CN1173843A - 压花的底片和光感受器装置及其制造方法 - Google Patents

压花的底片和光感受器装置及其制造方法 Download PDF

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CN1173843A
CN1173843A CN96191906A CN96191906A CN1173843A CN 1173843 A CN1173843 A CN 1173843A CN 96191906 A CN96191906 A CN 96191906A CN 96191906 A CN96191906 A CN 96191906A CN 1173843 A CN1173843 A CN 1173843A
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格雷戈.·F·戴维斯
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Abstract

一种压花底片(21)包括一塑料底片(22)并具有一表面,并且该底片表面带有一压花表面(62)。压花表面的特征是,它具有一平均粗糙度为100—300毫微米的图形,该粗糙度在该表面(62)上基本均匀分布。该图形具有脊和谷,在相邻脊和/或谷之间的水平距离比脊和谷之间的深度大。峰和谷是无规律无周期地分布,当具有薄平有机深层的压花表面(62)暴露在光中时,在压花表面上产生光线扩散,以将干涉效应减到最小或消除。

Description

压花的底片和光感受器 装置及其制造方法
本发明涉及压花的底片和光感受器装置以及其制造方法
各种薄膜层用于制造复印机用的光感受器带。为了提高这些带的感光度，希望把形成这些带的薄层制造的更薄更平。当这些层做的较薄较平时，发现在薄的平涂层中发生光干涉(莫尔(moire)效应)，换言之，莫尔效应在激光打印机中产生特别不希望有的颜色或木纹，因为它们会对所印的图象产生相长和/或相消干涉。因此，需要一种将这种光学干涉降低到最低的光感受器底片和能制造这种底片的方法。
总的来说，本发明的目的是提供一种压花底片和具有这种底片的光感受器装置及其制造方法，这种压花底片和光感受器可将这种光干涉效应减至最小或消除。
本发明的另一目的是提供具有上述特性的底片、装置和制造方法，其中，提供具有一图形的表面，该图形具有无规则无周期性的表面形貌以消除干涉效应。
本发明的另一目的是提供一种具有上述特性的底片、装置和方法，其中，压花表面的粗糙度被控制在预定范围之内。
本发明的另一目的是提供一种具有上述特性的底片、装置和方法，其中，其平均粗糙度是从100-300毫微米。
本发明的另一目的是提供一种底片、装置和方法，它可用于激光波长在350-1050毫微米的范围内。
本发明的另一目的是提供一种具有上述特性的底片、装置和方法，其中，图形具有峰和谷，并且其中，在相邻的峰和/或谷之间的距离大于从峰顶到相邻谷底的深度。
本发明另一目的，是提供适用于大量生产的技术上的底片、装置和方法。
本发明另一目的是提供，在生产光感受器带中可用的底片、装置和方法。
通过对以下结合附图的本发明优选实施的说明，本发明的其他目的和特征将更加明了。
图1是与本发明有关用的典型的底片截面图；
图2是在本发明方法中对其表面进行复制的腐蚀玻璃的截面图；
图3是图2腐蚀玻璃的截面图，在其上涂上了光致抗蚀剂(photoresist)层，以产生图2所示腐蚀玻璃表面的负片；
图4是光致抗蚀剂层从被腐蚀玻璃表面取下后的截面图；
图5是用图4所示的光致抗蚀剂负片在金薄膜上形成的被腐蚀玻璃表面的正片的截面图；
图6是在图5所示的步骤中产生的金薄膜靠模的截面图；
图7是表示利用金膜靠模制成具有图2所示腐蚀玻璃表面负形的金属盖片的方式的截面图；
图8压花的滚子的等距图，该滚子具有覆盖着多个在图7所示步骤中所制的金属盖片的无光泽(matted)圆柱面；
图9是装置示意图，说明图8所示压花滚子的金属盖片上的图形被传递，以形成一压花膜；
图10是被粘结到图1所示底片上的在图9中产生的压花膜的截面图，该膜带有真空沉淀在压花膜顶面上的屏蔽面(ground plane)；
图11是具有图10所示压花底片的光感受器装置的截面图。
一般来说，本发明的压花底片是由具有压花表面的底片所构成。这种压花表面的特征在于，它具有为100到300毫微米平均粗糙度的图形，这种粗糙度在图形上大体均匀分布。这些图形具有脊和谷，在相邻脊之间的距离比相邻峰和谷之间的深度大。峰和谷在图形上无规律无周期地分布，当底片涂上平的薄膜并曝露在光线中时，其将照射在上面的光线进行发散，使干涉减至最小或消除。
在图1至11所示的图中，在图10中示出本发明的压花底片21，该底片是用图1所示底片结合图2-9所示的步骤制成的。底片19具有上下面23和24。底片22可以用任何适当材料制造，但最好由柔性材料，例如具有1-10密耳厚度的PET塑料制造，且厚度最好为2-3密耳，并且，其中，表面23和24不具有实现本发明所需要的理想粗糙度。因此，例如，表面23可能有特别平的平均78毫微米或更小的粗糙度，但反之，如表面23有平均400毫微米的粗糙度则太过于粗糙。根据本发明，希望表面具有100-300毫微米的平均粗糙度，最好是120-250毫微米。
如下面所介绍的，表面23和24之一可以直接压花以便形成希望的粗糙度。当这样做时，希望底片22在表面23上形成由丙烯酸等适宜的物质形成的一硬涂层。这样的原始底片在市场上有销售，是由TEKRA供应的，牌号为TEKRA Marnot II，它是一种带有可压花的丙烯酸硬涂层的PET底片。
在下面介绍的制造压花底片21的方法中，应用了没有这种硬涂层的底片22。根据本发明，为了在底片22上产生可压制的图形，对种种表面进行了复制或拷贝的研究以形成这种压花表面。已经发现在具有腐蚀面27的标志为90°光泽度的腐蚀玻璃26上存在希望要的图形。结合到本发明，相信在60到97°光泽度范围可以应用，而90°光泽度最好。如在下文讨论这种玻璃表面复制过程中所述的，这种玻璃表面形貌27有多方面特征。一般90°光泽度的腐蚀玻璃在腐蚀面上具有100-150毫微米(平均约为150毫微米)的表面粗糙度Ra的图形。深度测量的RMS(均方根)平均值为140-200毫微米，Z平均值为430和410毫微米。图2示出长度为400微米以上的腐蚀玻璃的腐蚀表面试样的扫描图。在相邻谷和/或峰之间的距离约为10微米，峰顶和谷底之间的深度约为400毫微米。因此可见，在相邻谷和/或峰之间的宽度大于峰和一相邻谷之间的深度，并且更可取地例如大体上有20或更大的倍数。由这种90°光泽的腐蚀玻璃表面产生的图形在微观上是无规律无周期性的。
虽然如后所述用玻璃来形成希望要的具压花特性的表面，但其他材料也可形成这种希望要的特性表面，例如，塑料和金属板。
应理解，除了拷贝或复制一个物件表面形成的图形外，用计算机也可产生相似图形，以形成相似的表面形貌，如形成在表面上高幅值峰无规律地隔开的三维阻尼正弦波。作为例子，在相邻峰之间的间隔或宽度可以大约为10微米，而峰顶到谷底的深度可以约为0.1微米。为了防止形成衍射光栅，阻尼是需要的。换言之，形成的图形应是弥散而无规则的，以避免在表面上有周期性，也避免衍射效应。
假定根据本发明所希望复制的理想表面已选定，则将图3所示的玻璃底片26的表面27涂上分形膜31，该膜是由象硅油一类的适宜材料所形成，厚度在约0.1微米以下。在分形膜31上淀积一光致抗蚀剂层，如通过采用呈光聚合物形的液体负性光致抗蚀剂，如Eastman Kodak光致抗蚀剂，并用常规方法将它离心旋转到分形膜31的表面上并干燥。
在光致抗蚀层32干燥和固化后，将光致抗蚀层32从腐蚀玻璃底片26的表面27上剥离下来，以形成图4所示腐蚀玻璃26表面27的反形。在用计算机产生想要的压花表面时，可以用计算机产生的图形，通过电子束光刻技术来产生光致抗蚀剂靠模32。光致抗蚀剂层32的一个表面33是希望复制的表面27的反形。利用这个表面形成正形靠模盖片36，它具有表面37，表面37是玻璃底片26的腐蚀表面27的正形复制表面。相反，如果需要的话，可以形成反形靠模盖片，它产生腐蚀表面的反形复制面。可以用适宜的材料，如金，以常规化学镀法形成盖片36，产生金靠模片36，它具有玻璃底片26表面27的正形复制表面37。一旦金膜靠模36形成，光致抗蚀剂层可以用常规方式被溶解或洗掉，使得的留下如图6所示的具有表面37的金膜靠模片36。片36可以有合适的尺寸，例如1/2″×1/2″的方形。
然后由该金膜靠模片36形成多个盖片41，在盖片41上形成玻璃底片26的表面27的反形表面42和表面43。为此，在靠模片36的表面37上设置分形层44，该层是由硅油或氯化钠等适宜的材料形成的，然后，将象镍一类的金属用化学镀技术镀到表面37上，镀层厚度例如为10微米。在镀完后，将分形44溶解从而剩下表面42，它具有玻璃26腐蚀面27的第二次反形。镍盖片可以有适宜的大小，如与金靠模片36一般大的1/2″×1/2″的尺寸。
应理解，根据本发明，也可利用表面的反形复制面。为了生成一表面的反形复制面，只需制出压花片的更下一代复制面，以将盖片由负形变成正形。
根据本发明，假设希望敷设成一具有圆柱表面47的压花滚子46。滚子46可由不锈钢或铝等适宜的材料形成。例如，用直径6″、宽36″的圆柱面，并要用2000多1/2″方盖片盖住它表面。然后取镍敷设盖片，并通过适当方法，如粘结剂(未示出)将它们的表面43固定到圆柱表47上，即将盖片46并排一个接一个地，以一种无光泽(matte)方式来设置，形成一个与从圆柱表面47径向向外的盖片41的表面42一致的表面图形，从而形成了圆柱压花面。在盖片41以无光泽的方式敷设到表面47后，滚子46就可以用来直接在柔性底片的硬涂层面上(如带有丙烯酸硬涂层的PET底片上)压印它所具有的图形。这可在适宜的温度和压力，如150℃、每平方英寸80磅的条件下，使该底片在压花圆柱和一个平滑钢滚之间进行滚压来实现。
另外，压花滚子或圆柱46可用于如图9所示的装置和系统中。在供辊51上装PET底片22，该底片22在压花滚子46和玻璃滚子52之间运行，然后由收集辊54收集，在玻璃滚子52中有一紫外线光源53。如图9所示，压花滚46运行经过一可用紫外线(UV)固化的聚合物浸泡液体56，该液体位于顶部开口的罐57内。可固化聚合物浸泡液可以是UV可固化丙烯酸聚合物，或者是利用IR热源的可快速加热固化系统中以环氧树脂为基础的聚合物。当图9所示装置工作时，压花滚子46从浸泡液56中取得一薄层的紫外线可固化聚合物，并与底片22的下表面24接合，将聚合物由浸泡液挤压到压花滚子46上所装盖片41的图形中。在聚合物到达柔性底片22下面之前，可用刮片从压花滚子除去过多的聚合物。与压花滚子46接触的聚合物被UV光源53固化，产生一粘结到底片22的表面24上的铸造压花膜61，并使层61形成适宜的厚度(如2微米)，并随继续转动的压花滚子46而与之分离。当压花底片21在收集辊54上，被固化的聚合物层61与底片22一起运动。在图9所示的过程完成后，收集辊54可以被运往用户，用以制成前述类型的光感受器装置。层61为底片22提供了一个压花表面62，它是所希望复制的玻璃底片26的腐蚀表面27上图形的正形或反形。
另外，在将收集辊54运往用户之前，表面62上可以形成一由适宜的材料(如金属)形成的真空淀积屏蔽面66。将收集辊54所装的压花底片21通过传统真空室，在该真空室中将铝或其他合适金属蒸发，以使表面62喷镀金属形成作为屏蔽面的共形涂层。在表面62上形成金属化屏蔽面66后，该压花并金属化的底片被卷绕在另一收集辊上(没示出)，然后运往用户，以制造光感受器装置。
带有或不带有真空淀积屏蔽面66的压花底片21，可用于制造例如图11所示的光感受器装置。如图所示，装有如上所述屏蔽面66的压花表面62，随后加上一系列有机涂层，这些都是本领域技术人士所熟知的。这里有胶粘(subbing adhesion)层/电荷封闭(charge blocking)层71盖在屏蔽层66上。跟着是电荷生成(charge generation)层72和电荷运送(charge transport)层73，以致形成最终产品69。PET底片22例如可有75微米的适宜的厚度。铸造压花膜或层可有例如2微米的适宜厚度。屏蔽层可有比0.1微米小的厚度。一般胶粘/电荷封闭层71可有大于1微米厚度，电荷生成层72可有0.1-1微米厚度，电荷运送层73可有20微米厚度。
带有图11结构的光感受器装置69有一盖在底片22上的压花表面62，并为光感受器装置69提供了一散光能力，即使在屏蔽面66上覆盖有多种薄平有机层时，也使得在通过电荷运送层73发射的图像中的光学干涉(moire)效应如颜色或木纹等消除或减至最低。在与玻璃26的表面27相关的所述的压花表面62具有的形貌中，形成的脊和谷是无规律无周期性的，并且，脊和谷的彼此之间间隔宽度比峰和谷之间垂直距离大，从而提供了散光的微观形貌，它不具有任何相干干涉效应。平均粗糙度Ra应小于300毫微米，大于100毫微米。有这种形貌的光感受器装置可用于一般使用780-950毫微米波长红外线二极管激光光源的激光打印机。因此本发明特别适用于IR激光复印机及打印机。但与上述本发明的光感受器装置相同的装置也可用于白光复印机。
虽然本发明原则上是就柔性塑料片进行的描述，但应理解，同一原理也可用于平表面，如在平塑料板上的表面。从上述可以见到，本发明提供了用于光感受器装置的压花表面，当组成的光感受器装置的各层被制成较薄较平时，将光干涉效应消除或减至最小。

Claims (22)

1.一种压花底片，包括一塑料底片，并且有一表面和设在该底片的表面上的压花表面，该压花表面的特征在于，它具有一图形，该图形具有100-300毫微米的平均粗糙度，该粗糙度在该表面上大致均匀分布，所述图形具有脊和谷，相邻脊和/或谷之间的距离大于峰顶和谷底之间的深度，峰和谷是无规律无周期的，当该压花表面暴露在光中时，在上面就会产生光扩散，以将干涉效应减到最小或消除。
2.根据权利要求1所述的底片，其中，压花表面是底片的表面。
3.根据权利要求2所述的装置还包括一在底片的所述表面上的硬涂层。
4.根据权利要求3所述的装置，其中，所述底片是PET，并且其中，所述硬涂层是一丙烯酸物质。
5.根据权利要求1所述的底片还包括一塑料分开层，该层具有第一和第二表面，所述层的所述第一表面被粘结到底片的所述表面上，其中，所述压花表面形成在所述层的所述第二表面中。
6.根据权利要求5所述的底片，其中，所述层是由紫外线可固化聚合物形成的。
7.根据权利要求6所述的底片，其中，所述底片是由PET制成的。
8.根据权利要求7所述的底片还包括形成在该压花表面上的一真空淀积金属层。
9.根据权利要求1所述的底片，具有一与盖片共形的结构。
10.一光感受器装置，该装置包括带压花表面的塑料底片，所述压花表面具有一粗糙度为100-300毫微米的图形，该粗糙度在该压花表面上基本均匀分布，所述图形具有脊和谷，相邻的脊和/或谷之间的距离比峰顶和谷底之间的深度大，峰和谷在图形中无规律无周期地分布，在压花表面上粘结一屏蔽面，在屏蔽面上粘结一电荷封闭层，在电荷封闭层上粘结一电荷发生层，并在电荷发生层上粘结一电荷运送层，所述压花表面的作用是当该光感受器装置经受光照时，在其上面产生光扩散，以将光干涉效应减至最小或消除。
11.根据权利要求10所述的装置，其中，所述底片具有一由硬丙烯酸涂层形成的表面，并在其中，所述图形是压印在所述硬丙烯酸涂层中。
12.根据权利要求10所述的装置，其中所述压花表面是形成在该塑料层中。
13.根据权利要求12所述的装置，其中，所述压花表面是在该层中铸造的。
14.根据权利要求10所述的装置，其中，所述底片是由PET制成的。
15.一种形成一盖片的方法，该盖片具有一粗糙度为100-300毫微米的表面，该粗糙度在表面上基本均匀分布，该表面带有一图形，该图形具有脊和谷，在相邻脊和/或谷之间的水平距离比脊顶和谷底之间的垂直深度大，峰和谷在图形中无规律无周期性分布，在盖片的表面上，形成一压花表面并形成一与被复制的图象一致的该图象复制器。
16.根据权利要求15所述的方法，其中，被复制的盖片直接用于将底片表面压花。
17.根据权利要求15所述的方法，其中，被复制的盖片被用于在与底片表面上粘结的分开的塑料层的表面上压花。
18.根据权利要求15所述的方法，其中，通过由想要的表面图形制成一反向表面形貌、通过复制该反向表面形貌制成一正向表面形貌，通过复制该正向表面形貌又制成另一个反向表面形貌，并最后将该反向表面形貌传递到压花塑料底面上，在塑料底片中形成想要表面的正向复制图形。
19.根据权利要求18所示的方法，其中，正表面形貌是形成在一金属层中，其中另一个反向表面形貌形成到另一金属层中。
20.根据权利要求19的方法，其中，该反表面形貌是形成在与具有圆柱面的压花滚子在一起的多个盖片中，并以一种无光泽方式在压花滚子的圆柱表面上固定该多个盖片，使压花滚子通过一紫外线可固化聚合物浸泡液，并将紫外线可固化聚合物传送到底片的一侧面上，使紫外线可固化聚合物暴露在紫外线固化光线下，使紫外线聚合物固化、凝固，并由压花滚子传到底片上，从而使底片具有带着想要表面图象的压花表面。
21.根据权利要求20所述的方法，其中包括在压花表面上施加一真空淀积屏蔽面的步骤。
22.根据权利要求21所述的方法，其中包括将多个有机物层覆盖在屏蔽面层上的步骤。
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DE69618929T2 (de) 2002-06-27
TW337003B (en) 1998-07-21
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EP0802854A1 (en) 1997-10-29
US5993702A (en) 1999-11-30
US5789125A (en) 1998-08-04
CA2209852C (en) 2001-01-09
CA2209852A1 (en) 1997-05-15
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US5670240A (en) 1997-09-23
DE69618929D1 (de) 2002-03-14

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