JP2008114387A - Sheet element, method and apparatus for producing sheet element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and apparatus for producing a sheet element which can easily and accurately produce a single layer sheet element having an aimed thickness, a multilayer sheet element, or a multilayer sheet element containing a core material. <P>SOLUTION: In the sheet element production apparatus 1, a first sheet 31 is stretched on a first heat roll 43a, a second sheet 32 is stretched on a second heat roll 43b so as to face the first sheet 31, the first and second sheets 31 and 32 are conveyed, a thermosetting resin liquid 30 is supplied between the first and second sheets 31 and 32, and a resin liquid layer is formed. The first and second sheets 31 and 32 sandwiching the resin liquid layer are fed to a resin liquid curing part 15 and heated. The resin liquid layer between the first and second sheets 31 and 32 is cured to form a thermosetting resin layer, and a sheet element 95 including the thermosetting resin layer is produced. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a sheet body including a curable resin layer formed of a curable resin such as a thermosetting resin, and a manufacturing method and a manufacturing apparatus thereof, and more specifically, a cleaning blade used in an electrophotographic apparatus, The present invention relates to a sheet body such as an elastic sheet suitable for a developing blade or a recovery blade, and a manufacturing method and manufacturing apparatus thereof.

  A sheet body including a thermosetting resin layer formed of a thermosetting resin removes toner adhering to an image carrier such as a photoconductor when, for example, an image is formed by electrophotography or electrostatic recording. It is used as a cleaning blade for developing or a developing blade for regulating the thickness of the toner layer on the developing sleeve while frictionally charging the toner in the developing device.

  The sheet body used as such a blade is composed of a thermosetting resin layer formed of thermosetting polyurethane rubber, for example, as a cleaning blade 90 shown in FIG. 3 described later.

  A blade composed of a thermosetting resin layer formed of thermosetting polyurethane rubber is manufactured, for example, by a centrifugal molding method. In the centrifugal molding method, a liquid material obtained by mixing a urethane prepolymer, which is a polyurethane precursor, and a curing agent is injected into the inside of a cylindrical molding drum, and the molding drum is rotated around its axis to form the molding. A liquid material layer is formed on the inner peripheral surface of the drum, and the liquid material layer is heated and reacted to form a cylindrical polyurethane sheet. This cylindrical polyurethane sheet is cut in the axial direction to open it into a flat polyurethane sheet, and then cut to a predetermined size to obtain a rectangular and flat blade, and a predetermined metal holder Bonding to obtain a cleaning blade unit as a composite.

  Another method for manufacturing the blade is a molding method. In the mold forming method, a metal holder pre-applied with an adhesive is placed in a mold, and a liquid material obtained by mixing a urethane prepolymer and a curing agent is injected into the mold and heated. After the blade and the holder to which the blade is attached are integrally molded, the blade is removed from the mold, and necessary portions are cut into predetermined dimensions to obtain a cleaning blade unit.

  Still another method for manufacturing a blade is disclosed in Patent Documents 1 and 2 (see Patent Documents 1 and 2). According to the production methods disclosed in Patent Documents 1 and 2, the liquid material of the urethane prepolymer and the liquid material of the crosslinking agent as the curing agent were mixed and stirred, and the resulting mixed stirring mixture was heated to a predetermined temperature. After discharging into the mold having a concave cross section of the forming drum, it is heated and pressurized via an endless belt to continuously form a band-shaped blade molding with a certain width, and after cooling the blade molding, a certain length Cut into pieces and bonded to a predetermined metal holder, and a necessary portion is cut into a predetermined size to obtain a cleaning blade unit as a composite.

JP-A-7-334060 (page 5-6, Fig. 1-2) Japanese Patent Laid-Open No. 9-141761 (page 5-6, FIG. 1-2)

  In the above-mentioned centrifugal molding method, since the polyurethane sheet is molded by rotating the molding drum, there is a problem that batch processing is required and it takes a long time from injection of the liquid material to removal of the molded sheet. Further, since the thickness of the polyurethane sheet varies due to, for example, vibration when the forming drum rotates and variations in the amount of liquid material injected into the forming drum, the blade thickness tends to vary. In addition, in the centrifugal molding method, the thinner the polyurethane sheet to be formed, the smaller the amount of the liquid material, and the liquid material is less likely to spread on the inner peripheral surface portion of the molding drum. It becomes difficult to form a sheet. Also, since a liquid material is spread on the inner peripheral surface of the forming drum to form a liquid material layer and a polyurethane sheet is formed, the first layer of molding and curing has progressed to some extent to produce a multi-layer blade. Thereafter, the molding process takes a long time, such as injecting the second layer. In addition, it is very difficult to form a multi-layer blade including a core, such as a three-layer blade having a core between polyurethane layers, which is not economical.

  Also, in the mold forming method, when changing the size and shape of the blade, it is necessary to change the mold for each type, so it is difficult to change the size and shape of the blade, and the manufacturing cost increases. There is. Also, in order to produce a large number of blades, it is necessary to prepare a considerable number of each type of mold, resulting in a further increase in manufacturing costs. In the mold forming method, since the blade is formed by curing the mixture of the urethane prepolymer and the curing agent in the mold, it is impossible to manufacture a blade having a multilayer structure.

  In the manufacturing methods disclosed in Patent Documents 1 and 2, the groove portion of the outer peripheral surface portion of the forming drum is covered with an endless belt to form a space having a concave cross section, and the stirring mixture is cured in the space to form a blade formed product. The thickness of the blade is determined by the depth of the groove formed in the outer peripheral surface portion of the forming drum. Therefore, when changing the thickness of the blade, it is necessary to change the depth of the groove, so that it is difficult to change the thickness of the blade, and the manufacturing cost increases. Further, when the ratio of thickness to width of the molded product (thickness: width) is larger than 1:10 to 1:15, the flow of liquid becomes non-uniform, and manufacturing a thin blade with a thickness of less than 0.5 mm, for example, Have difficulty.

  In the manufacturing methods disclosed in Patent Documents 1 and 2, the blade mixture is formed by curing the stirring mixture in a space having a concave cross section formed on the outer peripheral surface portion of the forming drum. A blade having a multilayer structure with a core cannot be manufactured.

  An object of the present invention is to provide a sheet body manufacturing method and manufacturing apparatus that can easily and accurately manufacture a sheet body having a target thickness, and a sheet body manufactured by the method.

  Another object of the present invention is to provide a multilayer structure sheet body including a plurality of thermosetting resin layers, a multilayer structure sheet body including a core body, and a method and apparatus for manufacturing the same.

The present invention is a method for producing a sheet body including a curable resin layer formed by curing a curable resin liquid,
Among the pair of sheets, one sheet is stretched on the first roll, the other sheet is stretched on the second roll so as to face the one sheet, and the pair of sheets are conveyed, A resin liquid supply step of supplying a curable resin liquid between a pair of sheets to form a resin liquid layer;
And a curing step of curing a resin liquid layer formed between the pair of sheets to form a curable resin layer.

  According to the present invention, in the resin liquid supply step, the curable resin liquid is supplied between the pair of sheets that are stretched and conveyed so as to face the first and second rolls to form a resin liquid layer. The resin liquid layer is cured in a curing process to form a curable resin layer, and a sheet body is manufactured. Thus, since the resin liquid layer is cured in a state of being sandwiched between the pair of sheets that are stretched and conveyed by the first and second rolls, the curable resin layer is formed. The containing sheet body can be manufactured with high thickness accuracy. Further, by adjusting the size of the gap between the pair of sheets by the first and second rolls, a thin curable resin layer having a thickness of 30 to 100 μm, for example, can be easily formed steplessly.

The present invention also includes a curing step,
A step of peeling a sheet provided on one surface portion or the other surface portion of the curable resin layer;
A sheet precursor formed by peeling the sheet is stretched on a precursor-side roll, and the opposing sheet is stretched on the facing-side roll so as to face the sheet precursor facing the curable resin layer. A step of conveying the precursor and the counter sheet, supplying a curable resin liquid between the curable resin layer and the counter sheet, and forming a laminated resin liquid layer;
A step of curing the laminated resin liquid layer to form a curable laminated resin layer.

  According to the present invention, after the curable resin layer is formed in the curing step, the sheet provided on one surface portion or the other surface portion of the curable resin layer is peeled to expose the curable resin layer. The sheet precursor formed by peeling the sheet is stretched on the precursor-side roll, and the facing sheet is stretched on the facing-side roll so as to face the sheet precursor facing the curable resin layer of the sheet precursor. In this state, the curable resin liquid is supplied between the exposed curable resin layer and the opposing sheet to form a laminated resin liquid layer. The laminated resin liquid layer is cured to form a curable laminated resin layer. In this way, the laminated resin liquid layer is cured in a state of being sandwiched between the exposed curable resin layer and the opposing sheet, so that a curable laminated resin layer is formed. A curable laminated resin layer can be formed on the part with high thickness accuracy.

In the present invention, at least one of the pair of sheets is a core sheet,
After the resin liquid supply process and before the curing process,
A pair of sheets sandwiching the resin liquid layer is stretched on a sheet-side roll, and the facing sheet is stretched on the facing-side roll so as to face the pair of sheets facing the core sheet of the pair of sheets. And a step of conveying the pair of sheets and the opposing sheet, supplying a curable resin liquid between the core sheet and the opposing sheet, and forming a resin liquid layer,
In the curing process,
Along with the resin liquid layer formed between the pair of sheets, the resin liquid layer formed between the core sheet and the counter sheet of the pair of sheets is cured to form a curable resin layer. It is characterized by.

  According to the invention, after the resin liquid layer is formed between the pair of sheets in which at least one of the sheets is a core sheet in the resin liquid supply step, the pair of sheets sandwiching the resin liquid layer is formed into a sheet. The resin is supplied with a curable resin liquid between the core sheet and the opposing sheet of the pair of sheets in a state where the sheet is stretched on the side roll and the opposing sheet is stretched on the opposing side roll and conveyed. A liquid layer is formed. The resin liquid layer formed between the core sheet and the counter sheet of the pair of sheets is cured in a curing step together with the resin liquid layer formed between the pair of sheets, and the pair of sheets and the pair of sheets are cured. A curable resin layer is formed between the core sheet and the opposing sheet. Thus, since the resin liquid layer formed between the pair of sheets and between the core sheet and the opposing sheet of the pair of sheets is cured in the curing step, a curable resin layer is formed. The curable resin layer can be formed on the surface portion of the core sheet of the pair of sheets sandwiching the curable resin layer.

Further, the present invention is a sheet body manufacturing apparatus for manufacturing a sheet body including a curable resin layer formed by curing a curable resin liquid,
A first roll on which one of the pair of sheets is stretched;
A second roll that is stretched so that the other sheet faces the other sheet of the pair of sheets;
Conveying means for conveying a pair of sheets;
A resin liquid supply means for supplying a curable resin liquid between the pair of sheets;
A sheet body manufacturing apparatus comprising: a curing unit that supplies a curable resin liquid to cure a resin liquid layer formed between a pair of sheets.

  According to the present invention, the pair of sheets is transported by the transport unit with one sheet stretched on the first roll and the other sheet stretched on the second roll so as to face the one sheet. Is done. A curable resin liquid is supplied between the pair of sheets by the resin liquid supply means to form a resin liquid layer. This resin liquid layer is cured by a curing means to form a curable resin layer. The resin liquid layer is cured while being sandwiched between a pair of sheets that are stretched and conveyed by the first and second rolls, thereby forming a curable resin layer. The containing sheet body can be manufactured with high thickness accuracy. Moreover, the thickness of the curable resin layer can be easily adjusted by adjusting the size of the gap between the pair of sheets by the first and second rolls.

In addition, the present invention peels off a sheet provided on one surface portion or other surface portion of the curable resin layer that is provided on the downstream side in the conveying direction of the pair of sheets from the curing means and is formed by curing the resin liquid layer. Peeling means to perform,
A precursor-side roll on which a sheet precursor formed by peeling the sheet is stretched;
An opposing roll on which an opposing sheet is stretched so as to face the sheet precursor facing the curable resin layer;
Conveying means for conveying the sheet precursor and the opposing sheet;
A resin liquid supply means for resin lamination for supplying a curable resin liquid between the curable resin layer and the opposing sheet;
It is provided with the hardening means for resin lamination which supplies the curable resin liquid and hardens the laminated resin liquid layer formed between a curable resin layer and an opposing sheet | seat.

  According to the present invention, after the resin liquid layer is cured by the curing means to form the curable resin layer, the sheet provided on one surface portion or the other surface portion of the curable resin layer is peeled off by the peeling means. The curable resin layer is exposed. The sheet precursor formed by peeling this sheet is stretched around the precursor side roll, and the counter sheet is stretched around the facing side roll so as to face the sheet precursor facing the curable resin layer of the sheet precursor. The curable resin liquid is supplied by the resin laminating resin supply means between the exposed curable resin layer and the opposing sheet while being conveyed by the laminating conveyance means, and a laminated resin liquid layer is formed. The This laminated resin liquid layer is heated and cured by the resin lamination heating means to form a curable laminated resin layer. As described above, the laminated resin liquid layer is cured in a state of being sandwiched between the exposed thermosetting resin layer and the opposing sheet, so that a curable laminated resin layer is formed. A curable laminated resin layer can be formed on the surface portion.

In the present invention, at least one of the pair of sheets is a core sheet,
A sheet side downstream of the resin liquid supply means in the conveyance direction of the pair of sheets and upstream of the curing means in the conveyance direction of the pair of sheets and on which the pair of sheets sandwiching the resin liquid layer is stretched Roles,
A facing roll on which the facing sheet is stretched so as to face the pair of sheets facing the core sheet of the pair of sheets;
Conveying means for conveying the pair of sheets and the opposing sheet;
A sheet laminating resin liquid supply means for supplying a curable resin liquid between the core sheet and the opposing sheet of the pair of sheets is provided.

  According to the present invention, a pair of sheets in which at least one of the sheets is a core sheet is stretched on the sheet side roll in a state of sandwiching the resin liquid layer, and the opposing sheet is stretched on the opposing side roll, It is conveyed by a conveying means. In this state, a thermosetting resin liquid is supplied between the core sheet and the counter sheet of the pair of sheets by the sheet laminating resin liquid supply means, and the resin liquid is provided between the core sheet and the counter sheet. A layer is formed. The resin liquid layer formed between the core sheet and the opposing sheet of the pair of sheets is cured by the curing unit together with the resin liquid layer formed between the pair of sheets, and the pair of sheets and the pair of sheets A curable resin layer is formed between the core sheet and the opposing sheet. Thus, since the resin liquid layer formed between the pair of sheets and between the core sheet and the opposing sheet of the pair of sheets is cured to form a curable resin layer, the curable resin is cured between the pair of sheets. While forming a resin layer, a curable resin layer can be formed in the surface part of a core sheet among a pair of sheet | seat which clamps the curable resin layer.

The present invention also includes a curable resin layer formed of a curable resin and having rubber elasticity;
Provided by laminating on one surface portion of the curable resin layer, formed of a curable resin, and including a curable laminated resin layer having rubber elasticity,
The hardness of the curable resin layer is higher than the hardness of the curable laminated resin layer,
The thickness of the curable resin layer is a sheet body characterized by being thinner than the thickness of the curable laminated resin layer.

  According to the present invention, a curable laminated resin layer formed of a curable resin is laminated on one surface portion of the curable resin layer of the sheet body, and the hardness of the curable resin layer is curable. It is higher than the hardness of the laminated resin layer. Thus, the durability of a sheet body can be improved by making a sheet body into a sheet body (henceforth a "composite sheet body") containing a curable resin layer and a curable laminated resin layer. Moreover, since the thickness of the curable laminated resin layer is thinner than the thickness of the curable resin layer, it is possible to reduce the permanent distortion of the composite sheet body and prevent sag. For example, when the sheet body is a cleaning blade for removing toner adhering to the surface portion of the image carrier, one end in the thickness direction of the curable laminated resin layer is used as a cleaning edge that contacts the image carrier. As a result, the contact pressure on the surface portion of the image carrier is increased and the toner and various external additives added to the toner are compared with the case where one end or the other end in the thickness direction of the curable resin layer is used as a cleaning edge. The additive can be easily removed, and contamination of the charging roller downstream of the cleaning unit can be reduced.

  In the present invention, the thickness of the curable resin layer is 30 μm or more and 300 μm or less.

  According to the present invention, the thickness of the curable resin layer is 30 μm or more and 300 μm or less. For example, when the total thickness of the composite sheet is 1.5 mm or more and 2.0 mm or less, and the thickness of the curable resin layer exceeds 300 μm, the thickness of the curable laminated resin layer is larger than the total thickness of the composite sheet. This is unfavorable because it becomes thin and the effect of reducing permanent distortion as a composite is poor, and it causes warping due to a difference in molding shrinkage between the curable resin layer and the curable laminated resin layer. When the thickness of the curable resin layer is less than 30 μm, for example, the sheet body is a cleaning blade, and a portion of the sheet body having a thickness of 10 μm or more and 50 μm or less in the thickness direction from one surface portion in the thickness direction of the curable resin layer is image When used as a cleaning edge that contacts the carrier, the contact portion of the cleaning edge with the image carrier includes a layer other than the curable resin layer, and as a composite that increases the contact pressure to the image carrier There is a possibility that the effect of is not fully exhibited. Further, for example, when the sheet body is a developing blade, the curable resin layer disappears at an early stage due to abrasion by rubbing with the developing sleeve, and the durability improving effect as a composite may not be sufficiently exhibited. By setting the thickness of the curable resin layer to 30 μm or more and 300 μm or less, the permanent distortion is small, the contact pressure to the image carrier is high, and a sheet body suitable as a cleaning blade is realized. Further, even if it is worn by rubbing against the developing sleeve, it does not easily disappear and has excellent durability, and a sheet body suitable as a developing blade is realized.

  Moreover, this invention is characterized by further including the sheet | seat provided by laminating | stacking on the other surface part of the curable laminated resin layer.

  According to the present invention, a curable resin layer that is harder and thinner than the curable laminated resin layer is laminated on one surface portion of the curable laminated resin layer, and a sheet is formed on the other surface portion of the curable laminated resin layer. Can be obtained.

The present invention also includes a first curable resin layer formed of a curable resin and having rubber elasticity,
A core sheet provided by being laminated on one surface portion of the first curable resin layer;
A sheet body characterized by including a second curable resin layer which is provided by being laminated on one surface portion of the core sheet, is formed of a curable resin, and has rubber elasticity.

  According to the present invention, the sheet body is a sheet body (hereinafter sometimes referred to as “composite sheet body”) including a first curable resin layer, a core sheet, and a second curable resin layer. Since the core sheet is interposed between the first curable resin layer and the second curable resin layer of the sheet body, for example, by adjusting the hardness and thickness of the core sheet, the composite sheet body Rigidity can be increased, permanent deformation of the composite sheet can be reduced, and settling can be prevented.

  The present invention is characterized in that the hardness of the second curable resin layer is higher than the hardness of the first curable resin layer.

  According to the present invention, since the hardness of the second curable resin layer is higher than the hardness of the first curable resin layer, the durability of the sheet body can be improved. For example, when the sheet body is a cleaning blade, one end or the other end in the thickness direction of the first curable resin layer is used by using one end in the thickness direction of the second curable resin layer as a cleaning edge. Compared to the case of using as a cleaning edge, the contact pressure to the surface portion of the image carrier can be increased, and the toner and various nano-sized external additives added to the toner can be easily removed.

  In the present invention, the thickness of the second curable resin layer is smaller than the thickness of the first curable resin layer.

  According to the present invention, since the thickness of the second curable resin layer is smaller than the thickness of the first curable resin layer, the permanent deformation of the sheet body is further reduced, and the sheet body is more reliably set. Can be prevented.

  In the present invention, the thickness of the second curable resin layer is 30 μm or more and 300 μm or less.

  According to the present invention, the thickness of the second curable resin layer is 30 μm or more and 300 μm or less. For example, when the total thickness of the composite sheet is 1.5 mm or more and 2.0 mm or less, and the thickness of the second curable resin layer exceeds 300 μm, the first curable property is compared with the total thickness of the composite sheet. The thickness of the resin layer is reduced, the permanent strain reducing effect as a composite is poor, and it is preferable to cause warpage due to a difference in molding shrinkage between the first curable resin layer and the second curable resin layer. Absent. Further, when the thickness of the second curable resin layer is less than 30 μm, for example, the sheet body is a cleaning blade, and among the sheet body, 10 μm or more in the thickness direction from one surface portion in the thickness direction of the second curable resin layer. When a portion of 50 μm or less is used as the cleaning edge, the cleaning edge portion includes a layer other than the second curable resin layer, and the effect as a composite of increasing the contact pressure to the image carrier is obtained. There is a risk that it will not be fully utilized. Further, for example, when the sheet body is a developing blade, the second curable resin layer disappears early due to abrasion by rubbing with the developing sleeve, and the durability improving effect as a composite may not be sufficiently exhibited. . By setting the thickness of the second curable resin layer to 30 μm or more and 300 μm or less, a permanent deformation is small and a contact pressure to the image carrier is high, and a sheet body suitable as a cleaning blade is realized. Further, even if it is worn by rubbing against the developing sleeve, it does not easily disappear and has excellent durability, and a sheet body suitable as a developing blade is realized.

  According to the present invention, in the resin liquid supply step, the curable resin liquid is supplied between the pair of sheets that are stretched and conveyed by the first and second rolls to form a resin liquid layer. Since the layer is cured while being sandwiched between the pair of sheets in the curing step to form the curable resin layer, a sheet body including the curable resin layer can be manufactured with high thickness accuracy. Further, the thickness of the curable resin layer can be easily adjusted by adjusting the size of the gap between the pair of sheets by the first and second rolls.

  Further, according to the present invention, a curable resin liquid is supplied between the curable resin layer formed in the curing step and the counter sheet to form a laminated resin liquid layer, and the laminated resin liquid layer is cured and cured. Since the curable laminated resin layer is formed, a sheet body having a curable laminated resin layer formed by curing the curable resin liquid on one surface portion or the other surface portion of the curable resin layer can be produced. .

  According to the invention, after the resin liquid layer is formed between the pair of sheets in the resin liquid supply step, the resin liquid layer is formed between the core sheet and the opposing sheet of the pair of sheets. Since the resin liquid layer is cured in the curing step, a curable resin layer is formed between the pair of sheets, and among the pair of sheets sandwiching the curable resin layer, the surface portion of the core sheet is curable. A resin layer can be formed. Therefore, it is possible to manufacture a sheet body in which the core sheet is interposed between the curable resin layer and the curable resin layer.

  According to the invention, the resin liquid layer is formed by supplying the curable resin liquid by the resin liquid supply means between the pair of sheets that are stretched between the first and second rolls and conveyed by the conveyance means, Since the resin liquid layer is cured by the curing means in a state of being sandwiched between the pair of sheets to form the curable resin layer, the sheet body including the curable resin layer can be manufactured with high thickness accuracy. A manufacturing apparatus is realized. The sheet body manufacturing apparatus can easily adjust the thickness of the curable resin layer steplessly by adjusting the size of the gap between the pair of sheets with the first and second rolls.

  According to the invention, the sheet provided on one surface portion or the other surface portion of the curable resin layer is peeled off by the peeling means to form a sheet precursor, and the sheet precursor and the counter sheet are transported for lamination. The curable resin liquid is supplied by the resin liquid supply means for resin lamination while being conveyed by the means, and is stretched between the curable resin layer of the sheet precursor stretched on the precursor side roll and the opposite side roll. A laminated resin liquid layer is formed between the opposite sheet and the laminated resin liquid layer is cured by a resin lamination curing means to form a curable laminated resin layer. A sheet body in which a curable laminated resin layer is formed on the other surface portion can be manufactured.

  Further, according to the present invention, after the curable resin liquid is supplied by the resin liquid supply means and the resin liquid layer is formed between the pair of sheets in which at least one of the sheets is a core sheet, the laminating resin A curable resin liquid is supplied by the liquid supply means to form a resin liquid layer between the core sheet and the opposing sheet of the pair of sheets, and these two resin liquid layers are cured by the curing means to be a curable resin layer. Is formed. Thereby, while forming a curable resin layer between a pair of sheet | seats, a curable resin layer can be formed in the surface part of a core sheet among a pair of sheet | seat which clamps the curable resin layer. Therefore, it is possible to manufacture a sheet body in which the core sheet is interposed between the curable resin layer and the curable resin layer.

  Further, according to the present invention, since one surface portion of the curable resin layer of the sheet body is provided with a curable laminated resin layer having a higher hardness and a smaller thickness than the curable resin layer, the durability of the sheet body In addition, the permanent distortion of the sheet body can be reduced and the settling can be prevented. Further, when the sheet body is a cleaning blade, one end in the thickness direction of the curable laminated resin layer is used as a cleaning edge, thereby increasing the contact pressure to the surface portion of the image carrier, and various kinds of toner and toner added to the toner. The nano-sized external additive can be easily removed.

  According to the present invention, since the thickness of the curable laminated resin layer is 30 μm or more and 300 μm or less, the permanent distortion is small, the contact pressure to the image carrier is high, and the durability is excellent. A sheet body suitable as a blade is realized.

  Further, according to the present invention, since the sheet is provided on the other surface portion of the curable resin layer of the sheet body, the rigidity of the sheet body can be increased by adjusting the hardness and thickness of the sheet, for example. It is possible to further reduce the permanent set of the sheet body and more reliably prevent sag.

  According to the present invention, since the core sheet is interposed between the first curable resin layer and the second curable resin layer of the sheet body, for example, the hardness and thickness of the core sheet are adjusted. As a result, the rigidity of the sheet body can be increased, the permanent distortion of the sheet body can be reduced, and the settling can be prevented.

  Moreover, according to this invention, since the hardness of a 2nd curable resin layer is higher than the hardness of a 1st curable resin layer, durability of a sheet | seat body can be improved. When the sheet body is a cleaning blade, the one end in the thickness direction of the second curable resin layer is used as a cleaning edge, thereby increasing the contact pressure to the surface portion of the image carrier and adding to the toner and toner. In addition, various nano-sized external additives can be easily removed.

  Moreover, according to this invention, since the thickness of the 2nd curable resin layer is smaller than the thickness of the 1st curable resin layer, the permanent set of a sheet body is made still smaller and settling is prevented more reliably. Can do.

  According to the present invention, since the thickness of the second curable resin layer is not less than 30 μm and not more than 300 μm, the permanent set is small, the contact pressure to the image carrier is high, and the durability is excellent. And a sheet body suitable as a developing blade is realized.

  FIG. 1 is a side view showing the configuration of the sheet body manufacturing apparatus 1 according to the first embodiment of the present invention, and FIG. 2 is an enlarged side view showing the configuration of the layer forming unit 13 shown in FIG. In FIG. 1 and FIG. 2, about the heating furnace main body 71 of the resin liquid hardening part 15, the cross-sectional structure in the virtual one plane parallel to the conveyance direction of the sheet precursor 94 is shown. In FIG. 1 and FIG. 2, a part of the thickness is omitted for easy understanding. FIG. 3 is a cross-sectional view illustrating a configuration of a cleaning blade 90 which is an example of a sheet body manufactured by the sheet body manufacturing apparatus 1 of the present embodiment, and FIG. 4 is a sheet by the sheet body cutting unit 18 of the sheet body manufacturing apparatus 1. 7 is a perspective view showing a state of the cleaning blade 90 obtained after the body 95 is cut. FIG.

  In the present embodiment, like the cleaning blade 90 shown in FIG. 3, it is composed of a curable resin layer formed of a curable resin, more specifically, a thermosetting resin layer 91 formed of a thermosetting resin. The sheet body 90 is manufactured. As shown in FIG. 4, the sheet body 90 is obtained as a sheet 95 in which the sheet body 90 is laminated on a first release film 31 that is a first sheet described later. The curable resin layer is not limited to the thermosetting resin layer, and may be, for example, a room temperature curable resin layer formed of a room temperature curable resin or a photo curable resin layer formed of a photo curable resin. .

  In the present embodiment, the thermosetting resin layer 91 has rubber elasticity. Therefore, the sheet body 90 shown in FIG. 3 is an elastic sheet body having elasticity. In the present embodiment, the thermosetting resin constituting the thermosetting resin layer 91 is a thermosetting urethane resin. The thermosetting resin constituting the thermosetting resin layer 91 is not limited to the thermosetting urethane resin, and may be, for example, a thermosetting silicone resin. A thermosetting resin such as a thermosetting urethane resin has a smaller permanent set than a thermoplastic resin such as a thermoplastic urethane resin. Since the cleaning blade of the present embodiment is composed of the thermosetting resin layer 91 formed of a thermosetting resin having a small permanent distortion as described above, the cleaning blade is made of a thermoplastic resin layer formed of a thermoplastic resin such as thermoplastic polyurethane. Compared to a cleaning blade, permanent deformation is small, sag is unlikely to occur, and durability is excellent.

  As shown in FIG. 1, the sheet body manufacturing apparatus 1 includes a resin liquid supply unit 11 that is a resin liquid supply unit, a sheet supply unit 12, a layer forming unit 13, a sheet transport unit 14, and a resin that is a curing unit. A liquid curing unit 15, a feed amount adjusting unit 16, a sheet winding unit 17, and a sheet body cutting unit 18 are configured. The resin liquid supply unit 11, the sheet supply unit 12, and the layer forming unit 13 constitute a layer forming unit 19.

  As shown in FIG. 2, the resin liquid supply unit 11 includes a mixing head 21, a raw material tank (not shown) in which raw materials for the thermosetting resin layer 91 shown in FIG. 3 are stored, and a liquid feeding means 25. The mixing head 21 is provided with a mixing chamber 22 in which the raw material supplied from the raw material tank is accommodated, a rotor 23 that is rotatably provided inside the mixing chamber 22, and agitates the raw material stored in the mixing chamber 22. And a mixing motor 24 that rotationally drives the motor 23. The rotational speed of the rotor 23 is 2000 revolutions / minute, for example.

  The mixing head 21 is provided so as to discharge the raw material supplied from the raw material tank in the vertical direction. The vertical direction Z1 that is the raw material discharge direction by the mixing head 21 and the direction Z2 opposite to the discharge direction Z1 are defined as the Z direction, and one direction orthogonal to the Z direction is defined as the X direction, The direction orthogonal to the Z direction is defined as the Y direction. In each figure, these X, Y, and Z directions are represented by arrows X, Y, and Z. The mixing head 21 is provided so as to be capable of reciprocating in the Y direction.

  Although not shown, the raw material tank includes a main agent tank in which main agent A containing a thermosetting resin prepolymer is stored, and a hardener tank in which hardener B is stored. The main agent A and the curing agent B constitute the raw material of the thermosetting resin layer 91. The thermosetting resin prepolymer contained in the main agent A is a precursor of the thermosetting resin, and is cured by heating and reacting with the curing agent B to become a thermosetting resin.

  The main agent tank is connected to the mixing chamber 22 of the mixing head 21 via the first pipe 26 shown in FIG. 2 and supplies the main agent A to the mixing chamber 22 via a supply port (not shown). Similarly, the curing agent tank is connected to the mixing chamber 22 of the mixing head 21 via the second pipe 27 shown in FIG. 2 and supplies the curing agent B to the mixing chamber 22 via a supply port (not shown).

  The liquid feeding means 25 includes first and second pipes 26 and 27, a liquid feeding metering pump and a pump driving motor (not shown), and first and second switching valves 28 and 29. The liquid feeding metering pumps are provided in the first and second pipes 26 and 27, respectively. The liquid feeding metering pump is driven by a pump driving motor (not shown), and supplies a predetermined amount of the main agent A from the main agent tank to the mixing chamber 22 and also supplies the curing agent B from the hardener tank to the mixing chamber 22. .

  The first switching valve 28 is provided in the first pipe 26 and switches between a discharge state in which the main agent A is discharged from the main agent tank into the mixing chamber 22 and a circulation state in which the main agent A is circulated to the main agent tank. Similarly, the second switching valve 29 is provided in the second pipe 27 and has a discharge state in which the curing agent B is discharged from the curing agent tank to the mixing chamber 22 and a circulation state in which the curing agent B is circulated to the curing agent tank. Is switched.

  When the first pipe 26 is discharged by the first switching valve 28, the main agent A is discharged from the main agent tank to the mixing chamber 22, and when the second pipe 27 is discharged by the second switching valve 29, The curing agent B is discharged from the curing agent tank to the mixing chamber 22. When the first pipe 26 is circulated by the first switching valve 28, the main agent A is fed from the main agent tank to the first pipe 26, and then flows into the main agent tank again through the first pipe 26. It circulates between the main agent tank and the first pipe 26 on the upstream side of the main agent A in the flow direction from the first switching valve 28. Similarly, when the second piping 27 is circulated by the second switching valve 29, the curing agent B is in the second piping 27 on the upstream side in the flow direction of the curing agent B from the curing agent tank and the second switching valve 29. Circulate between.

  In the discharge state, the main agent A flows into the mixing chamber 22 through the main agent introduction port, the curing agent B flows into the mixing chamber 22 through the curing agent introduction port, and the main agent A and the curing agent B that have flowed into the mixing chamber 22 are the rotor. The curable resin liquid 30 which is a mixture of the main agent A and the curing agent B is mixed by being agitated by the rotational drive of 23. The curable resin liquid 30 is discharged between the pair of sheets 31 and 32 supplied to the layer forming unit 13 through the discharge port of the mixing chamber 22.

  The viscosity of the curable resin liquid 30 obtained by mixing the main agent A and the curing agent B is preferably 300 mPa · s or more and 100,000 mPa · s or less at the liquid temperature during processing. When the viscosity of the curable resin liquid 30 at the time of processing (hereinafter sometimes simply referred to as “viscosity”) is less than 300 mPa · s, the resin liquid layer 92 formed between the pair of sheets 31 and 32 It becomes difficult to convey the sheet precursor 94 while maintaining the thickness, and the thickness of the thermosetting resin layer 91 in the obtained sheet body 95 may deviate from a desired value. When the viscosity of the curable resin liquid exceeds 100,000 mPa · s, it becomes difficult to uniformly mix the curable resin liquid in the mixing chamber 23, and the physical properties after curing become unstable.

  In the present embodiment, the curable resin layer 91 shown in FIG. 3 is a thermosetting resin layer composed of a thermosetting resin, and thus the curable resin liquid 30 is a thermosetting resin liquid that is cured by heat. . The curable resin layer 91 is not limited to the thermosetting resin layer, and may be, for example, a photocurable resin layer made of a photocurable resin. In this case, the curable resin liquid 30 is a photocurable resin liquid that is cured by irradiating light such as ultraviolet rays.

  In the present embodiment, the thermosetting resin layer 91 shown in FIG. 3 is formed of a thermosetting polyurethane resin. Therefore, a polyurethane prepolymer is used for the thermosetting resin prepolymer contained in the main agent A. The thermosetting polyurethane resin can be obtained, for example, by reacting a polyurethane prepolymer and a curing agent. The “polyurethane prepolymer” means a reaction product of a polyol and an isocyanate, and includes a polyurethane pseudo-prepolymer in which the blending equivalent ratio of polyol is smaller than the blending equivalent ratio of isocyanate.

  Examples of the polyol include polyether polyols, polyester polyols, polycarbonate polyols, and polyester polycarbonate polyols having a hydroxyl group at the terminal.

  Examples of polyether polyols include alkylene oxide adducts of alkylene glycols and polyhydric alcohols. Examples of alkylene glycols include polyethylene glycol, polypropylene glycol, and polytetramethylene glycol. “Alkylene oxide adduct of polyhydric alcohols” is a compound obtained by adding alkylene oxide such as ethylene oxide or propylene oxide to polyhydric alcohols such as bisphenol A or glycerin. Is 2,2-bis (p-hydroxyphenyl) propane. Examples of the alkylene oxide adduct of polyhydric alcohols include polyoxyethylene-2,2-bis (4-hydroxyphenyl) propane and polyoxypropylene-2,2-bis (4-hydroxyphenyl) propane.

  Polyester polyols include, for example, polybasic acids such as adipic acid, phthalic anhydride, isophthalic acid, maleic acid or fumaric acid, ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol or trimethylolpropane. It can be obtained by polymerization reaction with polyhydric alcohols such as Examples of the polyester polyol include polyethylene adipate, polybutylene adipate, polyethylene butylene adipate, polyhexamethylene adipate, and polycaprolactone polyol.

  Examples of the polycarbonate polyol include diols such as 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol, polyethylene glycol, polypropylene glycol or polytetramethylene glycol, phosgene, diphenyl carbonate, and the like. And the reaction product with a cyclic carbonate such as propylene carbonate.

  The polyester polycarbonate polyol includes a reaction product of a polyester polyol such as polycaprolactone polyol and an alkylene carbonate such as ethylene carbonate, a reaction product obtained by reacting an alkylene carbonate such as ethylene carbonate with a polyhydric alcohol, and an organic dicarboxylic acid. The reaction product of is mentioned.

  The number average molecular weight of the polyol is preferably 500 or more and 5000 or less, and more preferably 1000 or more and 3000 or less. A polyether may be used individually by 1 type and 2 or more types may be used together.

  Examples of isocyanates include aromatic diisocyanates such as tolylene diisocyanate, methylene diphenyl diisocyanate, 1,5-naphthalene diisocyanate, p-phenylene diisocyanate, m-phenylene diisocyanate, p-xylylene diisocyanate, m-xylylene diisocyanate, ethylene diisocyanate, Aliphatic diisocyanates such as 2,2,4-trimethylhexamethylene diisocyanate, 1,6-hexamethylene diisocyanate, 1,4-cyclohexane diisocyanate, 4,4′-dicyclohexylmethane diisocyanate, isophorone diisocyanate, norbornane diisocyanate Bifunctional isocyanate compounds such as cyclic diisocyanates are mentioned. The isocyanate is not limited to these difunctional isocyanate compounds, and may be a trifunctional or higher polyfunctional isocyanate compound. One type of isocyanate may be used alone, or two or more types may be used in combination.

  Curing agents B include bifunctionals such as ethylene glycol, 1,4-butanediol, diethylene glycol, low molecular weight diols such as 1,6-hexanediol and neopentyl glycol, and diamines such as ethylenediamine, hexamethylenediamine and isophoronediamine. Ingredients. The curing agent B may contain a trifunctional or higher functional component. Trifunctional or higher polyfunctional components include, for example, trifunctional or higher polyfunctional compounds such as triol such as trimethylolpropane, triethanolamine and glycerin, and alkylene oxide such as ethylene oxide or propylene oxide added to these polyfunctional compounds. And an alkylene oxide adduct of a polyfunctional compound. When the polyurethane prepolymer is a polyurethane pseudo-prepolymer, a polyol having a number average molecular weight of 500 or more and 5000 or less, in addition to a low molecular weight component such as a low molecular weight diol such as ethylene glycol and a low molecular weight triol such as trimethylolpropane, etc. Those having a high molecular weight component mixed therein are used as the curing agent B.

  The polyol and the isocyanate may be reacted by a one-shot method in which they are reacted as they are without forming a prepolymer, but after forming a prepolymer or pseudo-prepolymer as in this embodiment, the final product composition is obtained. It is preferable to use a prepolymer method or a pseudo-prepolymer method in which the reaction is performed. By using the prepolymer method or the pseudo-prepolymer method, the physical properties of the thermosetting resin layer 91 to be formed are stabilized, and a sheet body 90 having a certain quality can be stably manufactured.

  In the production of thermosetting polyurethane, the equivalent ratio (OH group / NCO group) of hydroxyl group (OH group) to isocyanate group (NCO group) is from 0.8 to 1.05 from the viewpoint of the physical properties of the resulting polyurethane. It is preferable that it is 0.85 or more and 1.00 or less.

  In the present embodiment, the thermosetting resin liquid 30 is made into a fast curing formulation containing a reaction accelerator. Accordingly, either or both of the main agent A and the curing agent B, in this embodiment, the curing agent B contains a reaction accelerator. By containing a reaction accelerator in the thermosetting resin liquid 30, the resin liquid curing unit 15 is conveyed after the curing reaction of the thermosetting resin liquid 30, more specifically, after stirring and mixing the main agent A and the curing agent B. It is possible to accelerate the curing reaction of the thermosetting resin liquid 30 until the curing time and shorten the time required for curing.

  Examples of the reaction accelerator include imidazole derivatives such as 2-methylimidazole and 1,2-dimethylimidazole, and 1,8-diazabicyclo [5.4.0] undecene-7-organic acid salt called block amine, Examples include 1,5-diazabicyclo [4.3.0] nonene-5-organic acid salts and mixtures thereof, dibutyltin dilaurate, and the like. The reaction accelerator is used in the range of 0.01 parts by weight to 0.1 parts by weight with respect to 100 parts by weight of the prepolymer. Although the usage-amount of a reaction accelerator is not limited to this, It is preferable that it is 0.01 to 0.1 weight part with respect to 100 weight part of prepolymers like this embodiment. When the amount of the reaction accelerator used is less than 0.01 parts by weight with respect to 100 parts by weight of the prepolymer, the reaction promoting action is poor, and the amount of the reaction accelerator used is 0.1 weight with respect to 100 parts by weight of the prepolymer If it exceeds the range, the reaction is too fast, and troubles such as solidification of the thermosetting resin liquid 30 in the mixing chamber 23 occur. Furthermore, if the reaction accelerator is excessively added in excess of 0.1 part by weight, the manufactured sheet member 90 may contaminate the photoconductor when it is used as a cleaning blade in an electrophotographic apparatus. Since it is easy to produce deterioration, it is not preferable.

  2, the main agent A is supplied from the main agent tank to the mixing chamber 22 of the mixing head 21, the hardener B is supplied from the hardener tank, and is stirred and mixed by the rotor 23. A thermosetting resin liquid is prepared as a mixture. This thermosetting resin liquid is discharged from the discharge port of the mixing chamber 22 and supplied between the pair of sheets 31 and 32.

  As shown in FIGS. 1 and 2, the sheet supply unit 12 includes a first sheet supply unit 33 that supplies a first sheet (hereinafter referred to as “first sheet”) 31 and a second sheet (hereinafter referred to as “second sheet”). A second sheet supply unit 34 for supplying 32). 1 and 2, the first sheet 31 is represented by a solid line, and the second sheet 32 is represented by a broken line. In the present embodiment, the first and second sheets 31 and 32 are both realized by a resin film, more specifically, a release film that is a resin film having releasability. Hereinafter, when it is not necessary to distinguish between the first release film 31 that is the first sheet and the second release film 32 that is the second sheet, they are simply referred to as “release film”.

  The first and second sheet supply units 33 and 34 have the same configuration, and each include an unillustrated unwinding constant tension device and an unillustrated end position adjusting device. The unwinding constant tension device adjusts the tension when the release films 31 and 32 wound around the unwinding shafts 35 and 36 are unwound to a constant value. More specifically, the unwinding constant tension device applies a constant tension to the release films 31 and 32 by a torque motor (not shown). The unwinding constant tension device controls the torque by the torque motor following the change in the winding diameter of the release films 31 and 32, thereby applying a constant tension to the release films 31 and 32. The edge position control (abbreviation EPC) device adjusts and aligns the positions of the end portions on the downstream side in the transport direction of the unwinding release films 31 and 32.

  According to the first sheet supply unit 33, the first release film 31 wound around the first unwinding shaft 35 is unwound by being given a constant tension by the unwinding constant tension device, and is conveyed by the EPC device. The ends on the downstream side in the direction are aligned and supplied to the layer forming unit 13. Similarly, according to the second sheet supply unit 34, the second release film 32 wound around the second unwinding shaft 36 is unwound by applying a constant tension by the unwinding constant tension device, and the EPC device. Thus, the end on the downstream side in the transport direction is aligned and supplied to the layer forming unit 13.

  As described above, the first and second sheets 31 and 32 are realized by the resin film in the present embodiment. The term “sheet” includes “film”, and “film” refers to a sheet having a thickness of 200 μm or less. Examples of the resin constituting the first and second sheets 31 and 32 include polyester resins such as polyethylene terephthalate (abbreviated as PET) and polyethylene naphthalate (abbreviated as PEN), polyimide resins, and polyethylene. Examples thereof include thermoplastic resins such as resins, polypropylene resins, etc. Among these, PET and PEN are preferable because their heat resistance, rigidity, and economy are superior to those of other resins such as polyethylene resins and polypropylene resins. The first and second sheets 31 and 32 are not limited to resin films, and for example, release paper that has been subjected to release treatment may be used, but the release paper is accompanied by generation of paper dust during use. It is preferable to use a resin film as in the embodiment.

  More specifically, the first and second sheets 31 and 32 are realized by a release film that is a resin film having releasability as described above. As a release film, the film in which the release layer was formed in the one surface part of the thickness direction of a base material layer is mentioned, for example. The base material layer is formed of, for example, a thermoplastic resin such as polyethylene terephthalate. The release layer is formed of, for example, a silicone resin or a fluororesin. The thicknesses of the first and second release films 31 and 32 that are the first and second sheets are selected from 30 μm to 100 μm. The thickness of the 1st and 2nd sheet | seats 31 and 32 is not limited to this.

  The thicknesses of the release films 31 and 32 are selected so as to suppress thermal shrinkage due to heating in the heating furnace main body 71 of the resin liquid curing unit 15 by an appropriate unwinding tension. In this embodiment, the thickness is 30 μm or more and 100 μm. Selected for the range. The heating furnace main body 71 includes a mechanism for clamping and transporting the end portion in the width direction orthogonal to the traveling direction of the release film in the heating furnace main body 71 in order to suppress thermal shrinkage of the release film due to heating. . Further, in order to more reliably suppress thermal shrinkage of the release film, the material of the thermosetting resin liquid 30 is selected so that the curing temperature of the thermosetting resin liquid 30 is 120 ° C. or lower, more preferably 110 ° C. or lower. Is done.

  As shown in FIG. 2, the layer forming unit 13 includes a first sheet stretching unit 41 on which the first release film 31 is stretched and a second sheet stretching unit on which the second release film 32 is stretched. 42. The first sheet stretching part 41 and the second sheet stretching part 42 are paired and configured to be bilaterally symmetric. The first sheet stretching unit 41 and the second sheet stretching unit 42 have the same configuration, and include a heat roll 43, three cleaner units 44, 45, and 46, and a static eliminator 48, respectively.

  The first release film 31 is fed from the first sheet supply section 33 to the first sheet stretch section 41, and the second release film is fed from the second sheet supply section 34 to the second sheet stretch section 42. 32 is sent. In the first sheet stretching portion 41, the static eliminator 48, the third cleaner unit 46, and the heat roll 43 are provided in this order from the upstream side to the downstream side in the transport direction of the first release film 31. Similarly, in the second sheet stretching portion 42, the static eliminator 48, the third cleaner unit 46, and the heat roll 43 are provided in this order from the upstream side to the downstream side in the transport direction of the second release film 32.

  FIG. 5 is an enlarged side view showing the configuration of the first sheet stretching portion 41 shown in FIG. In FIG. 5, a part of the thickness is omitted for easy understanding. The heat roll 43 is realized by a drilled roll. The heat roll 43 realized by the drilled roll has a substantially cylindrical shape, and a flow path is formed inside the roller body 51 so that the heat medium circulates around the outer peripheral surface portion along the axial direction. The outer peripheral surface of the roller body 51 is heated by causing a heat medium such as oil or water vapor to flow through the flow path. The heat roll 43 is provided so that the axial direction coincides with the Y direction. The outer diameter of the heat roll 43 is, for example, 150 mm.

  In the heat roll 43, for example, the axial end 51a is rotatably supported by a bearing (not shown). The bearing is realized by a rolling bearing such as a ball bearing or a sliding bearing, for example. Examples of the material of the heat roll 43 include metal materials such as aluminum and iron, and alloy materials such as aluminum iron alloy including stainless steel. The heat roll 43 is realized by, for example, an iron drilled roll whose surface is plated with hard chrome.

  Returning to FIG. 2, the heat rolls 43 of the first and second sheet stretching portions 41 and 42 are provided to face each other. A heat roll (hereinafter also referred to as “first heat roll”) 43a of the first sheet stretch portion 41 and a heat roll (hereinafter also referred to as “second heat roll”) of the second sheet stretch portion 42. 43b, the first release film 31 and the second release film 32 face each other, and the mixing head 21 is interposed between the first release film 31 and the second release film 32 facing each other. Is supplied with a thermosetting resin liquid 30. When the mixing head 21 of the resin liquid supply unit 11 reciprocates in the Y direction, the thermosetting resin liquid 30 can be supplied over the entire Y direction, which is the width direction of the first and second sheets 31 and 32.

  In this way, the resin liquid layer 92 formed between the first release film 31 and the second release film 32 when the thermosetting resin liquid 30 is supplied is heated by the heat roll 43. The curing reaction of the thermosetting resin liquid 30 constituting the resin liquid layer 92 is started by stirring and mixing in the mixing chamber 23, but is further accelerated by heating by the heat roll 43.

  The first heat roll 43a and the second heat roll 43b are rotationally driven in directions opposite to each other. In the present embodiment, the first heat roll 43a is driven to rotate in the clockwise direction toward FIGS. 1 and 2, and more specifically in the direction of arrow C, which is the clockwise direction toward FIG. 5, as shown in FIG. Then, the second heat roll 43b is driven to rotate counterclockwise toward FIG. The first heat roll 43a corresponds to the first roll, and the second heat roll 43b corresponds to the second roll.

  Of the three cleaner units 44, 45, 46, the first cleaner unit 44 is provided on one side Z <b> 1 in the Z direction of the heat roll 43, and the second cleaner unit 45 is provided on the other side Z <b> 2 in the Z direction of the heat roll 43. It is done. The first and second cleaner units 44 and 45 are similarly configured, and each include a cleaning roller 52 and a collection roller 53 provided in pressure contact with the cleaning roller 52. The cleaning roller 52 of the first cleaner unit 44 is provided in pressure contact with the heat roll 43. The cleaning roller 52 of the second cleaner unit 45 is provided so as to be in pressure contact with the heat roller 43 in a state where the release film 31 is not stretched. In the state where the release film 31 is stretched, the second cleaner unit A release film 31 is interposed between the 45 cleaning roller 52 and the heat roller 43. The heat roll 43 is provided so as to be driven to rotate, and the cleaning roller 52 and the collection roller 53 are provided to be driven to rotate. The heat roll 43, the cleaning roller 52, and the recovery roller 53 are supported by a housing (not shown) so that the axes are parallel to each other.

  The cleaning roller 52 is solid, in this embodiment, cylindrical, and is realized by, for example, a solid roller. As a material of the cleaning roller 52, a material having moderate adhesiveness, for example, adhesiveness that is capable of adhering and removing foreign matters attached to the release films 31, 32 without sticking to the release films 31, 32. Examples thereof include a material having an adhesive property, specifically, a silicone rubber or a butadiene rubber having appropriate adhesiveness.

  FIG. 6 is a perspective view showing the configuration of the collection roller 53 shown in FIG. The collection roller 53 has a performance of transferring and holding foreign matter removed by the cleaning roller 53 and preventing it from reattaching to the cleaning roller 52. In the present embodiment, the collection roller 53 is realized by a pressure-sensitive adhesive sheet 201 made of a material having a higher adhesive force than the pressure-sensitive adhesive material constituting the cleaning roller 52 and wound around the shaft member 202 in a roller shape. Examples of the adhesive sheet 201 constituting the collection roller 53 include a resin sheet coated with an adhesive, for example, an acrylic resin sheet coated with an adhesive. A perforation 203 is formed in the adhesive sheet 201 constituting the collection roller 53 along the width direction perpendicular to the unwinding direction, and the perforation 203 can be cut off. As a result, the collection roller 53 has a structure capable of peeling the surface layer at an appropriate timing and exposing a new surface.

  Returning to FIG. 2, the heat roll 43 is drivingly coupled to a driving source (not shown) such as an electric motor via a power transmission mechanism (not shown) including gears. The first and second sheets 31 and 32 are conveyed by the rotational drive of the heat roll 43. The heat roll 43 corresponds to a conveying unit.

  In the first and second sheet stretching portions 41, 42, the cleaning roller 52 of the first cleaner unit 44 is driven to rotate in the direction opposite to the rotation direction of the heat roll 43 as the heat roll 43 is driven to rotate. 53 is driven to rotate in the direction opposite to the rotation direction of the cleaning roller 52 as the cleaning roller 52 is driven. For example, in the first cleaner unit 44 of the first sheet extending portion 41, as shown in FIG. 5, when the first heat roll 43a is rotationally driven in the arrow C direction, which is the clockwise direction in FIG. 52 is driven to rotate in the direction of the arrow D, which is the counterclockwise direction, and the collection roller 53 is driven to rotate in the direction of the arrow C, which is the clockwise direction.

  In the first sheet stretching portion 41, the first release film 31 has one surface in the thickness direction in contact with the cleaning roller 52 of the second cleaner unit 45, and between the cleaning roller 52 and the first heat roll 43a. It winds around the heat roll 43 so that it may pass. Similarly, in the second sheet stretching portion 42, the second release film 32 has one surface portion in the thickness direction in contact with the cleaning roller 52 of the second cleaner unit 45, and the cleaning roller 52 and the second heat roll 43b. It winds around the 2nd heat roll 43b so that it may pass between.

  Thus, in the state where the release films 31 and 32 are wound around the heat roll 43, the release films 31 and 32 are interposed between the cleaning roller 52 and the heat roll 43 of the second cleaner unit 45. The cleaning roller 52 of the one cleaner unit 44 is in direct contact with the heat roll 43.

  According to the first cleaner unit 44, deposits such as dust adhered to the outer peripheral surface portion of the heat roll 43 are collected by being adhered to the outer peripheral surface portion of the cleaning roller 52, and attached to the outer peripheral surface portion of the cleaning roller 52. The kimono is collected by being attached to the outer peripheral surface portion of the collection roller 53. Thereby, since the outer peripheral surface part of the heat roll 43 can be kept clean, the adhering matter adhering to the outer peripheral surface part of the heat roll 43 is prevented from being transferred to the other surface part in the thickness direction of the first release film 31. be able to.

  The cleaning roller 52 of the second cleaner unit 45 is driven to rotate in the direction D opposite to the rotation direction C of the heat roll 43 as the release films 31 and 32 are moved by the rotation of the heat roll 43, and the recovery roller 53 is cleaned. As the roller 52 is driven to rotate, the cleaning roller 52 is driven to rotate in the direction C opposite to the rotation direction D.

  According to the second cleaner unit 45, deposits such as dust adhering to one surface portion in the thickness direction of the release films 31 and 32 that are in contact with the cleaning roller 52 are attached to the outer peripheral surface portion of the cleaning roller 52 and collected. The adhering matter collected on the outer peripheral surface portion of the cleaning roller 52 is attached to the outer peripheral surface portion of the collecting roller 53 and recovered. Thereby, one surface part in the thickness direction of the release films 31 and 32 can be kept clean. One surface portion in the thickness direction of the release films 31 and 32 is opposed at a position where the first and second heat rolls 43a and 43b are opposed to each other, and the thermosetting resin liquid 30 is supplied to the opposed surface portions. Therefore, the second cleaner unit 45 collects the deposit on the one surface portion in the thickness direction of the first and second sheets 31 and 32, so that the deposit on the resin liquid layer 92 formed by the thermosetting resin liquid 30. Mixing can be prevented. The deposits collected on the collection rollers 53 of the first to third cleaner units 44, 45, 46 are adhered and held on the collection rollers 53. Since the collection roller 53 has higher adhesive force than the cleaning roller 52, it is possible to prevent the collected deposits from reattaching to the cleaning roller 52. Moreover, since the collection | recovery roller 53 is comprised so that it can cut off with the perforation 203, when the stain | pollution | contamination of an outer peripheral surface part advances by adhesion of a deposit | attachment, it peels suitably and can use a new surface.

  The third cleaner unit 46 includes a guide roller 54, a cleaning roller 52 provided in pressure contact with the guide roller 54, and a collection roller 53 provided in pressure contact with the cleaning roller 52. The cleaning roller 52 of the third cleaner unit 46 is configured in the same manner as the cleaning roller 52 of the first and second cleaner units 44 and 45, and the recovery roller 53 of the third cleaner unit 46 is the first and second cleaner unit 44. 45, the same as the collecting roller 53. The guide roller 54 is provided so as to be driven to rotate.

  The release films 31 and 32 are wound around the guide roller 54 so that one surface portion in the thickness direction is in contact with the guide roller 54 and passes between the guide roller 54 and the cleaning roller 52. In the third cleaner unit 46, the guide roller 54 is driven to rotate in the direction D opposite to the rotation direction C of the heat roll 43 as the release films 31 and 32 are moved by the rotation of the heat roll 43, and the cleaning roller 52 is heated. The roll 43 is driven to rotate in the same direction C as the rotation direction C of the roll 43. The collection roller 53 is driven to rotate in a direction D opposite to the rotation direction C of the cleaning roller 52 as the cleaning roller 52 is driven. The third cleaner unit 46 can remove and collect deposits such as dust adhered to the other surfaces in the thickness direction of the release films 31 and 32.

  Returning to FIG. 2, the static eliminator 48 is provided to face the other surface portion in the thickness direction of the release films 31 and 32. The static eliminator 48 is realized by, for example, an ionizer. According to the static eliminator 48, static electricity generated in the release films 31 and 32 is removed, and adhesion of foreign substances existing in the environment around the sheet body manufacturing apparatus 1 is suppressed, and adhered foreign substances are removed by the cleaning roller 52. It can be made easier.

  The sheet conveying unit 14 includes a guide roller 61 and a fourth cleaner unit 62. The fourth cleaner unit 62 is configured in the same manner as the first and second cleaner units 44 and 45. The first and second sheets 31 and 32 face each other at a portion where the heat rolls 43 of the first and second sheet stretching portions 41 and 42 face each other, and the resin liquid layer 92 is formed therebetween. The sheet is fed to the conveyance unit 14, guided by the guide roller 61 of the sheet conveyance unit 14, and fed to the resin liquid curing unit 15. Since the fourth cleaner unit 62 can remove and collect the attached matter such as dust attached to the outer peripheral surface portion of the guide roller 61, the attached matter of the guide roller 61 comes into contact with the guide roller 61. It is possible to prevent transfer to the other surface portion in the thickness direction.

  Returning to FIG. 1, the resin liquid curing unit 15 is realized by a heating device in the present embodiment, and includes a heating furnace main body 71, a plurality of receiving rollers 72, and a hot air generation unit 73. Each receiving roller 72 is formed in a cylindrical shape, and is provided so as to be rotatable around the axis line so that the axis line direction coincides with the Y direction. The plurality of receiving rollers 72 are provided inside the heating furnace main body 71 so as to be aligned in the X direction so that the axes thereof are parallel to each other. The two sheets 31, 32 are conveyed in the X direction. The hot air generator 73 is connected to the heating furnace body 71 and sends hot air into the heating furnace body 71. Hot air sent from the hot air generator 73 circulates in the heating furnace main body 71. With this hot air, the resin liquid layer 92 formed between the first and second sheets 31 and 32 is heated and cured. Thereby, the sheet body 95 is formed. The formed sheet body 95 is fed to the feed amount adjusting unit 16.

  The heating furnace body 71 is provided with a viewing window portion 74, and an operator can observe the inside of the heating furnace body 41 through the viewing window section 74. In this embodiment, the resin curing unit 15 is realized by a heating unit. The resin curing unit 15 is not limited to the one heated by hot air, and may be any one that can heat the resin liquid layer 92 formed between the first and second sheets 31 and 32, for example, far infrared rays. It may be realized by a heater or the like.

  As described above, the resin liquid curing unit 15 that is a curing unit is realized by the heating device in the present embodiment, but is not limited thereto, and is selected according to the type of the curable resin layer. For example, when the curable resin layer is a photocurable resin layer, a light irradiation means for irradiating light is used as the curing means. When the curable resin layer is a room temperature curable resin layer, the first and second resin liquids are cured in the process of transporting the first and second sheets 31 and 32 sandwiching the resin liquid layer. The conveyance path of the sheets 31 and 32 corresponds to a curing unit.

  The feed amount adjusting unit 16 is realized by a festoon mechanism. The feed amount adjusting unit 16 includes a carry-in roller 75 and a carry-out roller 76 provided on the downstream side in the conveyance direction of the sheet body 95 with respect to the carry-in roller 75. FIG. 7 is a cross-sectional view showing the configuration of the carry-in side roller 75 of the feed amount adjusting unit 16. FIG. 7 corresponds to a cross-sectional view of the carry-in roller 75 viewed from one side in the X direction. In FIG. 7, the sheet precursor 94 is also shown. The carry-in side roller 75 includes a carry-in side drive roller 75a that is rotationally driven by a drive unit (not shown), and a carry-in side presser roller 75b that faces the carry-in side drive roller 75a from the other Z2 side in the Z direction. The driving means is realized by a motor.

  The carry-in side driving roller 75a has a substantially cylindrical shape, and is provided such that the axial direction coincides with the Y direction. The carry-in side driving roller 75 a is drawn at both ends 210 in the axial direction, and both ends 210 are rotatably supported by the bearings 211. The bearing 211 is realized by, for example, a rolling bearing such as a ball bearing or a sliding bearing. The sheet precursor 94 is conveyed to one side in the X direction by the rotation of the roller main body 212 that is a central portion between both end portions in the axial direction of the carry-in side driving roller 75a.

  The carry-in side pressing roller 75b is a portion between the shaft 220 extending in the Y direction and the end portions 223 and 224 in the axial direction of the shaft 220 and closer to the one end portion 223 than the central portion between the both end portions 223 and 224. The first presser roller 221 provided on the shaft 220 and the intermediate portion between the two end portions 223 and 224 in the axial direction of the shaft 220, and the first press roller 221 provided at a portion closer to the other end portion 224 than the central portion between the two end portions 223 and 224. 2 presser rollers 222. Hereinafter, the longitudinal direction of the shaft 220 is referred to as the axial direction of the carry-in side pressing roller 75b. The first and second pressing rollers 221 and 222 are fixed to the shaft 220.

  The carry-in side pressing roller 75b is rotatably supported at both ends 223 and 224 of the shaft 220 by the bearing 225 so that the first and second pressing rollers 221 and 222 can be driven to rotate. The first and second pressing rollers 221 and 222 are provided in pressure contact with the roller body 212 of the carry-in side driving roller 75a. The sheet precursor 94 is sandwiched between the first and second pressing rollers 221 and 222 and the roller main body 212 of the carry-in side drive roller 75a, and is conveyed in the X direction by the rotational drive of the carry-in side drive roller 75a. The first and second presser rollers 221 and 222 are driven to rotate as the sheet precursor 94 moves.

  The first and second pressing rollers 221 and 222 are provided so as to press both end portions in the width direction of the sheet precursor 94 against the carry-in driving roller 75a. At both ends in the width direction of the sheet precursor 94 pressed by the first and second pressing rollers 221, 222, the first release film 31 and the second release film 32 are in pressure contact with each other, and the first release film 31 is pressed. The thermosetting resin layer 91 is not formed between the mold film 31 and the second release film 32. The thermosetting resin layer 91 is formed to have a uniform thickness except for the portions near both ends in the width direction of the sheet precursor 94, and the uniform thickness portion is the sheet shown in FIG. It becomes the body 90. Therefore, the dimension in the width direction of the sheet precursor 31 (hereinafter referred to as “width”) and the interval W between the first pressing roller 221 and the second pressing roller 222 in the axial direction of the carry-in pressing roller 75b are the sheets to be manufactured. Depending on the width of the body 90, the sheet body 90 having a desired width is selected.

  The carry-out side roller 76 shown in FIG. 1 is configured in the same manner as the carry-in side roller 75, and carries out a carry-out side drive roller 76a that is rotationally driven by a driving means (not shown) and a carry-out side presser provided opposite to the carry-out side drive roller 76a. A roller 76b. The carry-out side drive roller 76a is configured in the same manner as the carry-in side drive roller 75a, and the carry-out side press roller 76b is configured in the same manner as the carry-in side press roller 75b. The carry-in side drive roller 75a and the carry-in side presser roller are provided so that their axes are parallel to each other, and the carry-out side drive roller 76a and the carry-out side presser roller 76b are provided so that their axes are parallel. The rolls 75a and 75b of the carry-in side roller 75 and the rolls 76a and 76b of the carry-out side roller 76 are provided so that their axes are parallel to each other.

  As shown in FIG. 1, the sheet precursor 94 is fed between a carry-in side drive roller 75 a and a carry-in side press roller 75 b of the carry-in side roller 75, and then is carried out with a carry-out side drive roller 76 a of the carry-out side roller 76. It is fed between the carry-out side pressing roller 76b. The feed amount of the sheet precursor 94 by the carry-in side roller 75 can be adjusted by the rotation speed of the carry-in side drive roller 75a. Further, the feed amount of the sheet precursor 94 by the carry-out side roller 76 can be adjusted by the rotation speed of the carry-out side drive roller 76a.

  The feed amount adjusting unit 16 further includes a plurality of position detection sensors 77 and a control unit (not shown) that controls driving means for driving the carry-in side roller 75 and the carry-out side roller 76 according to the detection output from the position detection sensor 77. Including. The position detection sensor 77 detects the position in the Z direction of the slack portion 78 of the sheet body 95 formed between the carry-in roller 75 and the carry-out roller 76 in the conveyance direction of the sheet body 95. The position detection sensor 77 is realized by a photoelectric sensor such as a photo interrupter. The control unit controls the driving means of the carry-in side roller 75 and the carry-out side roller 76 so that the position of the slack portion 78 of the sheet body 95 detected by the position detection sensor 77 becomes a predetermined position, and the carry-in side roller The feeding amount of the sheet body 95 by 75 and the carry-out side roller 76 is adjusted.

  According to the feed amount adjusting unit 16, the feed amount of the sheet body 95 can be adjusted by the carry-in side roller 75 and the carry-out side roller 76, and a slack can be formed in the sheet precursor 94. Thereby, the conveyance speed to the sheet winding part 17 of the sheet precursor 94 can be adjusted. In the present embodiment, the feed amount adjusting unit 16 temporarily stops the conveyance speed of the sheet precursor 94 to the sheet winding unit 17 by temporarily stopping the rotation driving of the carry-out side driving roller 76a of the carry-out side roller 76. Then, the conveyance of the sheet precursor 94 to the sheet winding unit 17 is temporarily stopped. In this way, the sheet body 95 obtained by peeling the second release film 32 from the sheet precursor 94 by temporarily stopping the conveyance of the sheet precursor 94 to the sheet take-up unit 17 in the sheet body cutting unit 18. When cutting, it is possible to earn time for cutting to a predetermined length. Therefore, the sheet body 95 can be cut into a target dimension with higher accuracy.

  Further, according to the feed amount adjusting unit 16, the tension applied to the sheet body 95 can be adjusted. Therefore, when the second release film 32 is taken up by the sheet take-up unit 17, Wrinkles can be prevented from occurring. Accordingly, for example, when the second sheet 32 is realized by a release film as in the present embodiment, the second release film 32 can be easily reused.

  The feed amount adjusting unit 16 is not limited to the configuration in which the conveyance of the sheet precursor 94 is temporarily stopped, and for example, the conveyance speed of the sheet precursor 94 in the resin liquid curing unit 15 and the sheet precursor 94 in the sheet winding unit 17. You may be comprised so that a conveyance speed may be synchronized. As a result, the sheet body 95 can be conveyed at a speed suitable for the cutting of the sheet body 95 by the sheet cutting unit 18, so that the sheet body 95 can be cut to a target dimension with higher accuracy.

  The sheet winding unit 17 includes a winding roll 81, a plurality of, in this embodiment, two guide rollers 82, and a static eliminator 83. Of the sheet precursor 94 configured to include the first and second sheets 31 and 32 and the thermosetting resin layer 91, the sheet winding unit 17 includes the second release film 32 via the guide roller 82. Then, it is wound around the winding roll 81. Thereby, the second release film 32 is peeled from the thermosetting resin layer 91. The static eliminator 83 is realized by, for example, an ionizer, removes static electricity generated in the second release film 32, and facilitates winding of the second release film 32 onto the winding roll 81. The sheet winding unit 17 is further provided with a cleaner unit (not shown) for cleaning one surface portion and the other surface portion of the second release film 32 wound from the sheet precursor 94. The cleaner unit is configured in the same manner as the first and second cleaner units 44 and 45 described above.

  The sheet body cutting unit 18 is provided on the downstream side in the transport direction of the sheet body 95 with respect to the cutting table 84 to which the sheet body 95 is fed, the cutting blade 85 that cuts the sheet body 95, and the sheet body 95 is cut. And a cutting length detection sensor 86 for detecting the length of the sheet body. The cutting table 84 is realized by an air table, for example. The cutting blade 85 is held so as to be movable in the Z direction. The sheet body cutting unit 18 is configured to be able to cut the sheet body 95 into a certain length.

  The sheet body 95 from which the second release film 32 has been peeled is fed to the sheet body cutting unit 18 and cut to a certain length by the cutting blade 85. As a result, as shown in FIG. 4 described above, the cleaning blade 90 is obtained as a sheet body 95 laminated on the first release film 31.

  FIG. 8 is a flowchart showing the procedure of the sheet body manufacturing method according to another embodiment of the present invention. The sheet body manufacturing method of the present embodiment is executed by the sheet body manufacturing apparatus 1 shown in FIGS. 1 and 2. In the sheet body manufacturing method according to the present embodiment, when materials necessary for manufacturing and the sheet body manufacturing apparatus 1 are prepared, the procedure is started in step a0 and proceeds to step a1.

  FIG. 9 is a cross-sectional view showing a state in which the resin liquid supply process of step a1 shown in FIG. 8 is completed. In step a1, which is a resin liquid supply process, as shown in FIG. 1, the first release film 31 is stretched over the first heat roll 43a, and the second release film 32 is stretched over the second heat roll 43b. The first and second release films 31 and 32 are conveyed while being laid, and are hardened by the resin liquid supply unit 11 between the first and second release films 31 and 32 which are a pair of sheets facing each other. A thermosetting resin liquid 30 that is a resin liquid is supplied. As a result, as shown in FIG. 9, a resin liquid layer 92 is formed between the first release film 31 and the second release film 32. When the resin liquid layer 92 is formed in this manner, the first and second release films 32 sandwiching the formed resin liquid layer 92 are resinated via the guide roller 61 as shown in FIG. It is fed to the liquid curing unit 15 and proceeds to step a2.

  FIG. 10 is a cross-sectional view showing a state where the curing process in step a2 shown in FIG. 8 has been completed. In step a3 which is a curing process, the resin liquid layer 92 formed between the first and second release films 31 and 32 is cured by the resin liquid curing unit 15. In the present embodiment, the resin liquid layer 92 formed between the first and second release films 31 and 32 is thermosetting, and is cured by being heated in the resin liquid curing unit 15 to be thermosetting. Resin layer 91 is formed. As a result, as shown in FIG. 10, a sheet precursor 94 is obtained in which the thermosetting resin layer 91 and the second release film 32 are laminated in this order on one surface portion in the thickness direction of the first release film 31. When the resin liquid layer 92 is cured in this manner to form the thermosetting resin layer 91 and the sheet precursor 94 is obtained, the sheet precursor 94 is fed by the feed amount adjusting unit 16 as shown in FIG. After the feeding is temporarily stopped, the sheet is fed to the sheet winding unit 17 at a predetermined timing, and the process proceeds to Step a3.

  FIG. 11 is a cross-sectional view showing a state in which the peeling process in step a3 shown in FIG. 8 has been completed. In step a3, which is a peeling process, the second release film 32 formed on one surface in the thickness direction of the thermosetting resin layer 91 in the sheet precursor 94 shown in FIG. It is wound up by the take-up part 17. As a result, the second release film 32 is peeled, and a sheet body 95 including the first release film 31 and the thermosetting resin layer 91 is formed as shown in FIG. When the sheet body 95 is formed in this way, the sheet body 95 is fed to the sheet body cutting unit 18 shown in FIG. 1, and the process proceeds to step a4.

  In step a4 which is a cutting process, the sheet body 95 is cut by the cutting blade 85 of the sheet body cutting portion 18 as shown in FIG. The sheet body cutting unit 18 cuts the sheet body 95 so as to have a certain length. By cutting the sheet body 95 in this manner, as shown in FIG. 4 described above, the sheet body 90 is obtained in a state where the first release film 31 is provided on one surface portion in the thickness direction. When the sheet body 90 is manufactured in this way, the process proceeds to step a5 and the manufacturing operation is completed.

  As described above, in the present embodiment, as shown in FIG. 9, the sheet is sandwiched between the pair of sheets 31 and 32 that are stretched and conveyed by the first and second heat rolls 43a and 43b shown in FIG. In this state, the resin liquid layer 92 is cured to form a thermosetting resin layer 92 shown in FIG. Therefore, the sheet body 90 that is the thermosetting resin layer 91 can be manufactured with high thickness accuracy.

  In the present embodiment, the thickness of the thermosetting resin layer 91 depends on the size of the gap between the pair of sheets 31 and 32, and the size of the gap between the pair of sheets 31 and 32 is shown in FIG. It depends on the size of the gap between the first heat roll 43a and the second heat roll 43b. Therefore, the thickness of the thermosetting resin layer 91 is adjusted by adjusting the size of the gap between the pair of sheets 31 and 32 by adjusting the size of the gap between the first heat roll 43a and the second heat roll 43b. Can be adjusted easily.

  In the present embodiment, since the thermosetting resin layer 91 is formed by sandwiching and curing the thermosetting resin liquid 30 between the pair of sheets 31 and 32, a mold is unnecessary. Therefore, the manufacturing cost can be reduced as compared with the case where a mold is used. The thickness of the sheet 90 can be easily adjusted by changing the distance between the first heat roll 43a and the second heat roll 43b and the injection amount of the thermosetting resin liquid 30. Compared to the case of using the sheet member 90, it is possible to easily manufacture the sheet body 90 having a target thickness.

  When the resin liquid layer 92 to be the thermosetting resin layer 91 is formed, the thermosetting resin liquid 30 is supplied between the first sheet 31 and the second sheet 32, and the first and second sheets 31, It spreads in a direction parallel to the thickness direction of 32. If the thermosetting resin liquid 30 spreads excessively, the thermosetting resin liquid 30 may flow out from the ends in the X direction that is the unwinding direction of the first and second sheets 31 and 32 and the Y direction that is the width direction. There is. In the present embodiment, in order to prevent the thermosetting resin liquid 30 from flowing out, a stock guide (not shown) is provided in the resin liquid supply section 11, and the width when the thermosetting resin liquid 30 is injected with this stock guide, that is, The width | variety of the part into which the thermosetting resin liquid 30 of the 1st and 2nd sheets 31 and 32 is inject | poured is controlled to a fixed value.

  Thus, in this embodiment, since the width | variety when inject | pouring the thermosetting resin liquid 30 is controlled by the fixed value, the thickness direction of the 1st and 2nd sheet | seats 31 and 32 of the thermosetting resin liquid 30 is carried out. The amount of spread in the direction parallel to is determined by the viscosity and blending of the thermosetting resin liquid 30. Therefore, in the present embodiment, the size of the gap between the first heat roll 43a and the second heat roll 43b that defines the distance between the first sheet 31 and the second sheet 32 (hereinafter also referred to as “roll gap”) is set in advance. A value for obtaining the target sheet 90 is obtained by experiment and is selected as this value. When the resin liquid layer 92 that becomes the thermosetting resin layer 91 contracts with the curing reaction in the resin liquid curing unit 17, the roll gap between the first heat roll 43a and the second heat roll 43b is In consideration of the shrinkage rate of the resin liquid layer 92, the sheet body 90 having a target thickness is selected.

  As shown in FIG. 11 described above, in the present embodiment, the sheet body 90 is manufactured in a state where the first release film 31 is provided on one surface portion in the thickness direction. The first release film 31 provided on one surface portion in the thickness direction of the sheet body 90 is peeled off when the sheet body 90 is used, for example. For example, when the sheet body 90 is a cleaning blade, the cleaning blade 90 which is a sheet body is cut into a predetermined width and length after being peeled off from the first release film 31 and assembled to a holder.

  The cleaning blade manufactured by the sheet body manufacturing apparatus 1 of the present embodiment is not limited to the cleaning blade 90 shown in FIG. For example, a sheet obtained by cutting the sheet body 95 shown in FIG. 11 may be used as it is as a cleaning blade. In this case, the first sheet 31 constituting the sheet body 95 includes one or more layers formed of a thermoplastic resin such as PET or PEN, and a release layer is provided as a surface layer thereof. I can't.

  As described above, the cleaning blade may have a configuration in which the first sheet 31 is provided on one surface portion in the thickness direction of the thermosetting resin layer 91. In the case of such a configuration, for example, by adjusting the hardness and thickness of the first sheet 31, the rigidity of the cleaning blade can be increased, so that the permanent distortion of the cleaning blade can be reduced and sag can be prevented. it can.

  FIG. 12 is a side view showing the configuration of the sheet body manufacturing apparatus 2 according to the second embodiment of the present invention, and FIG. 13 is an enlarged side view showing the configuration of the resin lamination layer forming unit 111 shown in FIG. It is. 12 and 13, the heating furnace main body 71 of the resin liquid curing unit 15 and the resin laminating curing unit 113 has a cross-sectional configuration in a virtual plane parallel to the conveyance direction of the sheet precursor 94. In FIGS. 12 and 13, a part of the thickness is omitted for easy understanding. The sheet body manufacturing apparatus 2 of the present embodiment is similar to the sheet body manufacturing apparatus 1 of the first embodiment, and corresponding portions are denoted by the same reference numerals and description thereof is omitted.

  FIG. 14 is a cross-sectional view illustrating a configuration of a cleaning blade 100 which is an example of a sheet body manufactured by the sheet body manufacturing apparatus 2 of the present embodiment. In the present embodiment, like the cleaning blade 100 shown in FIG. 14, two curable resin layers formed of a curable resin, more specifically, two thermosetting resin layers 101 formed of a thermosetting resin. , 102 are manufactured in the thickness direction. The sheet body 100 is a composite sheet body including two layers, and the layers 101 and 102 constituting the composite sheet body are laminated in the thickness direction.

  Of the two thermosetting resin layers 101 and 102, one thermosetting resin layer 101 is formed in the same manner as the thermosetting resin layer 91 formed in the first embodiment described above. A curable laminated resin layer 102 that is the other thermosetting resin layer 102 is provided on one surface portion in the thickness direction of the curable resin layer 101. In the present embodiment, the thermosetting resin layer 101 is higher in hardness than the curable laminated resin layer 102. Further, the thickness of the thermosetting resin layer 101 is smaller than the thickness of the curable laminated resin layer 102. The two thermosetting resin layers 101 and 102 are formed of the same material as the thermosetting resin layer 91 in the first embodiment and have rubber elasticity. Therefore, the sheet body 100 is an elastic sheet body having rubber elasticity.

  As illustrated in FIG. 12, the sheet body manufacturing apparatus 2 includes a resin between the sheet winding unit 17 and the sheet body cutting unit 18 in the conveying direction of the sheet body 95 in the sheet body manufacturing apparatus 1 according to the first embodiment. It further includes a laminating layer forming unit 111, a resin laminating sheet conveying unit 112, a resin laminating curing unit 113, a resin laminating feed amount adjusting unit 114, and a counter sheet winding unit 115. The resin lamination curing portion 113 corresponds to a resin lamination curing means.

  As shown in FIG. 13, the resin lamination layer forming unit 111 includes a resin lamination liquid supply unit 116, a counter sheet supply unit 117, and a resin lamination layer formation unit 118. The resin lamination liquid supply unit 116 corresponds to a resin liquid supply means for resin lamination. The resin lamination liquid supply unit 116 is configured in the same manner as the resin liquid supply unit 11. A raw material tank (not shown) of the resin laminating liquid supply unit 116 stores the raw material of the curable laminated resin layer 102 shown in FIG. 14, and the raw material is supplied to the mixing chamber 22 and mixed by stirring. Liquid 120 is prepared. The thermosetting resin liquid 30 and the resin liquid 120 for resin lamination are selected such that the hardness of the thermosetting resin layer 101 is higher than the hardness of the curable laminated resin layer 102.

  The counter sheet supply unit 117 supplies the counter sheet 110 to the resin lamination layer forming unit 118. In FIG. 13, the opposing sheet 110 is represented by a dotted line. The counter sheet supply unit 117 is configured in the same manner as the first and second sheet supply units 33 and 34. According to the facing sheet supply unit 117, the facing sheet 110 wound around the facing sheet unwinding shaft 119 is unwound by being given a constant tension by the unwinding constant tension device, and is downstream of the transport direction by the EPC device. The ends are aligned and supplied to the resin lamination layer forming unit 118. The facing sheet 110 is configured in the same manner as the first and second sheets 31 and 32.

  The resin lamination layer forming unit 118 includes a sheet body stretching unit 121 on which the sheet body 95 that is fed after the second sheet 32 is peeled off by the sheet winding unit 17 and a counter sheet 110 is stretched. Counter sheet stretching portion 122. The sheet body stretching unit 121 includes a heat roll 43, first to third cleaner units 44, 45, 46, and a static eliminator 47, similar to the first and second sheet stretching units 41, 42, Two guide rollers 123 and 125 and another static eliminator 124 are included. Of the two guide rollers 123 and 125, the first guide roller 123 is provided downstream of the guide roller 82 of the sheet winding unit 17 in the conveyance direction of the sheet body 95. The second guide roller 125, which is another guide roller, is located downstream of the first guide roller 123 in the transport direction of the sheet body 95 and upstream of the third cleaner unit 46 in the transport direction of the sheet body 95. It is provided on the other Z2 side in the Z direction with respect to the guide roller 54 of the third cleaner unit 46.

  The sheet body 95 is guided by the first guide roller 123, neutralized by the other neutralizer 124, then fed to the second guide roller 125, and further fed to the third cleaner unit 46. The sheet body 95 is wound around the guide roller 54 so that the other surface portion in the thickness direction is in contact with the guide roller 54 of the third cleaner unit 46, and the one surface portion in the thickness direction is in contact with the guide roller 54 and cleaned with the guide roller 54. It is wound around the guide roller 54 so as to pass between the rollers 52. A constant tension (hereinafter also referred to as “tension”) is applied to the sheet body 95 by a constant tension device (not shown) provided in the counter sheet stretcher 122. The constant tension device applies a constant tension to the sheet body 95 by a torque motor (not shown).

  The opposing sheet stretching unit 122 is configured in the same manner as the first and second sheet stretching units 41 and 42. The heat roll 43 of the sheet body stretch portion 121 and the heat roll 43 of the counter sheet stretch portion 122 are provided to face each other. At the position where the heat rolls 43 face each other, the sheet body 95, more specifically, the thermosetting resin layer 91 of the sheet body 95 and the facing sheet 110 face each other. The resin laminating resin liquid 120 is supplied from the resin laminating liquid supply unit 116 between the thermosetting resin layer 91 of the facing sheet body 95 and the opposing sheet 110.

  In the present embodiment, the sheet body 95 shown in FIG. 12 corresponds to a sheet precursor, and the sheet winding unit 17 corresponds to a peeling unit. Moreover, the heat roll 43 of the sheet | seat body stretching part 121 shown in FIG. 13 is equivalent to a resin side roll, and the heat roll 43 of the opposing sheet stretching part 122 is equivalent to an opposing side roll.

  12 is configured in the same manner as the sheet conveying unit 14, the resin laminating curing unit 113 is configured in the same manner as the resin liquid curing unit 15, and the resin laminating feed amount adjusting unit 114 is fed. The counter sheet winding unit 115 is configured in the same manner as the amount adjusting unit 16, and the counter sheet winding unit 115 is configured in the same manner as the sheet winding unit 17.

  FIG. 15 is a flowchart showing a procedure of a sheet body manufacturing method according to another embodiment of the present invention. The sheet body manufacturing method of the present embodiment is executed by the sheet body manufacturing apparatus 2 shown in FIGS. 12 and 13. In the sheet body manufacturing method of the present embodiment, when materials necessary for manufacturing and the sheet body manufacturing apparatus 2 are prepared, the procedure is started in step b0 and proceeds to step b1.

  FIG. 16 is a cross-sectional view showing a state in which the peeling process in step b3 shown in FIG. 15 has been completed. The resin liquid supply process in step b1 is executed in the same manner as the resin liquid supply process in step a1 in the first embodiment, and the curing process in step b2 is executed in the same manner as the curing process in step a2 in the first embodiment. And the peeling process of step b3 is performed similarly to the peeling process of step a3 in the first embodiment. Thereby, as shown in FIG. 16, a sheet body 95 including the first sheet 31 and the thermosetting resin layer 101 is formed. When the sheet body 95 is thus formed, the sheet body 95 is fed to the resin lamination layer forming unit 111 shown in FIG. 13, and the process proceeds to step b4.

  FIG. 17 is a cross-sectional view showing a state in which the resin liquid layer forming step in step b4 shown in FIG. 15 is completed. In step b4 which is a resin liquid layer forming step, as shown in FIG. 13, the sheet body 95 is stretched over the heat roll 43 of the sheet body stretching portion 121 so that the thermosetting resin layer 101 faces the facing sheet 110. The counter sheet 110 is stretched on the heat roll 43 of the counter sheet stretching section 122 to convey the sheet body 95 and the counter sheet 110, and between the thermosetting resin layer 101 and the counter sheet 110, the resin The laminating liquid supply unit 116 supplies the resin laminating resin liquid 120. As a result, as shown in FIG. 17, a resin liquid layer 126 for resin lamination is formed between the thermosetting resin layer 101 and the counter sheet 110.

  The distance between the heat roll 43 of the sheet body stretch part 121 shown in FIG. 13 and the heat roll 43 of the counter sheet stretch part 122 is the distance between the thermosetting resin layer 101 and the counter sheet 110 shown in FIG. 12 is smaller than the distance between the first and second sheets 31 and 32 shown in FIG. 12, and the thickness of the resin liquid layer 126 for resin lamination shown in FIG. 17 is larger than the thickness of the resin liquid layer 92 shown in FIG. Selected to be smaller. When the resin liquid layer 126 for resin lamination is formed in this way, the sheet body 95 and the opposing sheet 110 sandwiching the resin liquid layer 126 for resin lamination are used for resin lamination via the guide roller 61 shown in FIG. It is fed to the curing unit 113 and proceeds to step b5.

  FIG. 18 is a cross-sectional view showing a state in which the curing process in step b5 shown in FIG. 15 has been completed. In step b5, which is a curing process, the resin lamination resin liquid layer 126 formed between the thermosetting resin layer 101 and the opposing sheet 110 of the sheet body 95 shown in FIG. 17 is replaced with the resin lamination shown in FIG. The curable laminated resin layer 102 shown in FIG. As a result, as shown in FIG. 18, the first sheet precursor in which the thermosetting resin layer 101, the curable laminated resin layer 102, and the counter sheet 110 are laminated in this order on one surface portion in the thickness direction of the first sheet 32. Body (hereinafter referred to as “first sheet precursor”) 127 is obtained. When the first sheet precursor 127 is obtained in this manner, the first sheet precursor 127 is temporarily stopped by the resin lamination feed amount adjusting unit 114 shown in FIG. The sheet is fed to the laminating sheet take-up unit 115, and the process proceeds to step b6.

  FIG. 19 is a cross-sectional view showing a state in which the peeling process in step b6 shown in FIG. 15 has been completed. In step b6, which is a peeling process, the counter sheet 110 formed on one surface in the thickness direction of the curable laminated resin layer 102 in the first sheet precursor 127 shown in FIG. 18 is used for the resin lamination shown in FIG. Winding is performed by the winding unit 115. As a result, the opposing sheet 110 is peeled off, and as shown in FIG. 19, a second sheet precursor (hereinafter referred to as “hereinafter referred to as“ the second sheet precursor ”) including the first sheet 31, the thermosetting resin layer 101, and the curable laminated resin layer 102. 128) (referred to as "second sheet precursor"). When the second sheet precursor 128 is formed in this way, the second sheet precursor 128 is fed to the sheet cutting unit 18 as shown in FIG. 12, and the process proceeds to step b7.

  In step b <b> 7 which is a cutting process, the second sheet precursor 128 is cut by the cutting blade 85 of the sheet body cutting unit 18. By cutting the second sheet precursor 128 in this manner, the sheet body 100 shown in FIG. 14 is a first release sheet that is a first sheet on one surface in the thickness direction as shown in FIG. It is obtained with the film 31 provided. When the sheet body 100 is manufactured in this way, the process proceeds to step b8 and the manufacturing operation is finished.

  As described above, in the present embodiment, after the thermosetting resin layer 101 is formed in the curing process of step b2, the second release film 32 on the other surface portion in the thickness direction of the thermosetting resin layer 101 is formed in step b3. It peels at a peeling process and the thermosetting resin layer 101 is exposed. A resin liquid for resin lamination is supplied between the exposed thermosetting resin layer 101 and the opposing sheet 110 in the resin liquid supply process in step b4 to form a laminated resin liquid layer 126, and cured in the curing process in step b5. Let

  As shown in FIG. 13, the laminated resin liquid layer 126 includes the thermosetting resin layer 101 of the sheet body 95 that is stretched and conveyed by the heat roll 43 of the sheet body stretch portion 121, and the opposing sheet stretch portion 122. 18 is cured in a state of being sandwiched by the opposing sheet 110 that is stretched and conveyed by the heat roll 43 to form the curable laminated resin layer 102 shown in FIG. The curable laminated resin layer 102 can be formed on the surface portion with high thickness accuracy. Therefore, as shown in FIG. 19, a cleaning blade 100, which is a sheet body in which a curable laminated resin layer 102, which is another thermosetting resin layer, is formed on the other surface portion in the thickness direction of the thermosetting resin layer 101, It can be obtained in a state of being laminated on the first release film 31. As a result, as shown in FIG. 14, the cleaning blade 100 is a sheet body in which a curable laminated resin layer 102, which is another thermosetting resin layer, is formed on one surface portion in the thickness direction of the thermosetting resin layer 101. Can be manufactured.

  In the cleaning blade 100, the thermosetting resin layer 101 is formed with a higher hardness than the curable laminated resin layer 102. As described above, the cleaning blade 100 has the thermosetting resin layer 101 having a higher hardness than the curable laminated resin layer 102 on one surface in the thickness direction of the curable laminated resin layer 102. Therefore, compared with the case where the sheet body is formed only by the curable laminated resin layer 102, the wear of the cleaning edge is reduced and the life is prolonged, so that the durability of the cleaning blade 100 which is the sheet body is improved. be able to. Further, since the thickness of the thermosetting resin layer 101 is thinner than the thickness of the curable laminated resin layer 102, the thermosetting resin layer 101 is backed up, that is, reinforced by the curable laminated resin layer 102. Therefore, the permanent distortion of the cleaning blade 100 can be reduced and settling can be prevented.

  The cleaning blade 100 obtained by the present embodiment is used as a cleaning edge in which one end portion of the thermosetting resin layer 101 is in contact with the image carrier. As a result, compared with the case where the cleaning blade 100 uses one end portion of the curable laminated resin layer 102 as a cleaning edge, the contact pressure to the surface portion of the image carrier is increased, and the toner and various nano-types added to the toner are added. The size of the external additive can be easily removed.

  In the present embodiment, by using the sheet body manufacturing apparatus 2 shown in FIG. 12 described above, the cleaning blade 100 configured by laminating the plurality of thermosetting resin layers 101 and 102 having different hardnesses as described above is provided. Further, it can be easily manufactured with good thickness accuracy.

  As described above, in this embodiment, the thickness of the thermosetting resin layer 101 is selected to be thinner than the thickness of the curable laminated resin layer 102 in FIG. The relationship between the thickness of the thermosetting resin layer and the thickness of the curable laminated resin layer is not limited to this.

  FIG. 20 is a cross-sectional view illustrating a configuration of a cleaning blade 103 which is another example of a sheet body manufactured by the sheet body manufacturing apparatus 2 of the present embodiment. A cleaning blade 103 shown in FIG. 20 has a curable laminated resin layer 104 having a thickness equal to that of the thermosetting resin layer 101 on one surface portion of the thermosetting resin layer 101. Thus, the thermosetting resin layer 101 may be formed to have the same thickness as the curable laminated resin layer, or may be formed to have a thickness larger than that of the curable laminated resin layer.

  From the viewpoint of the durability of the cleaning blade, the thickness of the thermosetting resin layer 101 is preferably selected to be smaller than that of the curable laminated resin layer 102 as in the present embodiment shown in FIG. As a result, the permanent distortion of the cleaning blade can be reduced and settling can be prevented. The thickness of the curable laminated resin layer can be adjusted by the distance between the heat roll 43 of the sheet body stretch portion 121 and the heat roll 43 of the opposing sheet stretch portion 122.

  More specifically, the thickness of the thermosetting resin layer 101 is selected to be smaller than the thickness of the curable laminated resin layer 102 and more than the minimum thickness necessary for cleaning. In this embodiment, the minimum thickness required for the cleaning is 30 μm, and the thickness of the thermosetting resin layer 101 is selected from 30 μm to 300 μm. The thickness of the thermosetting resin layer 101 is not limited to the above range and is selected according to the material of the layers 101 and 102 of the cleaning blade 100, but is 30 μm or more and 300 μm or less as in this embodiment. It is preferable.

  FIG. 21 is a partial cross-sectional view schematically showing a state in which the cleaning blade 100 is in contact with the image carrier 160. When the sheet member 100 is used as a cleaning blade as in the present embodiment, the cleaning blade 100 is used in a state where one side surface portion 162 a that intersects one surface portion in the thickness direction contacts the image carrier 160. When contacted in this way, the contact range between the cleaning edge 100a and the image carrier 160 in the thickness direction of the cleaning blade 100 (hereinafter referred to as “thickness direction contact range”), that is, the image carrier represented by the arrow E. The length S of the contact portion 161 of the cleaning edge 100a with the image carrier 160 in the rotation direction 160 is from the one surface portion 161b in the thickness direction of the thermosetting resin layer 101, which is one surface portion in the thickness direction of the cleaning blade 100. A range of 10 μm or more and 50 μm or less in the thickness direction is an appropriate contact condition, and at least this range needs to be the thermosetting resin layer 101.

  In such a cleaning blade 100, when the thickness of the thermosetting resin layer 101 is less than 30 μm, the contact portion 161 of the cleaning edge 100a with the image carrier 160 is a layer other than the thermosetting resin layer 101, this embodiment. Then, there exists a possibility of comprising the curable laminated resin layer 102. When the contact portion 161 of the cleaning edge 100a includes a layer other than the thermosetting resin layer 101, the effect of making the cleaning blade 100 a composite of the thermosetting resin layer 101 and the curable laminated resin layer 102 is obtained. May not be sufficiently exhibited, and the contact pressure of the cleaning blade 100 to the image carrier 160 may not be sufficiently increased.

  In the present embodiment, the total thickness of the cleaning blade 100, that is, the sum of the thickness of the thermosetting resin layer 101 and the thickness of the curable laminated resin layer 102 is selected to be 1.5 mm or more and 2.0 mm or less. Thus, when the total thickness of the cleaning blade 100 is 1.5 mm or more and 2.0 mm or less, and the thickness of the thermosetting resin layer 101 exceeds 300 μm, the curable laminated resin compared to the total thickness of the cleaning blade 100. The thickness of the layer 102 is reduced, the permanent distortion reducing effect as a composite is poor, and it is not preferable because it causes warping due to a difference in molding shrinkage between the thermosetting resin layer 101 and the curable laminated resin layer 102.

  The effect of making the cleaning blade 100 a composite of the thermosetting resin layer 101 and the curable laminated resin layer 102 by setting the thickness of the thermosetting resin layer 101 to 30 μm or more and 300 μm or less as in the present embodiment. Therefore, the contact pressure to the image carrier 160 can be increased more reliably, and the sheet member 100 suitable as a cleaning blade is realized. In addition, the permanent distortion of the cleaning blade 100 can be more reliably reduced. Accordingly, the sheet body 100 that has a small permanent distortion and a high contact pressure with the image carrier 160 and is suitable as a cleaning blade is realized. Further, it is possible to prevent the difference between the molding shrinkage rate of the thermosetting resin layer 101 and the molding shrinkage rate of the curable laminated resin layer 102 from being excessive, and to prevent the cleaning blade 100 from warping due to the molding shrinkage rate difference. .

  When the sheet body 100 is used as a developing blade, the contact object with which the sheet body 100 abuts is a developer carrying body that carries a developer, for example, a developing sleeve, and the sheet body 100 has a thickness direction shown in FIG. Is used in a so-called belly contact state in which the one surface portion 162b contacts the developing sleeve. In this case, the thermosetting resin layer 101 is worn by rubbing with the developing sleeve. If the thickness of the thermosetting resin layer 101 is less than 30 μm, the thermosetting resin layer 101 disappears early due to abrasion by rubbing with the developing sleeve, and the durability improvement effect as a composite may not be sufficiently exhibited. There is. Therefore, even when the sheet body 100 is used as a developing blade, the thickness of the thermosetting resin layer 101 is preferably 30 μm or more.

  Even when the sheet body 100 is used as a developing blade, the total thickness of the sheet body 100 is selected to be 1.5 mm or more and 2.0 mm or less. In this case, if the thickness of the thermosetting resin layer 101 exceeds 300 μm, the effect of reducing permanent distortion as a composite is poor as in the case where the sheet body 100 is used as a cleaning blade, and the thermosetting resin layer 101 And warping due to a difference in molding shrinkage between the curable laminated resin layer 102 and the curable laminated resin layer 102 is not preferable. Therefore, the thickness of the curable resin layer 101 is preferably 30 μm or more and 300 μm or less.

  In the case where the sheet body 100 is used as a developing blade, the thickness of the thermosetting resin layer 101 is set to 30 μm or more and 300 μm or less, whereby the sheet body 100 is combined with the thermosetting resin layer 101 and the curable laminated resin layer 102. Since the effect of forming the body is sufficiently exhibited, the durability of the sheet body 100 can be more reliably improved, and the early disappearance of the thermosetting resin layer 101 due to wear can be prevented. Moreover, the permanent distortion of the sheet body 100 can be reduced more reliably. Accordingly, the sheet body 100 is realized which has a small permanent set, is hardly lost even when worn by rubbing against the developing sleeve, has excellent durability, and is suitable as a developing blade. Further, it is possible to prevent the difference between the molding shrinkage rate of the thermosetting resin layer 101 and the molding shrinkage rate of the curable laminated resin layer 102 from being excessive, and to prevent warping of the sheet body 100 due to the molding shrinkage rate difference. .

  Thus, by setting the thickness of the thermosetting resin layer 101 having relatively high hardness in the sheet body 100 to 30 μm or more and 300 μm or less, the sheet body 100 suitable as a cleaning blade and a developing blade is realized.

  Further, the cleaning blade manufactured by the sheet body manufacturing apparatus 2 of the present embodiment is not limited to the cleaning blade 100 shown in FIG. 14 and the cleaning blade 103 shown in FIG. For example, the sheet precursor obtained by peeling the first sheet 31 from one surface portion in the thickness direction of the thermosetting resin layer 101 of the first sheet precursor 127 shown in FIG. 18 described above, that is, the thermosetting resin layer 101, curing What cut | disconnected the sheet | seat precursor containing the functional laminated resin layer 102 and the opposing sheet | seat 110 may be used as a cleaning blade as it is. Also in this case, one end portion of the thermosetting resin layer 101 is used as a cleaning edge. Further, in this case, the facing sheet 110 is configured to include one layer or two or more layers formed of a thermoplastic resin such as PET or PEN, and no release layer is provided as the surface layer.

  As described above, the cleaning blade is provided with the thermosetting resin layer 101 having a thickness higher and thinner than that of the curable laminated resin layer 102 on one surface portion in the thickness direction of the curable laminated resin layer 102, and the curable laminated resin. The configuration may be such that the opposing sheet 110 is provided on the other surface portion in the thickness direction of the layer 102. In the case of such a configuration, for example, by adjusting the hardness and thickness of the facing sheet 110, the rigidity of the cleaning blade can be increased. Therefore, the permanent distortion of the cleaning blade is further reduced, and the sag is more reliably secured. Can be prevented.

  In the present embodiment, since the thermosetting resin layer 101 and the curable laminated resin layer 102 are made of thermosetting polyurethane rubber, the hardness of the thermosetting resin layer 101 and the curable laminated resin layer 102 is the same as each layer 101. , 102 depending on the hardness of the thermosetting polyurethane rubber. The relationship between the hardness and the permanent strain of the thermosetting polyurethane rubber is a relationship that the amount of permanent strain is small when soft and the amount of permanent strain increases when it is hard with respect to a certain amount of initial strain. That is, the higher the hardness of the layer made of thermosetting polyurethane, the greater the amount of permanent strain with respect to a certain amount of initial strain.

  Therefore, the higher the hardness of the thermosetting resin layer 101 and the curable laminated resin layer 102, the greater the permanent distortion and the more likely the settling. On the other hand, if the hardness is too high, it becomes difficult to follow the image carrier, and it is impossible to sufficiently remove the toner and the adhering substances such as an external additive externally added to the toner.

  In this way, considering the permanent distortion, the thermosetting resin layer 101 and the curable laminated resin layer 102 should not have high hardness, but considering the contact pressure of the sheet body 100 to the image carrier, the image carrier It is preferable that the thermosetting resin layer 101 which is a layer in contact with the body has a high hardness. If the hardness of the thermosetting resin layer 101 is too low, the contact pressure on the image carrier is insufficient, and the toner and the external additives added to the toner are removed sufficiently. Can not do it.

  In particular, when a spherical toner having a volume average particle diameter of, for example, 10 μm or less, which is made by a polymerization method, is used, the cleaning blade 100 is more suitable than an irregular toner made by a pulverization method. The cleaning performance cannot be maintained unless the contact pressure is increased more than twice. Accordingly, deposits on the image bearing member, particularly nano-sized inorganic fine particles such as silica added as an external additive, are not removed by the cleaning blade 100 and can easily pass through the cleaning process.

  The deposit on the surface of the image carrier that has passed through the cleaning process is transported to the charging device portion provided downstream of the cleaning blade 100 in the rotation direction of the image carrier as the image carrier rotates. Causes a defect. For example, when the charging device is a contact type charging roller, the slipped external additive adheres to the charging roller and causes uneven charging, leading to image defects.

  In consideration of the above, in the present embodiment, the layer that contacts the image carrier of the cleaning blade 100 is constituted by the thermosetting resin layer 101 having relatively high hardness, and the thermosetting resin layer 101 The thickness is made thinner than the thickness of the curable laminated resin layer 102 having a relatively low hardness. With such a configuration, the contact pressure with respect to the image carrier is secured by the thermosetting resin layer 101, and the permanent distortion of the cleaning blade 100 is reduced by the curable laminated resin layer 102, thereby preventing sag. .

  Specifically, the hardness of the curable laminated resin layer 102 is selected from 65 to 75 in terms of the spring hardness Hs in consideration of permanent distortion of the cleaning blade 100 and ease of conforming to the image carrier. The hardness of the thermosetting resin layer 101 that is in direct contact with the image carrier is selected from 75 to 90 in terms of spring hardness Hs in consideration of the contact pressure to the image carrier.

  The spring hardness Hs of the thermosetting resin layer 101 is not limited to the above range, but is preferably 75 or more and 90 or less as in the present embodiment. Further, the spring hardness Hs of the curable laminated resin layer 102 is not limited to the above range, but is preferably 65 or more and 75 or less as in the present embodiment. The spring hardness Hs of the thermosetting resin layer 101 and the curable laminated resin layer 102 is such that the spring hardness Hs of the thermosetting resin layer 101 is higher than the spring hardness Hs of the curable laminated resin layer 102. Are selected from the above ranges.

  In this embodiment, “the hardness of the thermosetting resin layer” means the hardness of the surface portion of the thermosetting resin layer 101 opposite to the surface portion in contact with the curable laminated resin layer 102, that is, in the above-described FIG. 21. It refers to the hardness of one surface portion 162b in the thickness direction of the thermosetting resin layer 101 shown. The “hardness of the curable laminated resin layer” refers to the hardness of the surface portion of the curable laminated resin layer 102 that is in contact with the thermosetting resin layer 101. Although different from the present embodiment, when a layer is further interposed between the thermosetting resin layer 101 and the curable laminated resin layer 102, the “hardness of the thermosetting resin layer” means the thermosetting resin layer. The hardness of the surface portion opposite to the surface portion facing the curable laminated resin layer is referred to as “the hardness of the curable laminated resin layer” means the surface portion facing the thermosetting resin layer of the curable laminated resin layer. It means the hardness.

  As shown in FIG. 21, the thermosetting resin layer 101 is in contact with the image carrier 160. Therefore, the thermosetting resin having the spring hardness Hs of the one surface portion 162b in the thickness direction of the thermosetting resin layer 101 is used. When the spring hardness Hs of the layer 101 is less than 75, various physical properties such as tear strength of the polyurethane rubber constituting the thermosetting resin layer 101 are lowered, and the cleaning edge 100a is easily chipped. When the spring hardness Hs of the thermosetting resin layer 101 exceeds 90, the entire cleaning blade 100 that is a sheet body becomes rigid and becomes difficult to follow the image carrier 160. Therefore, the spring hardness Hs of the thermosetting resin layer 101 is preferably 75 or more and 90 or less.

  Further, when the spring hardness Hs of the curable laminated resin layer 102 is less than 65, various physical properties such as tear strength of the polyurethane rubber constituting the curable laminated resin layer 102 are lowered, and the end portion is easily chipped and permanently set. The reduction effect is also almost saturated, and the stacking effect is not exhibited. When the spring hardness Hs of the curable laminated resin layer 102 exceeds 75, the effect of reducing the sag due to the provision of the curable laminated resin layer 102 is not sufficiently exhibited, the entire cleaning blade 100 becomes rigid, and the image carrier 160. It becomes difficult to follow.

  Here, the “spring hardness Hs” is a reading of the hardness immediately after the pressing surface of the tester is in close contact with the measurement surface of the test piece in the type A spring test defined in Japanese Industrial Standard (JIS) K7312. Say. The spring hardness Hs of the thermosetting resin layer 101 is measured by using, for example, a sheet body obtained by peeling the first sheet 31 from the thermosetting resin layer 101 of the second sheet precursor 128 shown in FIG. . The spring hardness Hs of the curable laminated resin layer 102 is, for example, the side opposite to the surface portion in contact with the thermosetting resin layer 101 of the curable laminated resin layer 102 measured using the second sheet precursor 128 shown in FIG. It is calculated | required as equal to the spring hardness Hs of the surface part.

  The hardness of the thermosetting polyurethane rubber constituting the thermosetting resin layer 101 and the curable laminated resin layer 102 greatly depends on the amount of urethane structural units that are hard segments and the amount of trifunctional components in the curing agent. . Therefore, the hardness of the thermosetting resin layer 101 and the curable laminated resin layer 102 is adjusted to the above range by adjusting the amount of urethane structural units that are hard segments and the amount of trifunctional components in the curing agent. can do.

  Further, in the present embodiment, as shown in FIG. 12 described above, the counter sheet 110 is wound up by the counter sheet winding unit 115, and the counter sheet 110 is peeled off from the first sheet precursor 127 shown in FIG. The sheet peeled from the first sheet precursor 127 is not limited to the counter sheet. For example, the first sheet 31 may be peeled off, but the first sheet 31 is a thermosetting resin layer constituting a cleaning edge. Since it is in contact with 101, it is preferable that the first sheet 31 is covered as much as possible until the next processing step. Therefore, it is preferable to peel the opposing sheet 110 as in this embodiment.

  Further, in the present embodiment, as shown in FIG. 12, resin lamination is performed between the sheet winding unit 17 and the sheet body cutting unit 18 in the conveying direction of the sheet body 95 in the sheet body manufacturing apparatus 1 of the first embodiment. A plurality of thermosetting resin layers are formed by the sheet body manufacturing apparatus 2 including the use layer forming unit 111 and the like. The sheet body manufacturing apparatus used in the sheet body manufacturing method according to the present embodiment is not limited to this. For example, the conveyance direction of the sheet body 95 is more than the sheet body cutting unit 18 of the sheet body manufacturing apparatus 1 according to the first embodiment. A winding unit for winding the sheet body 95 from which the second release film 32 has been peeled is provided on the upstream side, and the wound sheet body 95 is sent to the first sheet supply unit 33 or the second sheet supply unit 34. It may be configured to supply.

  22 is a side view showing the configuration of the sheet body manufacturing apparatus 3 according to the third embodiment of the present invention. FIG. 23 is an enlarged side view showing the configuration of the resin lamination layer forming unit 140 shown in FIG. It is. 22 and FIG. 23, the heating furnace main body 71 of the resin liquid curing unit 15 shows a cross-sectional configuration in a virtual plane parallel to the conveying direction of the sheet precursor 94. 22 and 23, a part of the thickness is omitted for easy understanding. The sheet body manufacturing apparatus 3 of the present embodiment is similar to the sheet body manufacturing apparatus 1 of the first embodiment and the sheet body manufacturing apparatus 2 of the second embodiment, and corresponding portions are denoted by the same reference numerals. The description is omitted.

  FIG. 24 is a cross-sectional view illustrating a configuration of a cleaning blade 130 which is an example of a sheet body manufactured by the sheet body manufacturing apparatus 3 of the present embodiment. In this embodiment, like the cleaning blade 130 shown in FIG. 24, two curable resin layers formed of a curable resin, more specifically, two thermosetting resin layers 131 formed of a thermosetting resin. , 133, the sheet body 130 with the core body sheet 132 interposed therebetween is manufactured. The sheet body 130 is a composite sheet body including two or more layers, and each layer constituting the composite sheet body is laminated in the thickness direction.

  Of the two thermosetting resin layers 131 and 133, the first thermosetting resin layer (hereinafter referred to as “first thermosetting resin layer”) 131 is the thermosetting formed in the first embodiment described above. It is formed in the same manner as the conductive resin layer 91. A second thermosetting resin layer (hereinafter referred to as “second thermosetting resin layer”) 133 is provided on the other surface portion in the thickness direction of the thermosetting resin layer 101 via the core sheet 132. . In the present embodiment, the second thermosetting resin layer 133 is harder than the first thermosetting resin layer 131. The thickness of the second thermosetting resin layer 133 is smaller than the thickness of the first thermosetting resin layer 131. The first and second thermosetting resin layers 131 and 133 are formed of the same material as the thermosetting resin layer 91 in the first embodiment and have rubber elasticity. Therefore, the sheet body 130 is an elastic sheet body having rubber elasticity.

  The core sheet 132 interposed between the first and second thermosetting resin layers 131 and 133 is realized by a resin film in the present embodiment. Examples of the resin constituting the core sheet 132 include the same resins as those constituting the first and second sheets 31 and 32. The core sheet 132 includes one or more layers formed of a thermoplastic resin such as PET or PEN. Unlike the first release film 31 that is the first sheet, the core sheet 132 is not provided with a release layer as a surface layer thereof. The thickness of the core sheet 132 is smaller than the thickness of the first thermosetting resin layer 131 and is equal to the second thermosetting resin layer 133. The thickness of the core sheet 132 is not limited to this.

  As shown in FIG. 22, the sheet body manufacturing apparatus 3 is a sheet body manufacturing according to the first embodiment except that a sheet stacking layer forming unit 140 is provided instead of the layer forming unit 19 according to the first embodiment. It has the same configuration as the device 1. In the present embodiment, the sheet winding unit 17 winds the counter sheet 110 instead of the second release film 32 that is the second sheet.

  As shown in FIG. 23, the sheet stacking layer forming unit 140 includes a first layer forming unit 141 and a second layer forming unit 142. The first layer forming unit 141 has the same configuration as the layer forming unit 19 in the first embodiment. In the present embodiment, the raw material tank (not shown) of the resin liquid supply unit 11 stores the raw material of the first thermosetting resin layer 133 shown in FIG. 24 and supplies it to the mixing chamber 22, and the first thermosetting resin. A liquid (hereinafter also referred to as “first resin liquid”) 145 is prepared. The second sheet supply unit 34 supplies the core sheet 132 that is the second sheet to the layer forming unit 13. According to the first layer forming unit 141, the first resin liquid layer 147 is formed by supplying the first resin liquid 145 between the first sheet 31 and the core sheet 132 that is the second sheet. As a result, a first sheet precursor 148 in which the first resin liquid layer 147 is interposed between the first sheet 31 and the core sheet 132 is formed.

  The second layer forming unit 142 includes a sheet stacking liquid supply unit 143, an opposing sheet supply unit 117, and a sheet stacking layer forming unit 144. The sheet laminating liquid supply unit 143 corresponds to a sheet laminating resin liquid supply unit. The sheet stacking liquid supply unit 143 has the same configuration as the resin liquid supply unit 11 in the first embodiment. In the raw material tank (not shown) of the sheet stacking liquid supply unit 143, the raw material of the second thermosetting resin layer 133 shown in FIG. 24 is stored and supplied to the mixing chamber 22, and the second thermosetting resin liquid (hereinafter referred to as “second thermosetting resin liquid”). 146) (sometimes referred to as “second resin liquid”). The first and second thermosetting resin liquids 145 and 146 are selected such that the hardness of the second thermosetting resin layer 133 is higher than the hardness of the first thermosetting resin layer 131.

  The sheet stacking layer forming unit 144 includes a precursor stretching unit 149 on which the first sheet precursor 148 fed from the first layer forming unit 141 via the guide roller 61 is stretched, and an opposing sheet stretching unit. 122. The precursor stretching portion 149 includes a heat roll 43, first to third cleaner units 44, 45, 46, and a static eliminator 47, similar to the first and second sheet stretching portions 41, 42, A guide roller 125 is included. The heat roll 43 of the precursor stretching portion 149 corresponds to a precursor-side roll. The first sheet precursor 148 is guided by the guide roller 61 of the sheet conveying unit 14, is fed to the guide roller 125 of the precursor stretching unit 149, and is fed to the heat roll 43 through the third cleaner unit 46. The In the first sheet precursor 148, the other surface portion in the thickness direction of the first sheet 31 that is the other surface portion in the thickness direction is in contact with the guide roller 54 of the third cleaner unit 46, and the core sheet 132 that is one surface portion in the thickness direction. One surface portion in the thickness direction is in contact with the guide roller 54, and the other surface portion in the thickness direction of the first sheet 31, which is the other surface portion in the thickness direction, is wound around each roller so as to contact the heat roll 43.

  The heat roll 43 of the precursor stretch part 149 and the heat roll 43 of the counter sheet stretch part 122 are provided to face each other, and at a position where the heat rolls 43 face each other, the first sheet precursor 148 The opposing sheet 110 faces. In this embodiment, between the first sheet precursor 148 and the counter sheet 110 facing each other, between the core sheet 132 of the first sheet precursor 148 and the counter sheet 110, the sheet stacking liquid supply unit 143 performs the first operation. 2 resin liquid 146 is supplied, and the 2nd resin liquid layer 150 is formed. As a result, a second sheet precursor 151 in which the second resin liquid layer 150 is interposed between the first sheet precursor 148 and the counter sheet 110 is formed.

  FIG. 25 is a flowchart illustrating a procedure of a sheet body manufacturing method according to another embodiment of the present invention. The sheet body manufacturing method of the present embodiment is executed by the sheet body manufacturing apparatus 3 shown in FIGS. 22 and 23. In the sheet body manufacturing method according to the present embodiment, when materials necessary for manufacturing and the sheet body manufacturing apparatus 3 are prepared, the procedure is started in step c0 and proceeds to step c1.

  FIG. 26 is a cross-sectional view showing a state in which the first resin liquid supply step of step c1 shown in FIG. 25 has been completed. The first resin liquid supply process of step c1 is executed in the same manner as the resin liquid supply process of step a1 in the first embodiment by the first layer forming unit 141 shown in FIG. As a result, as shown in FIG. 26, a first sheet precursor 148 in which the first resin liquid layer 147 is interposed between the first sheet 31 and the core sheet 132 as the second sheet is formed. When the first sheet precursor 148 is thus formed, the first sheet precursor 148 is fed to the second layer forming unit 142 shown in FIG. 22, and the process proceeds to step c2.

  FIG. 27 is a cross-sectional view showing a state in which the second resin liquid supply process of step c2 shown in FIG. 25 has been completed. In step c2, which is the second resin liquid supply process, as shown in FIG. 23, the first sheet precursor 148 is placed on the precursor stretching portion 149 so that the core sheet 132, which is the second sheet, faces the counter sheet 110. The counter sheet 110 is stretched on the heat roll 43 of the counter sheet stretching section 122 to convey the core sheet 132 and the counter sheet 110, and the core sheet 132 and the counter sheet 110. In between, the 2nd resin liquid 146 is supplied by the sheet | seat lamination liquid supply part 143. Thereby, as shown in FIG. 27, the second resin liquid layer 150 is formed between the core sheet 132 and the counter sheet 110, and the second sheet precursor 151 is formed.

  The distance between the heat roll 43 of the precursor stretch part 149 shown in FIG. 23 and the heat roll 43 of the counter sheet stretch part 122 is the distance between the first sheet precursor 148 and the counter sheet 110 shown in FIG. In the embodiment, the interval between the core sheet 132 and the counter sheet 110 of the first sheet precursor 148 is smaller than the interval between the first sheet 31 and the core sheet 132, and the thickness of the second resin liquid layer 150 is the first. It is selected to be thinner than the thickness of one resin liquid layer 147. When the second sheet precursor 151 shown in FIG. 27 is thus formed, the second sheet precursor 151 is fed to the resin liquid curing unit 15 via the guide roller 61 shown in FIG. 23, and step c3. Proceed to

  FIG. 28 is a cross-sectional view showing a state in which the curing process in step c3 shown in FIG. 25 has been completed. In step c3 which is a curing process, the second sheet precursor 151 shown in FIG. 27 is heated by the resin liquid curing unit 15 shown in FIG. 22 to cure the first and second resin liquid layers 147 and 150, First and second thermosetting resin layers 131 and 133 shown in FIG. 28 are formed. As a result, as shown in FIG. 28, the first thermosetting resin layer 131, the core sheet 132, the second thermosetting resin layer 133, and the opposing sheet 110 are formed on one surface portion in the thickness direction of the first sheet 31. A third sheet precursor 152 laminated in order is obtained. When the third sheet precursor 152 is obtained in this manner, the third sheet precursor 152 is temporarily stopped by the feed amount adjusting unit 16 shown in FIG. 17 and proceeds to step c4.

  FIG. 29 is a cross-sectional view showing a state in which the peeling process in step c4 shown in FIG. 25 has been completed. In step c4, which is a peeling process, the counter sheet 110 formed on one surface in the thickness direction of the second thermosetting resin layer 133 in the third sheet precursor 152 shown in FIG. 28 is replaced with the sheet shown in FIG. Winding is performed by the winding unit 17. As a result, the opposing sheet 110 shown in FIG. 28 is peeled from the second thermosetting resin layer 133. As shown in FIG. 29, the first sheet 31, the first thermosetting resin layer 131, the core sheet 132, and the first sheet A fourth sheet precursor 153 configured to include the two thermosetting resin layer 133 is formed. Of the fourth sheet precursor 153, the first thermosetting resin layer 131, the core sheet 132, and the second thermosetting resin layer 133 constitute the sheet body 130 shown in FIG. When the fourth sheet precursor 153 is formed in this manner, the fourth sheet precursor 153 is fed to the sheet body cutting unit 18 shown in FIG. 22, and the process proceeds to step c5.

  In step c5, which is a cutting process, the fourth sheet precursor 153 shown in FIG. 29 is cut by the cutting blade 85 of the sheet cutting unit 18 shown in FIG. By cutting the fourth sheet precursor 153 in this way, the sheet body 130 shown in FIG. 24 described above is in a state in which the first sheet 31 is provided on one surface in the thickness direction as shown in FIG. It is obtained by. When the sheet body 130 is manufactured in this way, the process proceeds to step b8 and the manufacturing operation is finished.

  As described above, in the present embodiment, the first resin liquid layer 147 is formed by supplying the first resin liquid 145 between the first sheet 31 and the core sheet 132 in the first resin liquid supply process of step c1. Thereafter, the second resin liquid layer 146 is formed by supplying the second resin liquid 146 between the core sheet 132 and the counter sheet 110 in the second resin liquid supply step of step c2. Since the first and second resin liquid layers 147 and 150 are cured in the curing step of step c3, the first thermosetting resin layer 131 is formed between the first sheet 31 and the core body sheet 132, and the core A second thermosetting resin layer 133 can be formed between the body sheet 132 and the counter sheet 110. Therefore, as shown in FIG. 24, the cleaning blade 130 which is a sheet body in which the core sheet 131 is interposed between the first thermosetting resin layer 131 and the second thermosetting resin layer 133 can be manufactured.

  In this cleaning blade 130, since the core sheet 131 is interposed between the first thermosetting resin layer 131 and the second thermosetting resin layer 133, for example, the hardness and thickness of the core sheet 132 are adjusted. Therefore, the permanent distortion of the cleaning blade 130 can be reduced and the settling can be prevented.

  In addition, the cleaning blade 130 obtained by the present embodiment is harder than the first thermosetting resin layer 131 through the core sheet 132 on one surface in the thickness direction of the first thermosetting resin layer 131. Since the high second thermosetting resin layer 133 is formed, the durability of the cleaning blade 130 that is a sheet body is improved as compared with the case where the second thermosetting resin layer 133 is formed only by the first thermosetting resin layer 131. Can do. Moreover, since the thickness of the relatively hard second thermosetting resin layer 133 is thinner than the thickness of the first thermosetting resin layer 131, the permanent distortion of the cleaning blade 130 is reduced, and settling is prevented. Can do.

  In the present embodiment, the thickness of the second thermosetting resin layer 133 is selected from 30 μm to 300 μm. As a result, similar to the sheet body 100 shown in FIG. 14 manufactured in the second embodiment, the sheet body 130 is a composite including the first thermosetting resin layer 132 and the second thermosetting resin layer 133. Therefore, the contact pressure to the image carrier 160 can be increased more reliably, and the sheet member 130 suitable as a cleaning blade is realized. In addition, the permanent distortion of the sheet body 130 can be more reliably reduced. Therefore, the permanent deformation is small, the contact pressure to the image carrier is high, and the sheet member 130 suitable as a cleaning blade is realized. Further, the difference between the molding shrinkage rate of the first thermosetting resin layer 131 and the molding shrinkage rate of the second thermosetting resin layer 133 is prevented from becoming excessive, and the warping of the cleaning blade 130 due to the molding shrinkage rate difference is prevented. Can be prevented.

  Further, when the sheet body 130 is used as a developing blade, the effect of making the sheet body 130 into a composite is sufficiently exhibited by setting the thickness of the second thermosetting resin layer 133 to 30 μm or more and 300 μm or less. Therefore, the durability of the sheet body 130 can be improved more reliably, and the early disappearance of the second thermosetting resin layer 133 due to wear can be prevented. Accordingly, the sheet body 100 is realized which has a small permanent set, is hardly lost even when worn by rubbing against the developing sleeve, has excellent durability, and is suitable as a developing blade.

  In addition, the cleaning blade 130 obtained by the present embodiment is used as a cleaning edge in which one end portion of the second thermosetting resin layer 133 having relatively high hardness comes into contact with the image carrier. As a result, compared with the case where the cleaning blade 130 uses one end portion of the first thermosetting resin layer 131 as a cleaning edge, the contact pressure on the surface portion of the image carrier is increased and the toner is easily removed. Can do.

  The hardness of the first thermosetting resin layer 131 is the same as that of the curable laminated resin layer 102 in the cleaning blade 100 shown in FIG. In consideration of easiness along the carrier, the spring hardness Hs is selected from 65 to 75. The hardness of the second thermosetting resin layer 133 that is in direct contact with the image carrier is determined in consideration of the contact pressure to the image carrier in the same manner as the thermosetting resin layer 101 in the cleaning blade 100 according to the second embodiment. The spring hardness Hs is selected from 75 to 90.

  In this embodiment, “the hardness of the first thermosetting resin layer” refers to the hardness of the surface portion of the first thermosetting resin layer 131 that contacts the core sheet 132, and “the hardness of the curable laminated resin layer”. “S” means the hardness of the surface portion of the second thermosetting resin layer 133 opposite to the surface portion in contact with the core sheet 132. Although different from the present embodiment, when a layer or sheet is further interposed between the first thermosetting resin layer 131 and the core sheet 132, the “hardness of the first thermosetting resin layer” The hardness of the surface part which faces the core sheet | seat 132 of 1 thermosetting resin layer is said. When a layer or a sheet is further interposed between the second thermosetting resin layer 133 and the core sheet 133, the “hardness of the second thermosetting resin layer” refers to the second thermosetting resin layer. It means the hardness of the surface portion opposite to the surface portion facing the core sheet.

  In the present embodiment, by using the sheet body manufacturing apparatus 3 shown in FIG. 22, the cleaning blade 130 in which the sheet 132 is interposed between the thermosetting resin layers 131 and 133 in this way can be easily and accurately obtained. Can be manufactured.

  As described above, in the present embodiment, the thickness of the second thermosetting resin layer 133 is selected to be smaller than the thickness of the first thermosetting resin layer 131. The relationship between the thickness of the first thermosetting resin layer 131 and the thickness of the second thermosetting resin layer 133 is not limited to this.

  FIG. 30 is a cross-sectional view illustrating a configuration of a cleaning blade 134 which is another example of a sheet body manufactured by the sheet body manufacturing apparatus 3 of the present embodiment. A cleaning blade 134 shown in FIG. 30 has a second thermosetting resin layer 135 having a thickness equal to that of the first thermosetting resin layer 131 on one surface portion in the thickness direction of the core sheet 132. As described above, the second thermosetting resin layer may be formed to have the same thickness as the first thermosetting resin layer 131, and may be formed to have a thickness larger than that of the first thermosetting resin layer 131. Also good.

  From the viewpoint of durability of the cleaning blade, the thickness of the second thermosetting resin layer is preferably selected to be smaller than that of the first thermosetting resin layer 131 as in the present embodiment. As a result, the permanent distortion of the cleaning blade can be reduced and sag can be prevented, so that the durability of the cleaning blade can be improved. The thickness of the 2nd thermosetting resin layer 133 can be adjusted with the space | interval of the heat roll 43 of the precursor stretch part 149 and the heat roll 43 of the opposing sheet stretch part 122. FIG.

  In the first to third embodiments described above, the first and second heat rolls 43a and 43b on which the pair of sheets 31 and 32 sandwiching the resin liquid layer 92 are stretched as shown in FIG. Although it is provided at the same position in the direction so as to face each other, the arrangement of the first and second heat rolls 43a and 43b is not limited to this. For example, in the first and second heat rolls 43 a and 43 b, one heat roll 43 may be provided on one Z1 side or the other Z2 side in the Z direction with respect to the other heat roll 43.

  Moreover, although a thermosetting resin liquid is supplied to the position where a pair of sheet | seats 31 and 32 mutually oppose, the supply position of a thermosetting resin liquid is not limited to this. The thermosetting resin liquid is first supplied to one of the pair of sheets 31 and 32, for example, at a portion where the pair of sheets 31 and 32 does not face each other, and the pair of sheets 31 and 32 face each other. It may be supplied between the pair of sheets 31 and 32 by being conveyed to the part.

  In the first to third embodiments described above, the thermosetting resin layer is formed by a prepolymer method using a prepolymer and a curing agent as raw materials, but is not limited to this, and by a one-shot method. It may be formed. When forming a thermosetting resin layer, for example, a thermosetting polyurethane layer, by the one-shot method, the thermosetting resin liquid contains a polyol, a polyisocyanate, and a curing agent.

  Each layer of the sheet bodies 90, 100, 103, 130, 134 manufactured by the first to third embodiments described above may contain particles as a filler. Examples of the particles used as the filler include inorganic particles such as aluminum hydroxide and silicon dioxide. The particle size of the particles as the filler is, for example, 10 to 100 nm.

  By incorporating particles having a particle size of nanometer level in the thermosetting resin layer in this way, for example, when the sheet body is a cleaning blade, the cleaning blade is increased in hardness and applied to the surface portion of the image carrier. Since the contact pressure can be increased, the removal performance of the toner and the external additive added to the toner, that is, the cleaning property can be improved. Further, the wear resistance is improved, and the durability of the cleaning blade can be improved.

  When forming a thermosetting resin layer containing such particles as a filler, the particles are contained in a thermosetting resin liquid. When particles having a particle size of nanometer level are contained in the thermosetting resin liquid as a filler, the viscosity of the thermosetting resin liquid increases and thixotropic properties appear. Using such a thermosetting resin liquid, for example, when trying to manufacture a sheet body by a centrifugal molding method, the thermosetting resin liquid cannot be spread over the entire inner peripheral surface portion of the forming drum, and the sheet body is manufactured. The problem of not being able to do arise. Further, when the mold forming method is used, there is a problem that the thermosetting resin liquid cannot be spread over the entire mold, and a sheet body having a target shape cannot be manufactured.

  In contrast to this, in the first to third embodiments described above, for example, as shown in FIG. Then, the thermosetting resin liquid 30 in an amount corresponding to the distance between the pair of rollers 43a and 43b is supplied from the bank 93 between the pair of sheets 31 and 32. Therefore, even when the thermosetting resin liquid contains particles having a particle size of nanometer level and has thixotropic properties, a certain amount of thermosetting resin liquid can be supplied between a pair of sheets. . Thus, since the resin liquid layer formed by supplying the thermosetting resin liquid is cured to form the thermosetting resin layer and the sheet body is manufactured, in the first to third embodiments, A thermosetting resin layer containing particles having a particle size of nanometer level as a filler can be easily formed, and a sheet body having such a thermosetting resin layer can be easily produced.

  Applications of the sheet bodies 90, 100, 103, 130, and 134 manufactured according to the first to third embodiments described above are not limited to the cleaning blade. The sheet member may be used as, for example, a developing blade, a recovery blade, or a seal blade of a developing device of the image forming apparatus. The sheet body is not limited to the field of image forming apparatuses, and may be used as various films and sheets used in the field of electronic equipment, for example, and may be used as a squeegee blade for screen printing.

It is a side view which shows the structure of the sheet | seat body manufacturing apparatus 1 which is 1st Embodiment of this invention. It is a side view which expands and shows the structure of the layer formation part 13 shown in FIG. It is sectional drawing which shows the structure of the cleaning blade 90 which is an example of the sheet body manufactured by the sheet body manufacturing apparatus 1 of this embodiment. 7 is a perspective view showing a state of a cleaning blade 90 obtained after the sheet body 95 is cut by the sheet body cutting unit 18 of the sheet body manufacturing apparatus 1. FIG. It is a side view which expands and shows the structure of the 1st sheet | seat stretch part 41 shown in FIG. FIG. 4 is a perspective view illustrating a configuration of a collection roller 53 illustrated in FIG. 3. FIG. 4 is a cross-sectional view illustrating a configuration of a carry-in side roller 75 of a feed amount adjusting unit 16. It is a flowchart which shows the procedure of the manufacturing method of the sheet | seat which is other form of implementation of this invention. It is sectional drawing which shows the state which the resin liquid supply process of step a1 shown in FIG. 8 was complete | finished. It is sectional drawing which shows the state which the hardening process of step a2 shown in FIG. 8 was complete | finished. It is sectional drawing which shows the state which the peeling process of step a3 shown in FIG. 8 was complete | finished. It is a side view which shows the structure of the sheet body manufacturing apparatus 2 which is the 2nd Embodiment of this invention. It is a side view which expands and shows the structure of the layer formation unit 111 for resin lamination shown in FIG. It is sectional drawing which shows the structure of the cleaning blade 100 which is an example of the sheet body manufactured by the sheet body manufacturing apparatus 2 of this embodiment. It is a flowchart which shows the procedure of the manufacturing method of the sheet | seat which is other form of implementation of this invention. It is sectional drawing which shows the state which the peeling process of step b3 shown in FIG. 15 was complete | finished. It is sectional drawing which shows the state which the resin liquid layer formation process of step b4 shown in FIG. 15 was complete | finished. It is sectional drawing which shows the state which the hardening process of step b5 shown in FIG. 15 was complete | finished. It is sectional drawing which shows the state which the peeling process of step b6 shown in FIG. 15 was complete | finished. It is sectional drawing which shows the structure of the cleaning blade 103 which is another example of the sheet body manufactured by the sheet body manufacturing apparatus 2 of this embodiment.

4 is a partial cross-sectional view schematically showing a state in which the cleaning blade 100 contacts the image carrier 160. FIG. It is a side view which shows the structure of the sheet | seat manufacturing apparatus 3 which is 3rd Embodiment of this invention. It is a side view which expands and shows the structure of the layer formation unit 140 for resin lamination shown in FIG. It is sectional drawing which shows the structure of the cleaning blade 130 which is an example of the sheet body manufactured by the sheet body manufacturing apparatus 3 of this embodiment. It is a flowchart which shows the procedure of the manufacturing method of the sheet | seat which is other form of implementation of this invention. It is sectional drawing which shows the state which the 1st resin liquid supply process of step c1 shown in FIG. 25 was complete | finished. It is sectional drawing which shows the state which the 2nd resin liquid supply process of step c2 shown in FIG. 25 was complete | finished. It is sectional drawing which shows the state which the hardening process of step c3 shown in FIG. 25 was complete | finished. It is sectional drawing which shows the state which the peeling process of step c4 shown in FIG. 25 completed. It is sectional drawing which shows the structure of the cleaning blade 134 which is another example of the sheet body manufactured by the sheet body manufacturing apparatus 3 of this embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Sheet body manufacturing apparatus 11 Resin liquid supply part 12 Sheet supply part 13 Layer formation part 14 Sheet conveyance part 15 Resin liquid hardening part 16 Feed amount adjustment part 17 Sheet winding part 18 Sheet body cutting part 31 1st sheet 32 2nd sheet 41 1st sheet stretch part 42 2nd sheet stretch part 43 Heat roll 43a 1st heat roll 43b 2nd heat roll

Claims (13)

A method for producing a sheet body including a curable resin layer formed by curing a curable resin liquid,
Among the pair of sheets, one sheet is stretched on the first roll, the other sheet is stretched on the second roll so as to face the one sheet, and the pair of sheets are conveyed, A resin liquid supply step of supplying a curable resin liquid between a pair of sheets to form a resin liquid layer;
And a curing step of curing a resin liquid layer formed between the pair of sheets to form a curable resin layer. After the curing process,
A step of peeling a sheet provided on one surface portion or the other surface portion of the curable resin layer;
A sheet precursor formed by peeling the sheet is stretched on a precursor-side roll, and the opposing sheet is stretched on the facing-side roll so as to face the sheet precursor facing the curable resin layer. A step of conveying the precursor and the counter sheet, supplying a curable resin liquid between the curable resin layer and the counter sheet, and forming a laminated resin liquid layer;
The method for producing a sheet body according to claim 1, further comprising a step of curing the laminated resin liquid layer to form a curable laminated resin layer. Of the pair of sheets, at least one of the sheets is a core sheet,
After the resin liquid supply process and before the curing process,
A pair of sheets sandwiching the resin liquid layer is stretched on a sheet-side roll, and the facing sheet is stretched on the facing-side roll so as to face the pair of sheets facing the core sheet of the pair of sheets. And a step of conveying the pair of sheets and the opposing sheet, supplying a curable resin liquid between the core sheet and the opposing sheet, and forming a resin liquid layer,
In the curing process,
Along with the resin liquid layer formed between the pair of sheets, the resin liquid layer formed between the core sheet and the counter sheet of the pair of sheets is cured to form a curable resin layer. The manufacturing method of the sheet | seat body of Claim 1 or 2 characterized by these. A sheet body manufacturing apparatus for manufacturing a sheet body including a curable resin layer formed by curing a curable resin liquid,
A first roll on which one of the pair of sheets is stretched;
A second roll that is stretched so that the other sheet faces the other sheet of the pair of sheets;
Conveying means for conveying a pair of sheets;
A resin liquid supply means for supplying a curable resin liquid between the pair of sheets;
A sheet body manufacturing apparatus comprising: a curing unit that supplies a curable resin liquid to cure a resin liquid layer formed between a pair of sheets. A peeling means that is provided on the downstream side in the conveying direction of the pair of sheets from the curing means, and peels off the sheet provided on one surface portion or the other surface portion of the curable resin layer formed by curing the resin liquid layer;
A precursor-side roll on which a sheet precursor formed by peeling the sheet is stretched;
An opposing roll on which an opposing sheet is stretched so as to face the sheet precursor facing the curable resin layer;
Conveying means for conveying the sheet precursor and the opposing sheet;
A resin liquid supply means for resin lamination for supplying a curable resin liquid between the curable resin layer and the opposing sheet;
The sheet body according to claim 4, further comprising a resin laminating curing unit that cures a laminated resin liquid layer formed between the curable resin layer and the opposing sheet by being supplied with the curable resin liquid. Manufacturing equipment. Of the pair of sheets, at least one of the sheets is a core sheet,
A sheet side downstream of the resin liquid supply means in the conveyance direction of the pair of sheets and upstream of the curing means in the conveyance direction of the pair of sheets and on which the pair of sheets sandwiching the resin liquid layer is stretched Roles,
A facing roll on which the facing sheet is stretched so as to face the pair of sheets facing the core sheet of the pair of sheets;
Conveying means for conveying the pair of sheets and the opposing sheet;
6. The sheet body production according to claim 4, further comprising a sheet stacking resin liquid supply unit configured to supply a curable resin liquid between the core sheet and the counter sheet of the pair of sheets. apparatus. A curable resin layer formed of a curable resin and having rubber elasticity;
Provided by laminating on one surface portion of the curable resin layer, formed of a curable resin, and including a curable laminated resin layer having rubber elasticity,
The hardness of the curable resin layer is higher than the hardness of the curable laminated resin layer,
A sheet body, wherein the thickness of the curable resin layer is thinner than the thickness of the curable laminated resin layer.   The sheet body according to claim 7, wherein the thickness of the curable resin layer is not less than 30 μm and not more than 300 μm.   The sheet body according to claim 7 or 8, further comprising a sheet provided by being laminated on the other surface portion of the curable laminated resin layer. A first curable resin layer formed of a curable resin and having rubber elasticity;
A core sheet provided by being laminated on one surface portion of the first curable resin layer;
A sheet body comprising: a second curable resin layer which is provided by being laminated on one surface portion of a core sheet, is formed of a curable resin, and has rubber elasticity.   The sheet body according to claim 10, wherein the hardness of the second curable resin layer is higher than the hardness of the first curable resin layer.   The thickness of a 2nd curable resin layer is thinner than the thickness of a 1st curable resin layer, The sheet | seat body of Claim 11 characterized by the above-mentioned.   The thickness of the 2nd curable resin layer is 30 micrometers or more and 300 micrometers or less, The sheet | seat body of Claim 12 characterized by the above-mentioned.

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