addition, in FIG. 10, 1 is a to-be-coated body and 5 is a hood.

  As shown in FIG. 11, a ring-shaped protrusion 17 may be provided between the plurality of openings 14 and the through-holes 8 so as to surround the through-holes 8. The protrusion 17 further suppresses the suction of the solvent vapor generated from the coating liquid, and there is a further concern that the solvent vapor may be locally sucked from the wet coating immediately after being applied to the surface of the coated body. Less. In FIG. 11, 1 is an object to be applied, 5 is a hood, and 7 is a cover lid.

  In FIG. 12, openings 14-1, 14-2 and 14-3 are arranged on the upper surface of the cover lid 7 so as to surround each of the through-holes 8-1, 8-2 and 8-3, The example of the coating device with which the ring-shaped protrusion parts 17-1, 17-2, and 17-3 are each provided between the opening part and the through-hole is shown. In FIG. 12, 1-1, 1-2, and 1-3 are objects to be coated, 5-1, 5-2, and 5-3 are hoods, and 9-1, 9-2, and 9- 3 is a coating tank, 10 is an overflow tank, 15 is a pipe, and 20 is a coating solution.

  Next, a method for producing an electrophotographic photoreceptor using the coating apparatus of the present invention will be described.

  An electrophotographic photoreceptor is generally produced by forming a photosensitive layer on a support. The photosensitive layer may be a single-layer type photosensitive layer containing a charge transport material and a charge generation material in the same layer, or a charge generation layer containing a charge generation material and a charge transport layer containing a charge transport material. It may be a laminated type (functionally separated type) photosensitive layer that is functionally separated. From the viewpoint of electrophotographic characteristics, the photosensitive layer is preferably a laminated photosensitive layer. Of the laminated photosensitive layers, those obtained by laminating a charge generation layer and a charge transport layer in this order from the support side (a normal photosensitive layer) are preferable. Further, a conductive layer and an intermediate layer described later may be provided between the support and the photosensitive layer, and a protective layer described later may be provided on the photosensitive layer.

The “coating film” may be a conductive layer, an intermediate layer, a photosensitive layer (charge generation layer, charge transport layer), or a protective layer. Other layers may be used. In addition, the “coated body” means that the “coating film” is formed on the surface thereof. For example, when the electrophotographic photosensitive member is formed by forming a conductive layer, an intermediate layer, a charge generation layer, a charge transport layer, and a protective layer in this order on a support,
When the “coating film” is a conductive layer, the “coated body” is a support,
When the “coating film” is an intermediate layer, the “coated body” is a product formed by forming a conductive layer on a support,
When the “coating film” is a charge generation layer, the “coated body” is a product in which a conductive layer and an intermediate layer are formed in this order on a support,
When the “coating film” is a charge transport layer, the “coated body” is a product in which a conductive layer, an intermediate layer, and a charge generation layer are formed in this order on a support,
When the “coating film” is a protective layer, the “coated body” is formed by forming a conductive layer, an intermediate layer, a charge generation layer, and a charge transport layer in this order on a support.

  The production apparatus of the present invention can be applied to any of the above-mentioned “coating films”, and can be applied to a plurality of layers. The case where the intermediate layer, the charge generation layer, and the protective layer, which are often set to relatively low viscosities, are “coating films” is particularly suitable.

  Hereinafter, an electrophotographic photosensitive member having a laminated photosensitive layer will be described in detail as an example.

  The support only needs to have conductivity (conductive support). For example, aluminum, aluminum alloy, copper, zinc, stainless steel, vanadium, molybdenum, chromium, titanium, nickel, indium, gold, A support made of metal (made of alloy) such as platinum can be used. Further, it is also possible to use a metal support or a plastic (polyethylene resin, polypropylene resin, polyvinyl chloride resin, polyethylene terephthalate resin, acrylic resin, etc.) support having a layer in which these metals (alloys) are formed by vacuum deposition. it can. In addition, a support in which conductive particles such as carbon black, tin oxide particles, titanium oxide particles, and silver particles are impregnated into plastic or paper together with an appropriate binder resin, or a plastic support having a conductive binder resin, etc. Can also be used.

  Examples of the shape of the support include a cylindrical shape and a seamless belt shape (endless belt shape), and a cylindrical shape is preferable.

  The surface of the support may be subjected to cutting treatment, roughening treatment, alumite treatment, etc. for the purpose of preventing interference fringes due to scattering of laser light or the like.

  Between the support and the photosensitive layer (charge generation layer, charge transport layer) or an intermediate layer described later, there is a conductive layer for the purpose of preventing interference fringes due to scattering of laser light or the like and covering the scratches on the support. It may be provided.

  The conductive layer can be formed by dispersing conductive particles such as carbon black, metal particles, and metal oxide particles in a binder resin.

  The thickness of the conductive layer is preferably 1 to 40 μm, and more preferably 2 to 20 μm.

  Further, an intermediate layer having a barrier function or an adhesive function may be provided between the support or the conductive layer and the photosensitive layer (charge generation layer, charge transport layer). The intermediate layer is formed for the purpose of improving the adhesion of the photosensitive layer, improving the coating property, improving the charge injection property from the support, and protecting the photosensitive layer from electrical breakdown.

  The intermediate layer is acrylic resin, allyl resin, alkyd resin, ethyl cellulose resin, ethylene-acrylic acid copolymer, epoxy resin, casein resin, silicone resin, gelatin resin, phenol resin, butyral resin, polyacrylate resin, polyacetal resin, polyamideimide resin , Polyamide resin, polyallyl ether resin, polyimide resin, polyurethane resin, polyester resin, polyethylene resin, polycarbonate resin, polystyrene resin, polysulfone resin, polyvinyl alcohol resin, polybutadiene resin, polypropylene resin, urea resin, aluminum oxide, etc. It can be formed using the material. Further, the intermediate layer may contain metals, alloys, oxides thereof, salts, surfactants and the like.

  The thickness of the intermediate layer is preferably 0.05 to 7 μm, and more preferably 0.1 to 2 μm.

  The charge generation layer is coated with a coating solution for a charge generation layer obtained by dispersing a charge generation material together with a binder resin and a solvent, and is dried and / or cured by heating and / or radiation irradiation. Can be formed. Examples of the dispersion method include a method using a homogenizer, an ultrasonic disperser, a ball mill, a sand mill, a roll mill, a vibration mill, an attritor, a liquid collision type high-speed disperser, and the like.

  Examples of the charge generation material include azo pigments such as monoazo, disazo, and trisazo, phthalocyanine pigments such as metal phthalocyanine and nonmetal phthalocyanine, indigo pigments such as indigo and thioindigo, perylene acid anhydride, and perylene imide. Perylene pigments, polycyclic quinone pigments such as anthraquinone and pyrenequinone, squarylium dyes, pyrylium salts and thiapyrylium salts, triphenylmethane dyes, inorganic substances such as selenium, selenium-tellurium, amorphous silicon, quinacridone pigments, And azurenium salt pigments, cyanine dyes, xanthene dyes, quinone imine dyes, styryl dyes, cadmium sulfide, and zinc oxide. These charge generation materials may be used alone or in combination of two or more.

  Examples of the binder resin used for the charge generation layer include acrylic resin, allyl resin, alkyd resin, epoxy resin, diallyl phthalate resin, silicone resin, styrene-butadiene copolymer, phenol resin, butyral resin, benzal resin, polyacrylate resin. , Polyacetal resin, polyamideimide resin, polyamide resin, polyallyl ether resin, polyarylate resin, polyimide resin, polyurethane resin, polyester resin, polyethylene resin, polycarbonate resin, polystyrene resin, polysulfone resin, polyvinyl acetal resin, polybutadiene resin, polypropylene resin Methacrylic resin, urea resin, vinyl chloride-vinyl acetate copolymer, vinyl acetate resin and the like. In particular, a butyral resin is preferable. These can be used singly or in combination of two or more as a mixture or copolymer.

  The ratio of the binder resin in the charge generation layer is preferably 90% by mass or less, more preferably 50% by mass or less, with respect to the total mass of the charge generation layer.

  The solvent used in the coating solution for the charge generation layer is selected based on the solubility and dispersion stability of the binder resin and charge generation material used. Examples of organic solvents include alcohols, sulfoxides, ketones, ethers, esters, fatty acids. Group halogenated hydrocarbons, aromatic compounds and the like.

  The thickness of the charge generation layer is preferably 0.001 to 6 μm, and more preferably 0.01 to 1 μm.

  In addition, various sensitizers, antioxidants, ultraviolet absorbers, plasticizers, and the like can be added to the charge generation layer as necessary.

  The charge transport layer is applied with a charge transport layer coating solution obtained by dissolving a charge transport material and a binder resin in a solvent, and dried and / or cured by heating and / or radiation irradiation. Can be formed.

  Examples of the charge transport material include triarylamine compounds, hydrazone compounds, styryl compounds, stilbene compounds, pyrazoline compounds, oxazole compounds, thiazole compounds, and triarylmethane compounds. These charge transport materials may be used alone or in combination of two or more.

  The ratio of the charge transport material in the charge transport layer is preferably 20 to 80% by weight, more preferably 30 to 70% by weight, based on the total weight of the charge transport layer. Therefore, the charge transport layer coating liquid preferably contains a charge transport material so that the ratio of the charge transport material after formation of the charge transport layer is within the above range.

  Examples of the binder resin used for the charge transport layer include acrylic resin, acrylonitrile resin, allyl resin, alkyd resin, epoxy resin, silicone resin, phenol resin, phenoxy resin, butyral resin, polyacrylamide resin, polyacetal resin, and polyamideimide. Resin, polyamide resin, polyallyl ether resin, polyarylate resin, polyimide resin, polyurethane resin, polyester resin, polyethylene resin, polycarbonate resin, polystyrene resin, polysulfone resin, polyvinyl butyral resin, polyphenylene oxide resin, polybutadiene resin, polypropylene resin, methacrylic resin Resins, urea resins, vinyl chloride resins, vinyl acetate resins and the like can be mentioned. In particular, polyarylate resin, polycarbonate resin and the like are preferable. These can be used singly or in combination of two or more as a mixture or copolymer.

  The ratio between the charge transport material and the binder resin is preferably in the range of 5: 1 to 1: 5 (mass ratio).

  Examples of the solvent used in the charge transport layer coating liquid include monochlorobenzene, dioxane, toluene, xylene, N-methylpyrrolidone, dichloromethane, tetrahydrofuran, and methylal.

  In addition, an antioxidant, an ultraviolet absorber, a plasticizer, and the like can be added to the charge transport layer as necessary.

  A protective layer may be provided on the photosensitive layer for the purpose of protecting it. The protective layer is formed by applying a coating solution for the protective layer obtained by dissolving the various binder resins described above in a solvent, and drying and / or curing the coating liquid by heating and / or radiation irradiation. can do.

  Further, the surface layer of the electrophotographic photoreceptor may contain a lubricant. Examples of the lubricant include polymers, monomers and oligomers containing silicon atoms and fluorine atoms. Specifically, N- (n-propyl) -N- (β-acryloxyethyl) -perfluorooctylsulfonic acid amide, N- (n-propyl)-(β-methacryloxyethyl) -perfluorooctylsulfone Acid amide, perfluorooctanesulfonic acid, perfluorocaprylic acid, Nn-propyl-n-perfluorooctanesulfonic acid amide-ethanol, 3- (2-perfluorohexyl) ethoxy-1,2-dihydroxypropane, N -N-propyl-N-2,3-dihydroxypropyl perfluorooctylsulfonamide and the like. Also, polytetrafluoroethylene, polychlorotrifluoroethylene, polyvinylidene fluoride, polydichlorodifluoroethylene, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-ethylene Examples also include particles of fluorine atom-containing resins such as copolymers and tetrafluoroethylene-hexafluoropropylene-perfluoroalkyl vinyl ether copolymers. These may be used alone or in combination of two or more. Moreover, it is preferable that the number average molecular weights of a lubricant are 3000-5 million, and it is especially preferable that it is 10000-3000000. When the lubricant is a particle, the average particle diameter is preferably 0.01 to 10 μm, and particularly preferably 0.05 to 2.0 μm.

The surface layer of the electrophotographic photosensitive member may contain a resistance adjusting agent. Examples of the resistance adjuster include SnO ₂ , ITO, carbon black, silver particles, and the like. Moreover, you may use what performed the hydrophobization process to these. The resistance of the surface layer when a resistance adjusting agent is added is preferably 10 ⁹ to 10 ¹⁴ Ω · cm.

  When the protective layer is provided, the protective layer is a surface layer of the electrophotographic photosensitive member, and when the protective layer is not provided and the photosensitive layer is a normal layer type photosensitive layer, the charge transport layer is an electrophotographic photosensitive layer. In the case where the protective layer is not provided and the photosensitive layer is a reverse layer type photosensitive layer, the charge generation layer is the surface layer of the electrophotographic photosensitive member.

  FIG. 13 shows an example of a schematic configuration of an electrophotographic apparatus provided with a process cartridge having an electrophotographic photosensitive member manufactured by the manufacturing method of the present invention.

  In FIG. 13, reference numeral 101 denotes a cylindrical electrophotographic photosensitive member, which is rotationally driven in a direction of an arrow about a shaft 102 at a predetermined peripheral speed.

  The surface of the rotationally driven electrophotographic photosensitive member 101 is uniformly charged to a predetermined positive or negative potential by a charging means (primary charging means: charging roller) 103, and then subjected to slit exposure, laser beam scanning exposure, or the like. Exposure light (image exposure light) 104 output from exposure means (not shown) is received. In this way, electrostatic latent images corresponding to the target image are sequentially formed on the surface of the electrophotographic photosensitive member 101.

  The electrostatic latent image formed on the surface of the electrophotographic photosensitive member 101 is developed with toner contained in the developer of the developing unit 105 to become a toner image. Next, the toner image formed and supported on the surface of the electrophotographic photosensitive member 101 is transferred from a transfer material supply unit (not shown) to the electrophotographic photosensitive member 1 and the transfer unit by a transfer bias from a transfer unit (transfer roller or the like) 106. The image is sequentially transferred to a transfer material (paper or the like) P that is taken out and fed in synchronization with the rotation of the electrophotographic photosensitive member 101 between them (contact portion) 106.

  The transfer material P that has received the transfer of the toner image is separated from the surface of the electrophotographic photosensitive member 101, introduced into the fixing means 108, and subjected to image fixing to be printed out as an image formed product (print, copy). Is done.

  The surface of the electrophotographic photosensitive member 101 after the transfer of the toner image is cleaned by a cleaning means (cleaning blade or the like) 107 after removal of the transfer residual developer (toner), and further from a pre-exposure means (not shown). After being subjected to charge removal processing by pre-exposure light (not shown), it is repeatedly used for image formation. As shown in FIG. 13, when the charging unit 103 is a contact charging unit using a charging roller or the like, pre-exposure is not necessarily required.

  Among the above-described components such as the electrophotographic photosensitive member 101, the charging unit 103, the developing unit 105, the transfer unit 106, and the cleaning unit 107, a plurality of components are housed in a container and integrally combined as a process cartridge. The process cartridge may be configured to be detachable from an electrophotographic apparatus main body such as a copying machine or a laser beam printer. In FIG. 13, an electrophotographic photosensitive member 101, a charging unit 103, a developing unit 105, and a cleaning unit 107 are integrally supported to form a cartridge, and an electrophotographic apparatus is used using a guide unit 110 such as a rail of the electrophotographic apparatus main body. The process cartridge 109 is detachable from the main body.

  Hereinafter, the present invention will be described in more detail with reference to specific examples. However, the present invention is not limited to these. In the examples, “part” means “part by mass”. The following examples and comparative examples are examples in which a total of nine electrophotographic photoreceptors were produced.

Example 1
An aluminum cylinder having a diameter of 30 mm and a length of 254 mm was used as a support.

  Next, 10 parts of tin oxide-coated titanium oxide, 10 parts of titanium oxide, 10 parts of phenol resin, 0.001 part of silicone oil, 15 parts of methanol, and 15 parts of methyl cellosolve are dispersed in a sand mill for 3 hours to produce a conductive layer. A coating solution was prepared.

  This conductive layer coating solution was dip-coated on a support and dried and cured at 140 ° C. for 30 minutes to form a conductive layer having a thickness of 15 μm. In addition, this dip coating was performed at the same time using a coating apparatus having the configuration shown in FIG. 4 and having an array of 3 to 3 rows (for a total of 9) coated bodies.

  Next, 10 parts of polyamide resin (trade name: M-4000, manufactured by Toray Industries, Inc.) is dissolved in a mixed solvent of 100 parts of methanol / 90 parts of isopropanol, thereby applying an intermediate layer having a viscosity of 8 mPa · s. A liquid was prepared.

  The intermediate layer coating solution was dip coated on the conductive layer using the same coating apparatus as the conductive layer, and dried at 90 ° C. for 10 minutes to form an intermediate layer having a thickness of 0.6 μm. .

  Next, 9 parts of a hydroxygallium phthalocyanine crystal (charge generation material) having strong peaks at 7.4 ° and 28.1 ° with a Bragg angle 2θ ± 0.2 ° in X-ray diffraction of CuKα and polyvinyl butyral (trade name: A solution obtained by dissolving 3 parts of S-REC BX-1 (manufactured by Sekisui Chemical Co., Ltd.) in 100 parts of tetrahydrofuran was dispersed for 3 hours in a sand mill apparatus using glass beads having a diameter of 1 mm. 200 parts of butyl acetate was added thereto for dilution, and then recovered to prepare a charge generation layer coating solution having a viscosity of 1 mPa · s.

  This charge generation layer coating solution is dip-coated on the intermediate layer using the same coating apparatus as that for the conductive layer and dried at 80 ° C. for 15 minutes to form a charge generation layer having a thickness of 0.15 μm. Formed.

  Next, 10 parts of a styryl compound (charge transport material) represented by the following structural formula,

Then, 10 parts of polycarbonate resin (trade name: Iupilon Z-400, manufactured by Mitsubishi Gas Chemical Co., Ltd.) was dissolved in 120 parts of monochlorobenzene to prepare a coating solution for charge transport layer.

  This charge transport layer coating solution was dip coated on the charge generation layer and dried at 120 ° C. for 60 minutes to form a charge transport layer. This dip coating has the configuration shown in FIG. 5, and each hood is provided with one opening, and an array of 3 to 3 rows (for a total of 9) of objects to be coated. Nine samples were simultaneously processed using a coating apparatus having In addition, an object to be coated (a product in which a conductive layer, an intermediate layer, and a charge generation layer are formed in this order on a support) is dipped in a coating solution for a charge transport layer and then pulled up, and a coating film of the coating solution is formed on the surface. Gas was continuously allowed to flow out from each opening by suction with a suction machine until the lower end of the formed coated body reached a position higher than the upper end of the hood. Further, the amount of gas (suction amount) sucked from the space in the hood was adjusted by each valve.

Measurement and Evaluation Regarding the nine electrophotographic photoreceptors thus produced, the thickness of the charge transport layer was measured by microscopic observation of the cross section. Measurement points were measured at 4 points at 90 ° intervals in the circumferential direction at a position of 20 mm, 115 mm, and 230 mm from the start of coating (upper end of coating film), and a total of 12 points was measured, and the average of 12 points was defined as the average film thickness. . In addition, an average value was calculated from four points in the circumferential direction at positions of 20 mm, 115 mm, and 230 mm, and the difference between these maximum and minimum values was defined as axial unevenness. In addition, an average value was calculated from three points in the axial direction at each of four locations in the circumferential direction, and the difference between the maximum value and the minimum value was defined as circumferential unevenness.

  The obtained results are shown in Table 1. In addition, the arrangement position of each to-be-coated body is represented by AI as shown in FIG.

(Comparative Example 1)
In Example 1, nine electrophotographic photosensitive members were produced, measured and evaluated in the same manner as in Example 1 except that the charge transport layer was applied using the same coating apparatus as that for the conductive layer. The obtained results are shown in Table 2.

(Comparative Example 2)
Example 1 in Example 1 except that the charge transport layer was formed using a coating apparatus having the configuration shown in FIG. 3 and an array of 3 to 3 columns (for a total of 9 objects). Nine electrophotographic photoreceptors were prepared in the same manner as in Example 1, and measured and evaluated. The obtained results are shown in Table 3.

(Example 2)
In Example 1, the structure shown in FIG. 5 is provided, and two openings are provided in one hood at positions facing each other by 180 °, and 3 rows × 3 rows (for a total of 9) Nine electrophotographic photosensitive members were produced in the same manner as in Example 1 except that the charge transport layer was formed using a coating apparatus having an arrangement of the coated bodies. Measurement and evaluation were performed. Table 4 shows the obtained results.

(Example 3)
Example 1 in Example 1 except that the charge transport layer was formed using a coating apparatus having the configuration shown in FIG. 6 and having an array of 3 to 3 columns (for a total of 9 objects). Nine electrophotographic photoreceptors were prepared in the same manner as in Example 1, and measured and evaluated. Here, as shown in FIG. 8, the openings are arranged so as to surround the through-holes evenly at 12 locations. The results obtained are shown in Table 5.

Example 4
Example 1 in Example 1 except that the charge transport layer was formed using a coating apparatus having the configuration shown in FIG. 12 and an array of 3 to 3 columns (for a total of 9 objects). Nine electrophotographic photoreceptors were prepared in the same manner as in Example 1, and measured and evaluated. Here, as shown in FIG. 11, the openings were arranged so as to surround the through-holes at 12 locations equally. In addition, a ring-shaped protrusion that surrounds the through hole is provided between the opening and the through hole. The results obtained are shown in Table 6.

  From the above, it can be seen that when the coating apparatus of the present invention is used (Examples 1 to 4), a coating film with little film thickness unevenness is obtained.

It is a figure which shows the example of the conventional coating device (immersion coating device). It is a figure showing the positional relationship which looked at the cover lid provided with the through-hole, hood, and to-be-coated body from the top. It is a figure of the coating device of the structure which provided the clearance gap for discharging | emitting the vapor | steam of a solvent in the lower part of the hood. It is a figure of the coating device of the structure which has arrange | positioned the mesh-shaped food | hood which has air permeability with the exterior around the to-be-coated body. It is a figure which shows an example of the coating device of this invention. It is a figure which shows another example of the coating device of this invention. It is a figure which shows the example of an arrangement | sequence of an opening part when a plurality of opening parts are provided in the upper surface of the cover lid. It is a figure which shows the example of an arrangement | sequence of an opening part when a plurality of opening parts are provided in the upper surface of the cover lid. It is a figure which shows the example of an arrangement | sequence of an opening part when a plurality of opening parts are provided in the upper surface of the cover lid. It is a figure for demonstrating an example of the adjustment method of the quantity (suction amount) of the gas attracted | sucked from the space in a hood. It is a figure which shows the example in which the ring-shaped protrusion part is provided so that a through-hole may be enclosed between an opening part and a through-hole. It is a figure which shows the example by which an opening part is arrange | positioned so that a through-hole may be surrounded and a ring-shaped projection part is provided between the opening part and the through-hole. It is a figure which shows an example of schematic structure of the electrophotographic apparatus provided with the process cartridge which has the electrophotographic photoreceptor manufactured with the manufacturing method of this invention. It is a figure which shows the arrangement position of each to-be-coated body.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 To-be-coated body 1-1 To-be-coated body 1-2 To-be-coated body 1-3 To-be-coated body 2 Collection tank 3 Liquid feeding means 4 Filter 5 Hood 5-1 Hood 5-2 Hood 5-3 Hood 6 Overflow surface 7 Cover Lid 8 Through port 8-1 Through port 8-2 Through port 8-3 Through port 9 Application tank 9-1 Application tank 9-2 Application tank 9-3 Application tank 10 Overflow tank 11 Crevice 12-1 Opening 12-2 Opening 12-3 Opening 13-1 Valve 13-2 Valve 13-3 Valve 14-1 Opening 14-2 Opening 14-3 Opening 15 Piping 16 Screw (lid of opening)
17 Protruding portion 20 Coating solution 101 Electrophotographic photosensitive member 102 Shaft 103 Charging means 104 Exposure light 105 Developing means 106 Transfer means 107 Cleaning means 108 Fixing means 109 Process cart 110 110 Guide means P Transfer material

Claims (7)

In a coating apparatus for forming a coating film on each surface of the plurality of coated bodies by immersing the plurality of coated bodies in a coating solution in a coating tank and pulling them up,
The coating apparatus includes a plurality of coating tanks corresponding to the plurality of objects to be coated, and a cover lid for covering the plurality of coating tanks from above,
The cover lid is provided with a plurality of through holes corresponding to each of the plurality of coated objects,
The applicator further includes a plurality of hoods disposed above each of the plurality of through-holes, and a suction device for sucking a gas in the hood inner space surrounded by the hood and the upper surface of the cover lid; With
The coating apparatus, wherein the amount of gas sucked from the space in the hood can be individually adjusted for each space in the hood. The upper surface of the cover lid is provided with an opening for the gas in the hood to flow out,
The inside of the cover lid is provided with a flow passage through which the gas flowing out from the space in the hood can flow,
The coating apparatus according to claim 1, wherein the gas in the space in the hood is sucked into the suction device through the opening and the flow path. A plurality of the openings are provided per one space in the hood,
The coating apparatus according to claim 1, wherein the amount of gas flowing out from the space in the hood can be individually adjusted for each of the plurality of openings.   The coating apparatus according to claim 3, wherein the plurality of openings are arranged on the upper surface of the cover lid so as to surround the through hole.   5. The coating according to claim 4, wherein a ring-shaped protrusion is provided on the upper surface of the cover lid and between the through hole and the plurality of openings provided so as to surround the through hole. apparatus.   The coating apparatus according to claim 1, wherein a hole diameter of the through hole is smaller than an inner diameter of the coating tank. In the method for producing an electrophotographic photosensitive member for producing a plurality of electrophotographic photosensitive members,
The manufacturing method includes a coating step of forming a coating film on each surface of the plurality of coated bodies by pulling up after immersing the plurality of coated bodies in a coating solution in a coating tank,
The method for producing an electrophotographic photosensitive member, wherein the coating step is performed using the coating apparatus according to claim 1.

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