Method of preparing toner and toner prepared using the method

Abstract

A method of preparing a toner, including: preparing a colorant dispersion by mixing a reactive emulsifier and a colorant; preparing a toner composition by mixing a macromonomer including a hydrophilic group, a hydrophobic group and at least one reactive functional group, at least one polymerizable monomer and a chain transfer agent with the colorant dispersion; emulsion polymerizing the toner composition in a medium; and separating and drying the polymerized toner, wherein the amounts of the macromonomer and the chain transfer agent are controlled to regulate the configuration of toner particles. A toner prepared using the method, an image forming method using the toner, and an image forming apparatus using the toner are also provided by the invention. According to the method, the size and configuration of toner particles are easily controlled. In addition, the method minimizes the use of a surfactant, and decreases polluted water and waste water, which is very advantageous environmentally.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:

FIG. 1 is a photo of toner particles prepared using a method according to an embodiment of the present invention; and

FIG. 2 is a schematic view of an image forming apparatus employing a toner prepared using a method according to an embodiment of the present invention.

Claims

1. A method of preparing a toner, comprising: preparing a colorant dispersion by mixing a reactive emulsifier and a colorant;preparing a toner composition by mixing a macromonomer including a hydrophilic group, a hydrophobic group, and at least one reactive functional group, at least one polymerizable monomer and a chain transfer agent with the colorant dispersion;emulsion polymerizing the toner composition in a medium; andseparating and drying the polymerized toner, wherein the amounts of the macromonomer and the chain transfer agent are controlled to regulate the configuration of toner particles.

2. The method of claim 1, wherein as the amount of the macromonomer increases, the configuration of toner particles changes from irregular shape to a spherical shape.

3. The method of claim 1, wherein as the amount of the chain transfer agent increases, the configuration of toner particles changes from irregular shape to a spherical shape.

4. The method of claim 1, wherein the reactive emulsifier comprises a polyoxyethylene alkylphenyl ether moiety and at least one anionic reactive emulsifier having a group selected from the group consisting of a vinyl group, an acrylate group and a methacrylate group.

5. The method of claim 1, wherein the weight average molecular weight of the reactive emulsifier is in the range of about 100 to 1,000.

6. The method of claim 1, wherein the amount of the reactive emulsifier is in the range of about 5 to 50 parts by weight based on 100 parts by weight of the colorant.

7. The method of claim 1, wherein the weight average molecular weight of the macromonomer is in the range of about 100 to 100,000.

8. The method of claim 1, wherein the macromonomer is a material selected from the group consisting of polyethylene glycol (PEG)-methacrylate, PEG-ethyl ether methacrylate, PEG-dimethacrylate, PEG-modified urethane, PEG-modified polyester, polyacrylamide (PAM), PEG-hydroxyethyl methacrylate, hexafunctional polyester acrylate, dendritic polyester acrylate, carboxy polyester acrylate, fatty acid modified epoxy acrylate, and polyester methacrylate.

9. The method of claim 1, wherein the amount of the macromonomer is in the range of about 1 to 50 parts by weight based on 100 parts by weight of the toner composition.

10. The method of claim 1, wherein the polymerizable monomer comprises at least one monomer selected from the group consisting of a vinyl monomer, a polar monomer having a carboxyl group, a monomer having unsaturated polyester, and a monomer having a fatty acid group.

11. The method of claim 1, wherein the polymerizable monomer comprises at least one material selected from the group consisting of a styrene-based monomer selected from the group consisting of styrene, vinyltoluene, and α-methylstyrene; acrylic acid; methacrylic acid; a (meth)acrylic acid derivative selected from the group consisting of methylacrylate, ethylacrylate, propylacrylate, butylacrylate, 2-ethylhexylacrylate, dimethylaminoethylacrylate, methylmethacrylate, ethylmethacrylate, propylmethacrylate, butylmethacrylate, 2-ethylhexylmethacrylate, and dimethylaminoethylmethacrylate; a (meth)acrylic acid derivative of amide selected from the group consisting of acrylonitrile, methacrylonitrile, acrylamide and methacrylamide; an ethylenically unsaturated monoolefin selected from the group consisting of ethylene, propylene and butylene; a halogenated vinyl selected from the group consisting of vinyl chloride, vinylidene chloride and vinyl fluoride; a vinyl ester selected from the group consisting of vinyl acetate and vinyl propionate; a vinyl ether selected from the group consisting of vinyl methyl ether and vinyl ethyl ether; a vinyl ketone selected from the group consisting of vinyl methyl ketone and methyl isopropenyl ketone; and a vinyl compound having nitrogen selected from the group consisting of 2-vinyl pyridine, 4-vinyl pyridine and N-vinyl pyrrolidone.

12. The method of claim 1, wherein the colorant is a material selected from the group consisting of yellow, magenta, cyan and black pigments.

13. The method of claim 1, wherein the toner composition generates a radical using an initiator and the radical reacts with the polymerizable monomer.

14. The method of claim 1, wherein the toner composition further comprises at least one material selected from the group consisting of wax, a charge control agent, and a release agent.

15. A toner obtained by emulsion-polymerizing a toner composition comprising a macromonomer having a hydrophilic group, a hydrophobic group and at least one reactive functional group, at least one polymerizable monomer and a chain transfer agent in a colorant dispersion of a reactive emulsifier and a colorant, wherein the amounts of the macromonomer and the chain transfer agent are controlled to regulate the configuration of toner particles.

16. The toner of claim 15, wherein as the amount of the macromonomer increases, the configuration of the toner particles changes from irregular shape to a spherical shape.

17. The toner of claim 15, wherein as the amount of the chain transfer agent increases, the configuration of the toner particles changes from irregular shape to a spherical shape.

18. The toner of claim 15, wherein the average volumetric particle size of the toner particle is in the range of about 0.5 to 20 μm.

19. The toner of claim 15, wherein the weight average molecular weight of the macromonomer is in the range of about 100 to 100,000.

20. The toner of claim 15, wherein the macromonomer is formed of a material selected from the group consisting of polyethylene glycol (PEG)-methacrylate, PEG-ethyl ether methacrylate, PEG-dimethacrylate, PEG-modified urethane, PEG-modified polyester, polyacrylamide (PAM), PEG-hydroxyethyl methacrylate, hexafunctional polyester acrylate, dendritic polyester acrylate, carboxy polyester acrylate, fatty acid modified epoxy acrylate, and polyester methacrylate.

21. The toner of claim 15, wherein the toner composition further comprises at least one material selected from the group consisting of wax, a charge control agent, and a release agent.

22. An image forming method comprising: forming a visible image by disposing the toner of claim 15 on an photoreceptor surface where an electrostatic latent image is formed; andtransferring the visible image to a transfer medium.

23. An image forming apparatus comprising: an organic photoreceptor;an image forming unit to form an electrostatic latent image on a surface of the organic photoreceptor;a toner cartridge to contain the toner of claim 15;a toner supplying unit to supply the toner to the surface of the organic photoreceptor to develop the electrostatic latent image on the surface of the organic photoreceptor into a toner image; anda toner transferring unit to transfer the toner image on the surface of the organic photoreceptor to a transfer medium.

24. A method of preparing a toner for an electrophotographic imaging device, the method comprising: admixing a reactive emulsifier and a colorant to obtain a colorant dispersion;admixing a macromonomer, at least one polymerizable monomer, a chain transfer agent and the colorant dispersion to obtain a toner composition, wherein the macromonomer has a hydrophilic group, a hydrophobic group and at least one reactive functional group;emulsion polymerizing the toner composition in a medium to produce polymerized toner particles; andseparating and drying the toner particles, wherein the macromonomer and chain transfer agent are included in amounts to obtain toner particles having a predetermined particle shape.

25. The method of claim 24, comprising including the macromonomer and chain transfer agent in amounts to produce substantially shaped toner particles.

26. The method of claim 24, comprising including the macromonomer and chain transfer agent in amounts to produce toner particles having an oblong shape.

27. The method of claim 24, wherein said toner particles have a particle size of about 0.5 to 20 μm.

28. The method of claim 24, wherein said toner particles have a particle size of about 5.0 to 10 μm.