Patent Application
20220244654
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2021-013924 filed Jan. 29, 2021.
The present disclosure relates to a toner for electrostatic image development.
Japanese Unexamined Patent Application Publication No. 2005-227671 proposes “a toner for electrophotography including a core layer containing at least a crystalline resin and a coloring agent, a wax layer containing a release agent and covering the core layer, and a shell layer containing an amorphous resin and covering the wax layer.”
Aspects of non-limiting embodiments of the present disclosure relate to a toner for electrostatic image development including toner particles containing a binder resin including a crystalline resin and an amorphous resin, a dye, and a release agent. With this toner for electrostatic image development, the difference in gloss that occurs when images are formed continuously is smaller than that when the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is more than 15%, when the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the amorphous resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is more than 20%, when the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is more than 200%, when 10>Qc1/Qc2 holds where Qc1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the crystalline resin in a first heating process in differential scanning calorimetry and Qc2 (J/g) is the amount of heat absorbed that is determined based on a endothermic peak derived from the crystalline resin in a second heating process in differential scanning calorimetry, or when 0.2>Qc1/Qw1 holds where Qc1 (J/g) is the amount of heat absorbed that is determined based on the endothermic peak derived from the crystalline resin in the first heating process in differential scanning calorimetry and Qw1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the release agent in the first heating process in differential scanning calorimetry.
Aspects of certain non-limiting embodiments of the present disclosure address the above advantages and/or other advantages not described above. However, aspects of the non-limiting embodiments are not required to address the advantages described above, and aspects of the non-limiting embodiments of the present disclosure may not address advantages described above.
According to an aspect of the present disclosure, there is provided a toner for electrostatic image development, the toner including toner particles containing a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent, wherein the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 15% or less.
Exemplary embodiments of the present disclosure will be described in detail based on the following figures, wherein:
Exemplary embodiments of the present disclosure will be described below. The following description and Examples are illustrative of the present disclosure and are not intended to limit the scope of the present disclosure.
In a set of numerical ranges expressed in a stepwise manner in the present specification, the upper or lower limit in one numerical range may be replaced with the upper or lower limit in another numerical range in the set of numerical ranges expressed in a stepwise manner. Moreover, in a numerical range described in the present specification, the upper or lower limit in the numerical range may be replaced with a value indicated in an Example.
Any component may contain a plurality of materials corresponding to the component.
When reference is made to the amount of a component in a composition, if the composition contains a plurality of materials corresponding to the component, the amount means the total amount of the plurality of materials in the composition, unless otherwise specified.
A toner for electrostatic image development according to a first exemplary embodiment (“the toner for electrostatic image development” may be hereinafter referred to simply as “the toner”) includes toner particles containing a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent.
The percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 15% or less.
With the above-described toner according to the first exemplary embodiment, the difference in gloss that occurs when images are formed continuously is small. The reason for this may be as follows.
In recent years, there is an increasing need for a toner having good low-temperature fixability. When a binder resin having a low glass transition temperature is used to improve the low-temperature fixability of the toner, the toner may tend to aggregate during storage.
To achieve an improvement in the low-temperature fixability and prevention of the aggregation of the toner simultaneously, a toner including toner particles containing a binder resin including an amorphous resin and a crystalline resin and a release agent is used in some cases. However, when the dispersion state of the amorphous resin and the crystalline resin in the toner particles of the toner is insufficient, defective fixation tends to occur when the toner is fixed onto a recording medium, so that the toner tends to adhere to a fixing member in some cases. The toner adhering to the fixing member is removed by a cleaning member. However, the release agent contained in the toner is not easily removed and is likely to remain on the fixing member. Therefore, in a portion of the fixing member in which the release agent remains present, the toner is unlikely to adhere to the fixing member during fixation when an image is again formed, so that an image with a smooth surface is obtained. However, in a portion of the fixing member in which no release agent remains present, the toner is likely to adhere to the fixing member. In this case, defective fixation is likely to occur, and a phenomenon in which part of the image is transferred to the fixing member (i.e., offset) is likely to occur. This is likely to cause a difference in gloss.
The difference in gloss is the difference in gloss between images.
As described above, this phenomenon occurs when a toner containing, as a binder resin, an amorphous resin and a crystalline resin is used. The phenomenon is significant when the toner used includes toner particles containing a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent. In some cases, the compatibility of the dye with the crystalline resin is low, and an excessively large amount of the crystalline resin tends to be present on the surface of the toner particles (for example, the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is more than 15%). This may be because, although the compatibility of the dye with the crystalline resin tends to be low, the compatibility of the dye with the amorphous resin tends to be high, so that the dye tends to be present on the inner side of the toner particles. Therefore, with the above toner, defective fixation is more likely to occur, and the toner tends to adhere to the fixing member. In this case, when images are formed continuously, the difference in gloss between the images is more likely to increase.
In the toner according to the first exemplary embodiment, the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 15% or less. Therefore, the amount of the crystalline resin present on the surface of toner particles is low. Thus, with this toner, defective fixation is less likely to occur, and the toner tends not to adhere to the fixing member. Therefore, although the toner according to the first exemplary embodiment includes the toner particles containing the binder resin including the amorphous resin and the crystalline resin, the dye, and the release agent, the difference in gloss when images are formed continuously is small.
It is therefore inferred that, with the toner according to the first exemplary embodiment, the difference in gloss that occurs when images are formed continuously is small because of the reason described above.
A toner according to a second exemplary embodiment includes toner particles containing a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent.
The ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the amorphous resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 20% or less, and the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 200% or less.
With the above-described toner according to the second exemplary embodiment, the difference in gloss when images are formed continuously is small. The reason for this may be as follows.
In the toner according to the second exemplary embodiment, the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the amorphous resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 20% or less. Therefore, the amount of the crystalline resin present on the surface of the toner particles is small. Moreover, the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 200% or less. Therefore, an appropriate amount of the release agent is present on the surface of the toner particles. Thus, with the toner according to the present exemplary embodiment, an appropriate amount of the release agent can be supplied to the fixing member during fixation. With the toner described above, defective fixation is less likely to occur, and the toner tends not to adhere to the fixing member. Therefore, although the toner according to the second exemplary embodiment includes the toner particles containing the binder resin including the amorphous resin and the crystalline resin, the dye, and the release agent, the difference in gloss between images when the images are formed continuously is small.
It is therefore inferred that, with the toner according to the second exemplary embodiment, the difference in gloss that occurs when images are formed continuously is small because of the reason described above.
A toner according to a third exemplary embodiment includes toner particles containing a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent.
In the toner, the formula: 10≤Qc1/Qc2 is satisfied. Here, Qc1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the crystalline resin in a first heating process in differential scanning calorimetry, and Qc2 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the crystalline resin in a second heating process in differential scanning calorimetry.
With the above-described toner according to the third exemplary embodiment, the difference in gloss that occurs when images are formed continuously is small. The reason for this may be as follows.
The amount of heat absorbed that is determined based on the endothermic peak derived from the crystalline resin in a heating process when the toner particles are subjected to differential scanning calorimetry is the amount of heat absorbed that is determined based on the endothermic peak of the crystalline resin phase-separated from the amorphous resin.
The amount of heat absorbed Qc1 (J/g) that is determined based on the endothermic peak derived from the crystalline resin in the first heating process represents the results of measurement performed when the amount (portion) of the crystalline resin compatibly mixed with the amorphous resin is small. The amount of heat absorbed Qc2 (J/g) that is determined based on the endothermic peak derived from the crystalline resin in the second heating process represents the results of measurement performed when the amount (portion) of the crystalline resin compatibly mixed with the amorphous resin is large. Specifically, when the ratio (Qc1/Qc2) of the amount of heat absorbed Qc1 to the amount of heat absorbed Qc2 is large, the amount (portion) of the crystalline resin compatibly mixed with the amorphous resin is small, and the amount of the phase-separated crystalline resin is large. When the ratio (Qc1/Qc2) of the amount of heat absorbed Qc1 to the amount of heat absorbed Qc2 is small, the amount (portion) of the crystalline resin compatibly mixed with the amorphous resin is large, and the amount of the phase-separated crystalline resin is small.
In the toner according to the third exemplary embodiment, the formula: 10≤Qc1/Qc2 is satisfied. Therefore, in the toner according to the third exemplary embodiment, the amount (portion) of the crystalline resin compatibly mixed with the amorphous resin tends to be small, and the amount of the phase-separated crystalline resin tends to be large. When the above formula is satisfied, the percentage of the phase-separated crystalline resin forming domains inside the toner particles tends to be large, so that the amount of the crystalline resin present on the surface of the toner particles is small. Therefore, with this toner, defective fixation is less likely to occur, and the toner tends not to adhere to the fixing member. Therefore, although the toner according to the third exemplary embodiment includes the toner particles containing the binder resin including the amorphous resin and the crystalline resin, the dye, and the release agent, the difference in gloss between images when the images are formed continuously is small.
It is therefore inferred that, with the toner according to the third exemplary embodiment, the difference in gloss that occurs when images are formed continuously is small because of the reason described above.
A toner according to a fourth exemplary embodiment includes toner particles containing a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent.
In the toner, the formula: 0.2≤Qc1/Qw1 is satisfied. Here, Qc1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the crystalline resin in a first heating process in differential scanning calorimetry, and Qw1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the release agent in the first heating process in differential scanning calorimetry.
The amount of heat absorbed that is determined based on the endothermic peak derived from the release agent in a heating process when the toner particles are subjected to differential scanning calorimetry is the amount of heat absorbed that is determined based on the endothermic peak derived from the release agent phase-separated from the binder resin.
Since the toner according to the fourth exemplary embodiment satisfies the formula: 0.2≤Qc1/Qw1, the value of Qc1 is relatively large, and the value of Qw1 is relatively small. In this case, the amount (portion) of the crystalline resin compatibly mixed with the amorphous resin tends to be small, and the portion of the release agent compatibly mixed with the binder resin tends to be large. With the toner in this state, the release agent tends to exude during fixation, and an appropriate amount of the release agent can be supplied to the fixing member.
With this toner, defective fixation is less likely to occur because of the reason described above, and the toner tends not to adhere to the fixing member. Therefore, although the toner according to the fourth exemplary embodiment includes the toner particles containing the binder resin including the amorphous resin and the crystalline resin, the dye, and the release agent, the difference in gloss when images are formed continuously is small.
A toner corresponding to all the toners according to the first to fourth exemplary embodiments (this toner is referred to also as “the toner according to the present exemplary embodiment”) will be described in detail. However, an example of the toner of the present disclosure may be a toner corresponding to any one of the toners according to the first to fourth exemplary embodiments.
Toner particles contain a binder resin including an amorphous resin and a crystalline resin, a dye, and a release agent.
Examples of the binder resin include: vinyl resins composed of homopolymers of monomers such as styrenes (such as styrene, p-chlorostyrene, and α-methylstyrene), (meth)acrylates (such as methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, lauryl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, lauryl methacrylate, and 2-ethylhexyl methacrylate), ethylenically unsaturated nitriles (such as acrylonitrile and methacrylonitrile), vinyl ethers (such as vinyl methyl ether and vinyl isobutyl ether), vinyl ketones (such as vinyl methyl ketone, vinyl ethyl ketone, and vinyl isopropenyl ketone), and olefins (such as ethylene, propylene, and butadiene); and vinyl resins composed of copolymers of combinations of two or more of the above monomers.
Other examples of the binder resin include: non-vinyl resins such as epoxy resins, polyester resins, polyurethane resins, polyamide resins, cellulose resins, polyether resins, and modified rosins; mixtures of the non-vinyl resins and the above-described vinyl resins; and graft polymers obtained by polymerizing a vinyl monomer in the presence of any of these resins.
One of these binder resins may be used alone, or two or more of them may be used in combination.
The binder resin includes the amorphous resin and the crystalline resin.
The amorphous resin exhibits only a stepwise endothermic change instead of a clear endothermic peak in thermal analysis measurement using differential scanning calorimetry (DSC), is a solid at room temperature, and is thermoplastic at temperature equal to or higher than its glass transition temperature.
The crystalline resin exhibits a clear endothermic peak instead of a stepwise endothermic change in the differential scanning calorimetry (DSC).
Specifically, the crystalline resin means that, for example, the half width of the endothermic peak measured at a heating rate of 10° C./minute is 10° C. or less, and the amorphous resin means a resin in which the half width exceeds 10° C. or a resin in which a clear endothermic peak is not observed.
The amorphous resin will be described.
Examples of the amorphous resin include well-known amorphous resins such as amorphous polyester resins, amorphous vinyl resins (such as styrene-acrylic resins), epoxy resins, polycarbonate resins, and polyurethane resins. Of these, amorphous polyester resins, and amorphous vinyl resins (particularly styrene-acrylic resins) resins are preferred, and amorphous polyester resins are more preferred.
The amorphous polyester resin is, for example, a polycondensation product of a polycarboxylic acid and a polyhydric alcohol. The amorphous polyester resin used may be a commercial product or a synthesized product.
Examples of the polycarboxylic acid include aliphatic dicarboxylic acids (such as oxalic acid, malonic acid, maleic acid, fumaric acid, citraconic acid, itaconic acid, glutaconic acid, succinic acid, alkenyl succinic acids, adipic acid, and sebacic acid), alicyclic dicarboxylic acids (such as cyclohexanedicarboxylic acid), aromatic dicarboxylic acids (such as terephthalic acid, isophthalic acid, phthalic acid, and naphthalenedicarboxylic acid), anhydrides thereof, and lower alkyl (having, for example, 1 to 5 carbon atoms) esters thereof. In particular, the polycarboxylic acid may be, for example, an aromatic dicarboxylic acid.
The polycarboxylic acid used may be a combination of a dicarboxylic acid and a tricarboxylic or higher polycarboxylic acid having a crosslinked or branched structure. Examples of the tricarboxylic or higher polycarboxylic acid include trimellitic acid, pyromellitic acid, anhydrides thereof, and lower alkyl (having, for example, 1 to 5 carbon atoms) esters thereof.
One of these polycarboxylic acids may be used alone, or two or more of them may be used in combination.
Examples of the polyhydric alcohol include aliphatic diols (such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, butanediol, hexanediol, and neopentyl glycol), alicyclic diols (such as cyclohexanediol, cyclohexanedimethanol, and hydrogenated bisphenol A), and aromatic diols (such as an ethylene oxide adduct of bisphenol A and a propylene oxide adduct of bisphenol A). In particular, the polyhydric alcohol is, for example, preferably an aromatic diol or an alicyclic diol and more preferably an aromatic diol.
The polyhydric alcohol used may be a combination of a diol and a trihydric or higher polyhydric alcohol having a crosslinked or branched structure. Examples of the trihydric or higher polyhydric alcohol include glycerin, trimethylolpropane, and pentaerythritol.
One of these polyhydric alcohols may be used alone, or two or more of them may be used in combination.
The amorphous polyester resin is obtained by a well-known production method. Specifically, the amorphous polyester resin is obtained, for example, by the following method. The polymerization temperature is set to from 180° C. to 230° C. inclusive. If necessary, the pressure inside the reaction system is reduced, and the reaction is allowed to proceed while water and alcohol generated during condensation are removed.
When the raw material monomers are not dissolved or not compatible with each other at the reaction temperature, a high-boiling point solvent may be added as a solubilizer to dissolve the monomers. In this case, the polycondensation reaction is performed while the solubilizer is removed by evaporation. When a monomer with poor compatibility is present, the monomer with poor compatibility and an acid or an alcohol to be polycondensed with the monomer are condensed in advance, and then the resulting polycondensation product and the rest of the components are subjected to polycondensation.
Examples of the amorphous polyester resin other than the unmodified amorphous polyester resins described above include modified amorphous polyester resins. The modified amorphous polyester resin is an amorphous polyester resin including a bonding group other than the ester bonds or an amorphous polyester resin including a resin component that is different from the amorphous polyester resin component and is bonded through a covalent bond, an ionic bond, etc. Examples of the modified amorphous polyester resin include: an amorphous polyester resin in which a functional group such as an isocyanate group reactable with an acid group or a hydroxy group is introduced into an end of the resin; and a resin reacted with an active hydrogen compound to modify an end of the resin.
The modified amorphous polyester resin may be an amorphous polyester resin modified with urea (hereinafter referred to simply as a “urea-modified polyester resin”).
When the binder resin contains a urea-modified polyester resin as the amorphous polyester resin, the effect of improving releasability may be obtained by controlling the molecular weight distribution and viscoelasticity of the urea-modified polyester resin, so that the difference in gloss that occurs when images are formed continuously can be further reduced.
The urea-modified polyester resin may be obtained by the reaction of an amorphous polyester resin having isocyanate groups (amorphous polyester prepolymer) with an amine compound (at least one of a crosslinking reaction and an elongation reaction). The urea-modified polyester resin may have urethane bonds in addition to the urea bonds.
Examples of the amorphous polyester prepolymer having isocyanate groups include amorphous polyester resins that are polycondensation products of polycarboxylic acids and polyhydric alcohols, i.e., amorphous polyester prepolymers obtained by reacting amorphous polyester resins having active hydrogen with polyisocyanate compounds. Examples of the group having active hydrogen and included in the amorphous polyester resin include hydroxy groups (such as an alcoholic hydroxy group and a phenolic hydroxy group), an amino group, a carboxyl group, and a mercapto group, and the group having active hydrogen may by an alcoholic hydroxy group.
For the amorphous polyester prepolymer having isocyanate groups, the polycarboxylic acids and the polyhydric alcohols may be the same as the compounds explained as the polycarboxylic acids and the polyhydric alcohols for the amorphous polyester resin.
Examples of the polyisocyanate compound include: aliphatic polyisocyanates (such as tetramethylene diisocyanate, hexamethylene diisocyanate, and 2,6-diisocyanatomethyl caproate); alicyclic polyisocyanates (such as isophorone diisocyanate and cyclohexylmethane diisocyanate); aromatic diisocyanates (such as tolylene diisocyanate and diphenylmethane diisocyanate); aromatic aliphatic diisocyanates (such as α,α,α′,α′-tetramethylxylylene diisocyanate); isocyanurates; and compounds obtained by blocking the above polyisocyanates with blocking agents such as phenol derivatives, oximes, and caprolactam.
One of these polyisocyanate compounds may be used alone, or two or more of them may be used in combination.
The ratio of the polyisocyanate compound in terms of the equivalent ratio [NCO]/[OH] of the isocyanate groups [NCO] to the hydroxy groups [OH] in the amorphous polyester prepolymer having hydroxy groups is preferably from 1/1 to 5/1 inclusive, more preferably from 1.2/1 to 4/1 inclusive, and still more preferably from 1.5/1 to 2.5/1 inclusive.
In the amorphous polyester prepolymer having isocyanate groups, the content of a component derived from the polyisocyanate compound with respect to the total mass of the amorphous polyester prepolymer having isocyanate groups is preferably from 0.5% by mass to 40% by mass inclusive, more preferably from 1% by mass to 30% by mass inclusive, and still more preferably from 2% by mass to 20% by mass inclusive.
The average number of isocyanate groups per molecule of the amorphous polyester prepolymer having isocyanate groups is preferably 1 or more, more preferably from 1.5 to 3 inclusive, and still more preferably from 1.8 to 2.5 inclusive.
Examples of the amine compound to be reacted with the amorphous polyester prepolymer having isocyanate groups include diamines, polyamines having three or more amino groups, amino alcohols, amino mercaptans, amino acids, and these amines with a blocked amino group.
Examples of the diamines include: aromatic diamines (such as phenylenediamine, diethyltoluenediamine, and 4,4′-diaminodiphenylmethane); alicyclic diamines (such as 4,4′-diamino-3,3′-dimethyldicyclohexylmethane, diaminecyclohexane, and isophoronediamine); and aliphatic diamines (such as ethylenediamine, tetramethylenediamine, and hexamethylenediamine).
Examples of the polyamines having three or more amino groups include diethylenetriamine and triethylenetetramine.
Examples of the amino alcohols include ethanolamine and hydroxyethyl aniline.
Examples of the amino mercaptans include aminoethyl mercaptan and aminopropyl mercaptan.
Examples of the amino acids include aminopropionic acid and aminocaproic acid.
Examples of the amines with a blocked amino group include oxazoline compounds and ketimine compounds obtained from amine compounds such as diamines, polyamines having three or more amino groups, amino alcohols, amino mercaptans, and amino acids and ketone compounds (such as acetone, methyl ethyl ketone, and methyl isobutyl ketone).
Of these amine compounds, ketimine compounds may be used.
One of these amine compounds may be used alone, or two or more of them may be used in combination.
The urea-modified polyester resin may have a molecular weight controlled using a terminator that terminates at least one of the crosslinking reaction and the elongation reaction (the terminator is hereinafter referred to also as a “crosslinking/elongation reaction terminator”) to control the reaction of the amorphous polyester resin having isocyanate groups (amorphous polyester prepolymer) with the amine compound (at least one of the crosslinking reaction and the elongation reaction).
Examples of the crosslinking/elongation reaction terminator include monoamines (such as diethylamine, dibutylamine, butylamine, and laurylamine) and blocked compounds thereof (ketimine compounds).
The ratio of the amine compound in terms of the equivalent ratio [NCO]/[NHx] of the isocyanate groups [NCO] in the amorphous polyester prepolymer having isocyanate groups to the amino groups [NHx] in the amine is preferably from 1/2 to 2/1 inclusive, more preferably from 1/1.5 to 1.5/1 inclusive, and still more preferably from 1/1.2 to 1.2/1 inclusive.
The properties of the amorphous resin will be described.
The glass transition temperature (Tg) of the amorphous resin may be from 45° C. to 60° C. inclusive, may be from 48° C. to 65° C. inclusive, and may be from 50° C. to 60° C. inclusive.
When the glass transition temperature Tg of the amorphous resin is within the above range, the adhesion of the toner to the fixing member is more likely to occur during fixation. However, with the toner according to the present exemplary embodiment, even when the glass transition temperature Tg of the amorphous resin is within the above range, the difference in gloss that occurs when images are formed continuously can be reduced by controlling the content of the crystalline resin on the surface of the toner particles.
The glass transition temperature is determined using a DSC curve obtained by differential scanning calorimetry (DSC). More specifically, the glass transition temperature is determined from “extrapolated glass transition onset temperature” described in a glass transition temperature determination method in “Testing methods for transition temperatures of plastics” in JIS K 7121-1987.
The weight average molecular weight (Mw) of the amorphous resin is preferably from 5000 to 1000000 inclusive and more preferably from 7000 to 500000 inclusive.
The number average molecular weight (Mn) of the amorphous resin may be from 2000 to 100000 inclusive.
The molecular weight distribution Mw/Mn of the amorphous resin is preferably from 1.5 to 100 inclusive and more preferably from 2 to 60 inclusive.
The weight average molecular weight and the number average molecular weight are measured by gel permeation chromatography (GPC). In the molecular weight distribution measurement by GPC, a GPC measurement apparatus HLC-8120GPC manufactured by TOSOH Corporation is used. A TSKgel Super HM-M (15 cm) column manufactured by TOSOH Corporation and a THF solvent are used. The weight average molecular weight and the number average molecular weight are computed from the measurement results using a molecular weight calibration curve produced using monodispersed polystyrene standard samples.
The crystalline resin will be described.
Examples of the crystalline resin include well-known crystalline resins such as crystalline polyester resins and crystalline vinyl resins (such as polyalkylene resins and long chain alkyl (meth)acrylate resins). Of these, crystalline polyester resins are preferred from the viewpoint of the mechanical strength of the toner and its low-temperature fixability.
The crystalline polyester resin is, for example, a polycondensation product of a polycarboxylic acid and a polyhydric alcohol. The crystalline polyester resin used may be a commercial product or a synthesized product.
To facilitate the formation of the crystalline structure in the crystalline polyester resin, a polycondensation product obtained using a polymerizable monomer having a linear aliphatic group is preferable to that obtained using a polymerizable monomer having an aromatic group.
Examples of the polycarboxylic acid include aliphatic dicarboxylic acids (such as oxalic acid, succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, 1,9-nonanedicarboxylic acid, 1,10-decanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, 1,14-tetradecanedicarboxylic acid, and 1,18-octadecanedicarboxylic acid), aromatic dicarboxylic acids (for example, dibasic acids such as phthalic acid, isophthalic acid, terephthalic acid, and naphthalene-2,6-dicarboxylic acid), anhydrides thereof, and lower alkyl (having, for example, 1 to 5 carbon atoms) esters thereof.
The polycarboxylic acid used may be a combination of a dicarboxylic acid and a tricarboxylic or higher polycarboxylic acid having a crosslinked or branched structure. Examples of the tricarboxylic acid include aromatic carboxylic acids (such as 1,2,3-benzenetricarboxylic acid, 1,2,4-benzenetricarboxylic acid, and 1,2,4-naphthalene tricarboxylic acid), anhydrides thereof, and lower alkyl (having, for example, 1 to 5 carbon atoms) esters thereof.
The polycarboxylic acid used may be a combination of a dicarboxylic acid, a dicarboxylic acid having a sulfonic acid group, and a dicarboxylic acid having an ethylenic double bond.
One of these polycarboxylic acids may be used alone, or two or more of them may be used in combination.
The polyhydric alcohol is, for example, an aliphatic diol (e.g., a linear aliphatic diol with a main chain having 7 to 20 carbon atoms). Examples of the aliphatic diol include ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 1,11-undecanediol, 1,12-dodecanediol, 1,13-tridecanediol, 1,14-tetradecanediol, 1,18-octadecanediol, and 1,14-eicosanedecanediol. In particular, the aliphatic diol is preferably 1,8-octanediol, 1,9-nonanediol, or 1,10-decanediol.
The polyhydric alcohol used may be a combination of a diol and a trihydric or higher polyhydric alcohol having a crosslinked or branched structure. Examples of the trihydric or higher polyhydric alcohol include glycerin, trimethylolethane, trimethylolpropane, and pentaerythritol.
One of these polyhydric alcohols may be used alone, or two or more of them may be used in combination.
In the polyhydric alcohol, the content of the aliphatic diol may be 80% by mole or more and preferably 90% by mole or more.
The melting temperature of the crystalline polyester resin may be from 60° C. to 80° C. inclusive, may be from 62° C. to 75° C. inclusive, and may be from 65° C. to 70° C. inclusive.
The melting temperature is determined using a DSC curve obtained by differential scanning calorimetry (DSC) from “peak melting temperature” described in melting temperature determination methods in “Testing methods for transition temperatures of plastics” in JIS K7121-1987.
The weight average molecular weight (Mw) of the crystalline polyester resin may be from 6,000 to 35,000 inclusive.
Like, for example, the amorphous polyester resin, the crystalline polyester resin is obtained, for example, by a well-known production method.
The properties of the crystalline resin will be described.
The melting temperature Tm of the crystalline resin may be from 60° C. to 80° C. inclusive, may be from 62° C. to 75° C. inclusive, and may be from 65° C. to 70° C. inclusive.
When the melting temperature Tm of the crystalline resin is within the above range, the adhesion of the toner to the fixing member is more likely to occur during fixation. However, with the toner according to the present exemplary embodiment, even when the melting temperature Tm of the crystalline resin is within the above range, the difference in gloss that occurs when images are formed continuously can be reduced by controlling the content of the crystalline resin on the surface of the toner particles.
The melting temperature is determined using a DSC curve obtained by differential scanning calorimetry (DSC) from “peak melting temperature” described in melting temperature determination methods in “Testing methods for transition temperatures of plastics” in JIS K7121-1987.
The weight average molecular weight (Mw) of the crystalline resin may be from 6000 to 35000 inclusive.
The content of the binder resin is, for example, preferably from 40% by mass to 95% by mass inclusive, more preferably from 50% by mass to 90% by mass inclusive, and still more preferably from 60% by mass to 85% by mass inclusive based on the total mass of the toner particles.
The content of the crystalline resin is preferably from 1% by mass to 12% by mass inclusive, more preferably from 3% by mass to 10% by mass inclusive, and still more preferably from 5% by mass to 8% by mass inclusive based on the total mass of the toner particles.
When the content of the crystalline resin is within the above range, insufficient melting in a low-temperature range and insufficient viscoelasticity in a high-temperature range may be prevented, so that the occurrence of image offset to the fixing member may be reduced. Therefore, the difference in gloss that occurs when images are formed continuously is further reduced.
The toner particles contain the dye.
The “dye” is a coloring agent whose solubility in 100 g of water at 23° C. or solubility in 100 g of cyclohexanone at 23° C. is 0.1 g or more.
No particular limitation is imposed on the dye, and examples of the dye include basic dyes, acidic dyes, mordant dyes, acidic mordant dyes, direct dyes, disperse dyes, sulfide dyes, vat dyes, azoic dyes, oxidation dyes, reactive dyes, oil-soluble dyes, food colors, natural dyes, and fluorescent brightening agents.
One of these dyes may be used alone, or two or more of them may be used in combination.
From the viewpoint of color forming properties, the dye may be a basic dye.
When the dye is a basic dye, the difference in gloss that occurs when images are formed continuously tends to increase because the affinity of the basic dye for the crystalline resin is lower than that of other types of dyes. However, in the toner according to the present exemplary embodiment, the content of the crystalline resin on the surface of the toner particles is 15% or less. Therefore, the amount of the crystalline resin present on the surface of the toner particles is low. In this case, even when the dye is a basic dye, the difference in gloss that occurs when images are formed continuously is reduced.
When the dye is a basic dye and is at least one selected from rhodamine-based dyes having a cationic group and azo-based dyes having a cationic group, the difference in gloss that occurs when images are formed continuously tends to increase because the affinity of these basic dyes for the crystalline resin tends to be particularly low. However, in the toner according to the present exemplary embodiment, the content of the crystalline resin on the surface of the toner particles is 15% or less. Therefore, the amount of the crystalline resin present on the surface of the toner particles is low. In this case, even when the dye is the basic dye, the difference in gloss that occurs when images are formed continuously is reduced.
The basic dye will be described specifically.
The basic dye is a dye having a cationic group.
The cationic group is preferably an onium group, more preferably an ammonium group, an iminium group, or a pyridinium group, still more preferably an ammonium group, and particularly preferably a quaternary ammonium group.
The basic dye may have only one cationic group or may have two or more cationic groups. From the viewpoint of fluorescence intensity, the basic dye has preferably 1 to 4 cationic groups, more preferably one or two cationic groups, and particularly preferably only one cationic group.
Specific examples of the basic dye include diazine-based dyes having a cationic group, oxazine-based dyes having a cationic group, thiazine-based dyes having a cationic group, azo-based dyes having a cationic group, anthraquinone-based dyes having a cationic group, rhodamine-based dyes having a cationic group, triarylmethane-based dyes having a cationic group, phthalocyanine-based dyes having a cationic group, auramine-based dyes having a cationic group, acridine-based dyes having a cationic group, and methine-based dyes having a cationic group.
More specific examples of the basic dye include dyes described below. For example, “Basic Red 2” is referred to also as “C.I. Basic Red 2.”
The diazine-based dye having a cationic group is a dye having, in its molecule, a cationic group and a diazine skeleton.
Specific examples of the diazine-based dye having a cationic group include Basic Red 2, 5, 6, and 10, Basic Blue 13, 14, and 16, Basic Violet 5, 6, 8, and 12, and Basic Yellow 14.
The oxazine-based dye having a cationic group is a dye having, in its molecule, a cationic group and an oxazine skeleton.
Specific example of the oxazine-based dye having a cationic group include Basic Blue 3, 6, 10, 12, and 74.
The thiazine-based dye having a cationic group is a dye having, in its molecule, a cationic group and a thiazine skeleton.
Specific examples of the thiazine-based dye having a cationic group include Basic Blue 9, 17, 24, and 25 and Basic Green 5.
The azo-based dye having a cationic group is a dye having, in its molecule, a cationic group and an azo group.
Specific examples of the azo-based dye having a cationic group include Basic Red 18, 22, 23, 24, 29, 30, 31, 32, 34, 38, 39, 46, 51, 53, 54, 55, 62, 64, 76, 94, 111, and 118, Basic Blue 41, 53, 54, 55, 64, 65, 66, 67, and 162, Basic Violet 18 and 36, Basic Yellow 15, 19, 24, 25, 28, 29, 38, 39, 49, 51, 57, 62, and 73, and Basic Orange 1, 2, 24, 25, 29, 30, 33, 54, and 69.
The anthraquinone-based dye having a cationic group is a dye having, in its molecule, a cationic group and an anthraquinone skeleton.
Specific examples of the anthraquinone-based dye having a cationic group include Basic Blue 22, 44, 47, and 72.
The rhodamine-based dye having a cationic group is a dye having, in its molecule, a cationic group and a rhodamine skeleton.
The rhodamine skeleton is a structure represented by the following formula (1).
Specific examples of the rhodamine-based dye having a cationic group include Basic Red 1, 1:1, 3, 4, 8, and 11 and Basic Violet 10, 11, and 11:1.
The triarylmethane-based dye having a cationic group is a dye having, in its molecule, a cationic group and a triarylmethane skeleton. The triarylmethane skeleton is a structure having three aryl groups on one carbon atom.
Examples of the triarylmethane-based dye having a cationic group include Basic Red 9, Basic Blue 1, 2, 5, 7, 8, 11, 15, 18, 20, 23, 26, 35, and 81, Basic Violet 1, 2, 3, 4, 14, and 23, and Basic Green 1 and 4.
The phthalocyanine-based dye having a cationic group is a dye having, in its molecule, a cationic group and a phthalocyanine skeleton.
Specific examples of the phthalocyanine-based dye having a cationic group include Basic Blue 140.
The auramine-based dye having a cationic group is a dye having, in its molecule, a cationic group and an auramine skeleton.
Examples of the auramine-based dye having a cationic group include Basic Yellow 2, 3, and 37.
The acridine-based dye having a cationic group is a dye having, in its molecule, a cationic group and an acridine skeleton.
Examples of the acridine-based dye having a cationic group include Basic Yellow 5, 6, 7, and 9 and Basic Orange 4, 5, 14, 15, 16, 17, 18, 19, and 23.
The methine-based dye having a cationic group is a dye having, in its molecule, a cationic group and an indole skeleton.
Examples of the methine-based dye having a cationic group include Basic Red 12, 13, 14, 15, 27, 28, 37, 52, and 90, Basic Yellow 11, 13, 20, 21, 52, and 53, Basic Orange 21 and 22, and Basic Violet 7, 15, 16, 20, 21, and 22.
The ratio of the amount of the dye to the amount of the crystalline resin is preferably from 5% by mass to 40% by mass inclusive, more preferably from 8% by mass to 30% by mass inclusive, and still more preferably form 10% by mass to 20% by mass inclusive.
When the content of the dye is within the above range, the difference in gloss that occurs when images are formed continuously is further reduced.
The reason for this may be as follows.
When the ratio of the amount of the dye to the amount of the crystalline resin is 5% by mass or more, the amount of the amorphous resin and the crystalline resin compatibly mixed with each other is reduced, so that the fixability in the low-temperature range may be improved. When the ratio of the amount of the dye to the amount of the crystalline resin is 40% by mass or less, viscoelasticity increases due to a filler effect, and the releasability in a high-temperature range is improved. Therefore, the difference in gloss that occurs when images are formed continuously is further reduced.
Examples of the release agent include: hydrocarbon-based waxes; natural waxes such as carnauba wax, rice wax, and candelilla wax; synthetic and mineral/petroleum-based waxes such as montan wax; and ester-based waxes such as fatty acid esters and montanic acid esters. However, the release agent is not limited to these waxes.
The melting temperature of the release agent is preferably from 50° C. to 110° C. inclusive and more preferably from 60° C. to 100° C. inclusive.
The melting temperature is determined using a DSC curve obtained by differential scanning calorimetry (DSC) from “peak melting temperature” described in melting temperature determination methods in “Testing methods for transition temperatures of plastics” in JIS K7121-1987.
From the viewpoint of reducing the difference in gloss that occurs when images are formed continuously, the content of the release agent is, for example, preferably from 1.0% by mass to 20.0% by mass inclusive, from 5.0% by mass to 15.0% by mass inclusive, and still more preferably from 5.0% by mass to 10.0% by mass inclusive based on the total mass of the toner particles.
From the viewpoint of reducing the difference in gloss that occurs when images are formed continuously, the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is preferably from 20% to 50% inclusive, more preferably from 25% to 45% inclusive, and particularly preferably from 30% to 40% inclusive.
The procedure for measuring the content of the release agent on the surface of the toner particles will be described later.
In particular, the content of the release agent with respect to the mass of the toner particles may be from 5.0% by mass to 10.0% by mass inclusive, and the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy may be from 3% to 15% inclusive.
When the content of the release agent is within the above range and an appropriate amount of the release agent is present on the surface of the toner particles, the release agent is likely to exude during fixation, and defective fixation of the toner is further prevented, so that the adhesion of the toner to the fixing member may be prevented. Therefore, the difference in gloss that occurs when images are formed continuously is further reduced.
Examples of additional additives include well-known additives such as a magnetic material, a charge control agent, and an inorganic powder. These additives are contained in the toner particles as internal additives.
A pigment may be used as a coloring agent in combination with the dye.
Examples of the pigment include various pigments such as carbon black, chrome yellow, Hansa yellow, benzidine yellow, threne yellow, quinoline yellow, pigment yellow, permanent orange GTR, pyrazolone orange, vulcan orange, watchung red, permanent red, brilliant carmine 3B, brilliant carmine 6B, DuPont oil red, pyrazolone red, lithol red, rhodamine B lake, lake red C, pigment red, rose bengal, aniline blue, ultramarine blue, calco oil blue, methylene blue chloride, phthalocyanine blue, pigment blue, phthalocyanine green, and malachite green oxalate.
The percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 15% or less.
The procedure for measuring the content of the crystalline resin on the surface of the toner particles will be described later.
The percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is preferably from 1% to 8% inclusive and more preferably from 3% to 5% inclusive.
When the content of the crystalline resin on the surface of the toner particles is within the above range, the amount of the crystalline resin present on the surface of the toner particles is further reduced while the low-temperature fixability is maintained. Therefore, when images are formed continuously, the difference in gloss between the images is further reduced.
When the crystalline resin and the amorphous resin are mixed insufficiently during fixation onto a recording medium, image strength may decrease in some cases. However, when the content of the crystalline resin on the surface of the toner particles is within the above range, the crystalline resin and the amorphous resin are easily mixed during fixation onto a recording medium, and therefore the image strength may be improved.
In the toner according to the present exemplary embodiment, the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the amorphous resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 20% or less.
Moreover, the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is 200% or less.
From the viewpoint of reducing the difference in gloss that occurs when images are formed continuously, the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the amorphous resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is preferably from 1% to 20% inclusive, more preferably from 2% to 12% inclusive, and still more preferably from 3% to 8% inclusive.
From the viewpoint of reducing the difference in gloss that occurs when images are formed continuously, the ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is preferably from 5% to 200% inclusive, more preferably from 10% to 80% inclusive, and still more preferably from 20% to 40% inclusive.
The percentages of the crystalline resin, the amorphous resin, and the release agent on the surface of the toner particles are determined by XPS (X-ray photoelectron spectroscopy) measurement. The XPS measurement device used is JPS-9000MX manufactured by JEOL Ltd., and the measurement is performed using the MgKα line as an X-ray source at an acceleration voltage of 10 kV and an emission current of 30 mA.
First, attention is given to the percentage of carbon atoms to identify the release agent, the amorphous resin, and the crystalline resin among the components contained in the toner particles in the toner used as the measurement target. Then each of the release agent, the amorphous resin, and the crystalline resin contained in the toner particles in the toner used as the measurement target is independently subjected to XPS measurement to obtain a C1S spectrum. Next, the toner used as the measurement target is subjected to XPS measurement to quantify the percentages of the crystalline resin, the amorphous resin, and the release agent on the surface of the toner particles.
The percentages of the crystalline resin, the amorphous resin, and the release agent on the surface of the toner particles are quantified by subjecting the C1S spectrum to peak separation. In the peak separation method, the measured C1S spectrum is separated into individual components using least square curve fitting. For each of the release agent, the amorphous resin, and the crystalline resin contained in the toner particles in the toner used as the measurement target, the C1S spectrum of the component alone measured in advance is used as a component spectrum for a base of the separation.
The percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is the ratio of the C1S spectrum intensity of the crystalline resin on the surface of the toner particles to the C1S spectrum intensity on the surface of the toner particles.
The percentage of the amorphous resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is the ratio of the C1S spectrum intensity of the amorphous resin on the surface of the toner particles to the C1S spectrum intensity on the surface of the toner particles.
The percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy is the ratio of the C1S spectrum intensity of the release agent on the surface of the toner particles to the C1S spectrum intensity on the surface of the toner particles
In the toner according to the present exemplary embodiment, the formula: 10≤Qc1/Qc2 is satisfied. Here, Qc1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the crystalline resin in a first heating process in differential scanning calorimetry, and Qc2 (J/g) is the amount of heat absorbed that is determined based on a endothermic peak derived from the crystalline resin in a second heating process.
From the viewpoint of reducing the difference in gloss that occurs when images are formed continuously, Qc1 and Qc2 satisfy preferably the formula: 10≤Qc1/Qc2≤30, more preferably the formula: 12≤Qc1/Qc2≤25, and still more preferably the formula: 15≤Qc1/Qc2≤20.
In the toner according to the present exemplary embodiment, the formula: 0.2≤Qc1/Qw1 is satisfied. Here, Qc1 (J/g) is the amount of heat absorbed that is determined based on the endothermic peak derived from the crystalline resin in the first heating process in differential scanning calorimetry, and Qw1 (J/g) is the amount of heat absorbed that is determined based on an endothermic peak derived from the release agent in the first heating process.
From the viewpoint of reducing the difference in gloss that occurs when images are formed continuously, Qc1 and Qw1 satisfy preferably the formula: 0.2≤Qc1/Qw1≤0.6, more preferably the formula: 0.3≤Qc1/Qw1≤0.5, and still more preferably the formula: 0.35≤Qc1/Qw1≤0.45.
Qc1, Qc2, and Qw1 of the measurement target toner are measured according to ASTM D3418-8 (2008) as follows.
First, 10 mg of the measurement target toner is placed in a differential scanning calorimeter (DSC-60A manufactured by Shimadzu Corporation) equipped with an automatic tangent line processing system, heated from room temperature (25° C.) to 150° C. at a heating rate of 10° C./minute, and held at 150° C. for 5 minutes to thereby obtain a heating spectrum (DSC curve) in a first heating process.
Next, the toner is cooled using liquid nitrogen to 0° C. at a cooling rate of −10° C./minute and held at 0° C. for 5 minutes.
Then the toner is heated to 150° C. at a heating rate of 10° C./minute to obtain a heating spectrum (DSC curve) in a second heating process.
The endothermic peak derived from the crystalline resin and the endothermic peak derived from the release agent are identified in each of the obtained two heating spectra (DSC curves). Specifically, the two heating spectra are compared with the DSC chart of the crystalline resin alone and the DSC chart of the release agent alone that have been measured in advance, and endothermic peaks present in the same temperature range as that of the endothermic peak in the DSC chart of the crystalline resin alone are determined as the endothermic peaks derived from the crystalline resin. An endothermic peak is a peak with a half width of 15° C. or less.
The areas of the endothermic peaks derived from the crystalline resin in the heating spectra are computed and used as the amounts of heat absorbed Qc1 and Qc2. The area of the endothermic peak derived from the release agent in the heating spectrum in the first heating process is computed and used as the amount of heat absorbed Qw1.
The area of each of the endothermic peaks derived from the crystalline resin and the release agent is the area of a region surrounded by a base line and the endothermic peak and is determined according to ASTM D3418-8 (2008). Then the amounts of heat absorbed per mass of the sample are determined from the areas of the endothermic peaks, and the amounts of heat absorbed that are derived from the crystalline resin and the amount of heat absorbed that is derived from the release agent are thereby computed.
—Properties Etc. Of Toner Particles—
The toner particles may have a single layer structure or may be core-shell toner particles having a so-called core-shell structure including a core (core particle) and a coating layer (shell layer) covering the core.
The toner particles having the core-shell structure may each include, for example: a core containing the binder resin and optional additives such as the coloring agent and the release agent; and a coating layer containing the binder resin.
The volume average particle diameter (D50v) of the toner particles is preferably from 2 μm to 10 μm inclusive and more preferably from 4 μm to 8 μm inclusive.
Various average particle diameters of the toner particles and their various particle size distribution indexes are measured using Coulter Multisizer II (manufactured by Beckman Coulter, Inc.), and ISOTON-II (manufactured by Beckman Coulter, Inc.) is used as an electrolyte.
In the measurement, 0.5 mg or more and 50 mg or less of a measurement sample is added to 2 mL of a 5% aqueous solution of a surfactant (for example, sodium alkylbenzenesulfonate) serving as a dispersant. The mixture is added to 100 mL or more and 150 mL or less of the electrolyte.
The electrolyte with the sample suspended therein is subjected to dispersion treatment for 1 minute using an ultrasonic dispersion apparatus, and then the particle size distribution of particles having diameters within the range of from 2 μm to 60 μm inclusive is measured using the Coulter Multisizer II with an aperture having an aperture diameter of 100 μm. The number of particles sampled is 50000.
The particle size distribution measured and divided into particle size ranges (channels) is used to obtain volume-based and number-based cumulative distributions computed from the small diameter side. In the volume-based cumulative distribution, the particle diameter at a cumulative frequency of 16% is defined as a volume-based particle diameter D16v, and the particle diameter at a cumulative frequency of 50% is defined as a volume average particle diameter D50v. Moreover, the particle diameter at a cumulative frequency of 84% is defined as a volume-based particle diameter D84v. In the number-based cumulative distribution, the particle diameter at a cumulative frequency of 16% is defined as a number-based diameter D16p, and the particle diameter at a cumulative frequency of 50% is defined as a number average cumulative particle diameter D50p. Moreover, the particle diameter at a cumulative frequency of 84% is defined as a number-based diameter D84p.
These are used to compute a volume-based particle size distribution index (GSDv) defined as (D84v/D16v)1/2 and a number-based particle size distribution index (GSDp) defined as (D84p/D16p)1/2.
The average circularity of the toner particles is preferably from 0.94 to 1.00 inclusive and more preferably from 0.95 to 0.98 inclusive.
The circularity of a toner particle is determined as (the peripheral length of an equivalent circle of the toner particle)/(the peripheral length of the toner particle) [i.e., (the peripheral length of a circle having the same area as a projection image of the particle)/(the peripheral length of the projection image of the particle)]. Specifically, the average circularity is a value measured by the following method.
First, the toner particles used for the measurement are collected by suction, and a flattened flow of the particles is formed. Particle images are captured as still images using flashes of light, and the average circularity is determined by subjecting the particle images to image analysis using a flow-type particle image analyzer (FPIA-3000 manufactured by SYSMEX Corporation). The number of particles sampled for determination of the average circularity is 3500.
When the toner contains the external additive, the toner (developer) for the measurement is dispersed in water containing a surfactant, and the dispersion is subjected to ultrasonic treatment. The toner particles with the external additive removed are thereby obtained.
Examples of the external additive include inorganic particles. Examples of the inorganic particles include SiO2, TiO2, Al2O3, CuO, ZnO, SnO2, CeO2, Fe2O3, MgO, BaO, CaO, K2O, Na2O, ZrO2, CaO.SiO2, K2O.(TiO2)n, Al2O3.2SiO2, CaCO3, MgCO3, BaSO4, and MgSO4.
The surface of the inorganic particles used as the external additive may be subjected to hydrophobic treatment. The hydrophobic treatment is performed, for example, by immersing the inorganic particles in a hydrophobic treatment agent. No particular limitation is imposed on the hydrophobic treatment agent, and examples thereof include silane-based coupling agents, silicone oils, titanate-based coupling agents, and aluminum-based coupling agents. Any of these coupling agents may be used alone or in combination of two or more.
The amount of the hydrophobic treatment agent is generally, for example, from 1 part by mass to 10 parts by mass inclusive based on 100 parts by mass of the inorganic particles.
Other examples of the external additive include resin particles (particles of resins such as polystyrene, polymethyl methacrylate (PMMA), and melamine resins) and a cleaning activator (a metal salt of a higher fatty acid typified by zinc stearate or particles of a fluorine-based high-molecular weight material).
The amount of the external additives is, for example, preferably from 0.01% by mass to 5% by mass inclusive and more preferably from 0.01% by mass to 2.0% by mass inclusive based on the mass of the toner particles.
Next, a method for producing the toner according to the present exemplary embodiment will be described.
The toner according to the present exemplary embodiment is obtained by producing toner particles and then externally adding the external additive to the toner particles produced.
The toner particles may be produced by a dry production method (such as a kneading-grinding method) or by a wet production method (such as an aggregation/coalescence method, a suspension polymerization method, or a dissolution/suspension method). No particular limitation is imposed on the toner particle production method, and any known production method may be used.
In particular, the aggregation/coalescence method may be used to obtain the toner particles.
Next, a method for producing the toner according to the present exemplary embodiment will be described.
The toner according to the present exemplary embodiment is obtained by producing toner particles, subjecting the obtained toner particles to annealing treatment, and externally adding an external additive to the toner particles subjected to the annealing treatment.
The toner particles may be produced by a dry production method (such as a kneading-grinding method) or by a wet production method (such as an aggregation/coalescence method, a suspension polymerization method, or a dissolution/suspension method). No particular limitation is imposed on the toner particle production method, and any known production method may be used.
First, a method for producing the toner particles using the aggregation/coalescence method will be described.
The toner particles are produced through: the step of preparing a resin particle dispersion in which resin particles used as the binder resin are dispersed (a resin particle dispersion preparing step); the step of forming aggregated particles by aggregating the resin particles (and other optional particles) in the resin particle dispersion (or in a dispersion obtained by mixing another optional particle dispersion) (an aggregated particle forming step); and the step of forming the toner particles by heating the aggregated particle dispersion containing the aggregated particles dispersed therein to fuse and coalesce the aggregated particles (a fusion/coalescence step).
The resin particle dispersion used contains an amorphous resin particle dispersion containing amorphous resin particles dispersed therein and a crystalline resin particle dispersion containing crystalline resin particles dispersed therein. The resin particle dispersion used may be an amorphous resin particle dispersion in which resin particles containing the amorphous resin and the crystalline resin are dispersed.
These steps will next be described in detail.
In the following description, a method for obtaining toner particles containing the coloring agent (i.e., the dye and an optional pigment) and the release agent will be described. Of course, additional additives other than the coloring agent and the release agent may be used.
The resin particle dispersion in which the resin particles used as the binder resin are dispersed is first prepared. Moreover, for example, a coloring agent dispersion in which the coloring agent is dispersed and a release agent particle dispersion in which release agent particles are dispersed are prepared.
The resin particle dispersion is prepared, for example, by dispersing the resin particles in a dispersion medium using a surfactant.
Examples of the dispersion medium used for the resin particle dispersion include aqueous mediums.
Examples of the aqueous medium include: water such as distilled water and ion exchanged water; and alcohols. One of these aqueous mediums may be used alone, or two or more of them may be used in combination.
Examples of the surfactant include: anionic surfactants such as sulfate-based surfactants, sulfonate-based surfactants, phosphate-based surfactants, and soap-based surfactants; cationic surfactants such as amine salt-based surfactants and quaternary ammonium salt-based surfactants; and nonionic surfactants such as polyethylene glycol-based surfactants, alkylphenol ethylene oxide adduct-based surfactants, and polyhydric alcohol-based surfactants. Of these, an anionic surfactant or a cationic surfactant may be used. A nonionic surfactant may be used in combination with the anionic surfactant or the cationic surfactant.
One of these surfactants may be used alone, or two or more of them may be used in combination.
To disperse the resin particles in the dispersion medium to form the resin particle dispersion, a commonly used dispersing method that uses, for example, a rotary shearing-type homogenizer, a ball mill using media, a sand mill, or a dyno-mill may be used. The resin particles may be dispersed in the dispersion medium by, for example, a phase inversion emulsification method, but this depends on the type of resin particles.
In the phase inversion emulsification method, the resin to be dispersed is dissolved in a hydrophobic organic solvent that can dissolve the resin, and a base is added to an organic continuous phase (O phase) to neutralize it. Then the aqueous medium (W phase) is added to change the form of the resin from W/O to O/W (so-called phase inversion) to thereby form a discontinuous phase, and the resin is thereby dispersed as particles in the aqueous medium.
The volume average particle diameter of the resin particles dispersed in the resin particle dispersion is, for example, preferably from 0.01 μm to 1 μm inclusive, more preferably from 0.08 μm to 0.8 μm inclusive, and still more preferably from 0.1 μm to 0.6 μm inclusive.
The volume average particle diameter of the resin particles is measured as follows. A particle size distribution measured by a laser diffraction particle size measurement apparatus (e.g., LA-700 manufactured by HORIBA Ltd.) is used and divided into different particle diameter ranges (channels), and a cumulative volume distribution computed from the small particle diameter side is determined. The particle diameter at a cumulative frequency of 50% is measured as the volume average particle diameter D50v. The volume average particle diameters of particles in other dispersions are measured in the same manner. The content of the resin particles contained in the resin particle dispersion is, for example, preferably from 5% by mass to 50% by mass inclusive and more preferably from 10% by mass to 40% by mass inclusive.
For example, the coloring agent dispersion and the release agent particle dispersion are prepared in a similar manner to the resin particle dispersion. Specifically, the descriptions of the volume average particle diameter of the particles in each of the resin particle dispersion, the dispersion medium for the resin particle dispersion, the dispersing method, and the content of the resin particles are applicable to the coloring agent dispersed in the coloring agent dispersion and the release agent particles dispersed in the release agent particle dispersion.
Next, the resin particle dispersion, the coloring agent dispersion, and the release agent particle dispersion are mixed.
Then the resin particles, the coloring agent, and the release agent particles are hetero-aggregated in the dispersion mixture to form aggregated particles containing the resin particles, the coloring agent, and the release agent particles and having diameters close to the diameters of target toner particles.
Specifically, for example, a flocculant is added to the dispersion mixture, and the pH of the dispersion mixture is adjusted to acidic (for example, a pH of from 2 to 5 inclusive). Then a dispersion stabilizer is optionally added, and the resulting mixture is heated to the glass transition temperature of the resin particles (specifically, for example, a temperature from the glass transition temperature of the resin particles—30° C. to the glass transition temperature—10° C. inclusive) to aggregate the particles dispersed in the dispersion mixture to thereby form aggregated particles.
In the aggregated particle forming step, the flocculant may be added at room temperature (e.g., 25° C.) while the dispersion mixture is agitated, for example, in a rotary shearing-type homogenizer. Then the pH of the dispersion mixture is adjusted to acidic (e.g., a pH of from 2 to 5 inclusive), and the dispersion stabilizer is optionally added. Then the resulting mixture is heated in the manner described above.
Examples of the flocculant include a surfactant with polarity opposite to the polarity of the surfactant added to the dispersion mixture, inorganic metal salts, and divalent or higher polyvalent metal complexes. In particular, when a metal complex is used as the flocculant, the amount of the surfactant used can be reduced, and charging characteristics may be improved.
An additive that forms a complex with a metal ion in the flocculant or a similar bond may be optionally used. The additive used may be a chelating agent.
Examples of the inorganic metal salts include: metal salts such as calcium chloride, calcium nitrate, barium chloride, magnesium chloride, zinc chloride, aluminum chloride, and aluminum sulfate; and inorganic metal salt polymers such as polyaluminum chloride, polyaluminum hydroxide, and calcium polysulfide.
The chelating agent used may be a water-soluble chelating agent. Examples of the chelating agent include: oxycarboxylic acids such as tartaric acid, citric acid, and gluconic acid; iminodiacetic acid (IDA); nitrilotriacetic acid (NTA); and ethylenediaminetetraacetic acid (EDTA).
The amount of the chelating agent added is, for example, preferably from 0.01 parts by mass to 5.0 parts by mass inclusive and more preferably 0.1 parts by mass or more and less than 3.0 parts by mass based on 100 parts by mass of the resin particles.
Next, the aggregated particle dispersion containing the aggregated particles dispersed therein is heated to, for example, a temperature equal to or higher than the glass transition temperature of the resin particles (e.g., a temperature higher by 10° C. to 30° C. than the glass transition temperature of the resin particles) to fuse and coalesce the aggregated particles to thereby form toner particles.
The toner particles are obtained through the above-described steps.
Alternatively, the toner particles may be produced through: the step of forming second aggregated particles by, after the aggregated particle dispersion containing the aggregated particles dispersed therein has been obtained, mixing the aggregated particle dispersion with a resin particle dispersion containing resin particles dispersed therein to aggregate the resin particles such that the resin particles adhere to the surface of the aggregated particles; and the step of forming the toner particles having a core-shell structure by heating the second aggregated particle dispersion containing the second aggregated particles dispersed therein to fuse and coalesce the second aggregated particles.
The resin particles adhering to the surface of the aggregated particles may be amorphous resin particles.
After completion of the fusion/coalescence step, the toner particles formed in the solution are subjected to a well-known washing step, a well-known solid-liquid separation step, and a well-known drying step to thereby obtain dried toner particles.
From the viewpoint of chargeability, the toner particles may be subjected to displacement washing with ion exchanged water sufficiently in the washing step. No particular limitation is imposed on the solid-liquid separation step. From the viewpoint of productivity, suction filtration, pressure filtration, etc. may be performed in the solid-liquid separation step. No particular limitation is imposed on the drying step. From the viewpoint of productivity, freeze-drying, flash drying, fluidized drying, vibrating fluidized drying, etc. may be used.
Next, the production of toner particles containing the urea-modified polyester resin (the urea-modified amorphous polyester resin) will be described.
The toner particles containing the urea-modified polyester resin may be obtained by a solution suspension method described below. A method for obtaining toner particles containing, as the binder resin, the urea-modified polyester resin (the urea-modified amorphous polyester resin) and an unmodified crystalline polyester resin will be described, but the toner particles may contain, as the binder resin, an unmodified amorphous polyester resin. In the method for obtaining the toner particles to be described, the toner particles further contain the coloring agent and the release agent. However, the coloring agent and the release agent are optional components of the toner particles.
An oil phase solution is prepared by dissolving or dispersing toner particle materials including the unmodified crystalline polyester resin (hereinafter referred to simply as a “crystalline polyester resin”), the amorphous polyester prepolymer having isocyanate groups, the amine compound, the coloring agent, and the release agent in an organic solvent (an oil phase solution preparing step). In the oil phase solution preparing step, the toner particle materials are dissolved or dispersed in the organic solvent to obtain a toner material solution mixture.
Examples of the method for preparing the oil phase solution include: 1) an oil phase solution preparation method including dissolving or dispersing the toner particle materials at once in the organic solvent; 2) an oil phase solution preparation method including kneading the toner particle materials in advance and dissolving or dispersing the kneaded product in the organic solvent; 3) an oil phase solution preparation method including dissolving the crystalline polyester resin, the amorphous polyester prepolymer having isocyanate groups, and the amine compound in the organic solvent and then dispersing the coloring agent and the release agent in the resulting organic solvent; 4) an oil phase solution preparation method including dispersing the coloring agent and the release agent in the organic solvent and then dissolving the crystalline polyester resin, the amorphous polyester prepolymer having isocyanate groups, and the amine compound in the resulting organic solvent; 5) an oil phase solution preparation method including dissolving or dispersing the toner particle materials other than the amorphous polyester prepolymer having isocyanate groups and the amine compound (the crystalline polyester resin, the coloring agent, and the release agent) in the organic solvent and then dissolving the amorphous polyester prepolymer having isocyanate groups and the amine compound in the resulting organic solvent; and 6) an oil phase solution preparation method including dissolving or dispersing the toner particle materials other than the amorphous polyester prepolymer having isocyanate groups or the amine compound (the crystalline polyester resin, the coloring agent, and the release agent) in the organic solvent and then dissolving the amorphous polyester prepolymer having isocyanate groups or the amine compound in the resulting organic solvent. However, the method for preparing the oil phase solution is not limited to the above methods.
Examples of the organic solvent in the oil phase solution include: ester-based solvents such as methyl acetate and ethyl acetate; ketone-based solvents such as methyl ethyl ketone and methyl isopropyl ketone; aliphatic hydrocarbon-based solvents such as hexane and cyclohexane; and halogenated hydrocarbon-based solvents such as dichloromethane, chloroform, and trichloroethylene. These organic solvents can dissolve the binder resin and may have a solubility in water of from about 0% by mass to about 30% by mass inclusive and a boiling point of 100° C. or less. Among these organic solvents, ethyl acetate may be used.
Next, the obtained oil phase solution is dispersed in an water phase solution to prepare a suspension (a suspension preparing step).
While the suspension is prepared, the amorphous polyester prepolymer having isocyanate groups is reacted with the amine compound. The urea-modified polyester resin is generated through this reaction. This reaction involves at least one of the crosslinking reaction and elongation reaction of the molecular chain. The reaction of the amorphous polyester prepolymer having isocyanate groups with the amine compound may be performed during an organic solvent removing step described later.
The reaction conditions are selected according to the reactivity between the isocyanate group structure included in the amorphous polyester prepolymer and the amine compound. For example, the reaction time is preferably from 10 minutes to 40 hours inclusive and preferably from 2 hours to 24 hours inclusive. The reaction temperature is preferably from 0° C. to 150° C. inclusive and preferably from 40° C. to 98° C. inclusive. To produce the urea-modified polyester resin, a well-known catalyst (such as dibutyltin laurate or dioctyltin laurate) may be optionally used. Specifically, a catalyst may be added to the oil phase solution or the suspension.
One example of the water phase solution is a water phase solution obtained by dissolving a particle dispersant such as an organic particle dispersant or an inorganic particle dispersant in an aqueous solvent. Another example of the water phase solution is a water phase solution obtained by dispersing a particle dispersant in an aqueous solvent and dissolving a polymer dispersant in the resulting aqueous solvent. A well-known additive such as a surfactant may be added to the water phase solution.
Examples of the aqueous solvent include water (generally, for example, ion exchanged water, distilled water, and pure water). The aqueous solvent may be a solvent containing, in addition to water, an organic solvent such as an alcohol (such as methanol, isopropyl alcohol, or ethylene glycol), dimethylformamide, tetrahydrofuran, a cellosolve (such as methyl cellosolve), or a lower ketone (such as acetone or methyl ethyl ketone).
Examples of the organic particle dispersant include hydrophilic organic particle dispersants. Other examples of the organic particle dispersant include particles of alkyl poly(meth)acrylate resins (such as a polymethyl methacrylate resin), polystyrene resins, and poly(styrene-acrylonitrile) resins. Another example of the organic particle dispersant is particles of a styrene acrylic resin.
Examples of the inorganic particle dispersant include hydrophilic inorganic particle dispersants. Specific examples of the inorganic particle dispersant include particles of silica, alumina, titania, calcium carbonate, magnesium carbonate, tricalcium phosphate, clay, diatomaceous earth, bentonite, etc. The inorganic particle dispersant may be particles of calcium carbonate. One of these inorganic particle dispersants may be used alone, or two or more of them may be used in combination.
The particle dispersant may be surface-treated with a polymer having a carboxyl group.
Examples of the polymer having a carboxyl group include copolymers of an α,β-monoethylenically unsaturated carboxylic acid ester with an α,β-monoethylenically unsaturated carboxylic acid or at least one selected from salts (such as alkali metal salts, alkaline earth metal salts, ammonium salts, and amine salts) obtained by neutralizing a carboxyl group in an α,β-monoethylenically unsaturated carboxylic acid with an alkali metal, an alkaline earth metal, ammonium, or amine. Other examples of the polymer having a carboxyl group include salts (such as alkali metal salts, alkaline earth metal salts, ammonium salts, and amine salts) obtained by neutralizing carboxyl groups in a copolymer of an α,β-monoethylenically unsaturated carboxylic acid and an α,β-monoethylenically unsaturated carboxylic acid ester with an alkali metal, an alkaline earth metal, ammonium or amine. One of these polymers having a carboxyl group may be used alone, or two or more of them may be used in combination.
Representative examples of the α,β-monoethylenically unsaturated carboxylic acid include α,β-unsaturated monocarboxylic acids (such as acrylic acid, methacrylic acid, and crotonic acid) and α,β-unsaturated dicarboxylic acids (such as maleic acid, fumaric acid, and itaconic acid). Representative examples of the α,β-monoethylenically unsaturated carboxylic acid ester include alkyl esters of (meth)acrylic acid, (meth)acrylates having an alkoxy group, (meth)acrylates having a cyclohexyl group, (meth)acrylates having a hydroxy group, and polyalkylene glycol mono(meth)acrylates.
Examples of the polymer dispersant include hydrophilic polymer dispersants. Specific examples of the polymer dispersant include polymer dispersants having a carboxyl group and not having a lipophilic group (such as a hydroxypropoxy group or a methoxy group) (e.g., water-soluble cellulose ethers such as carboxymethyl cellulose and carboxyethyl cellulose).
Next, the organic solvent is removed from the obtained suspension to thereby obtain a toner particle dispersion (a solvent removing step). In the solvent removing step, the organic solvent contained in liquid droplets of the water phase solution dispersed in the suspension is removed to form toner particles. The organic solvent may be removed from the suspension immediately after the suspension preparing step or may be removed at least one minute after completion of the suspension preparing step.
In the solvent removing step, the organic solvent may be removed from the obtained suspension by cooling or heating the suspension in the range of, for example, from 0° C. to 100° C. inclusive.
Specific examples of a method for removing the organic solvent include the following methods.
(1) A method including blowing air onto the suspension to forcibly renew the gas phase on the surface of the suspension. In this case, the gas may be blown into the suspension.
(2) A method including reducing the pressure. In this case, the gas phase on the surface of the suspension may be forcibly renewed by charging a gas. The gas may be blown into the suspension.
The toner particles are obtained through the above steps.
After completion of the solvent removing step, the toner particles formed in the toner particle dispersion are subjected to well-known washing, solid-liquid separation, and drying steps to thereby obtain dried toner particles.
From the viewpoint of chargeability, the toner particles may be subjected to displacement washing with ion exchanged water sufficiently in the washing step.
No particular limitation is imposed on the solid-liquid separation step. From the viewpoint of productivity, suction filtration, pressure filtration, etc. may be performed in the solid-liquid separation step. No particular limitation is imposed on the drying step. From the viewpoint of productivity, freeze-drying, flash drying, fluidized drying, vibrating fluidized drying, etc. may be performed in the drying step.
Next, an annealing step will be described.
In the production of the toner particles, the toner particles obtained through the above steps are subjected to annealing treatment (heat treatment).
Specifically, for example, the obtained toner particles are heated to a temperature of from 50° C. to 60° C. inclusive and held at this temperature for a period of from 1 hour to 4 hours inclusive. This treatment allows the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to be 15% or less.
The timing at which the annealing step is performed is not limited to the above timing. For example, the dispersion containing the toner particles formed therein or the slurry obtained by reducing the amount of the solvent in the dispersion may be subjected to the annealing step.
The toner according to the present exemplary embodiment is produced, for example, by adding the external additive to the dried toner particles obtained through the anneal treatment and mixing them. The mixing may be performed, for example, using a V blender, a Henschel mixer, a Loedige mixer, etc. If necessary, coarse particles in the toner may be removed using a vibrating sieving machine, an air sieving machine, etc.
An electrostatic image developer according to an exemplary embodiment contains at least the toner according to the preceding exemplary embodiment.
The electrostatic image developer according to the present exemplary embodiment may be a one-component developer containing only the toner according to the preceding exemplary embodiment or a two-component developer containing the toner and a carrier.
No particular limitation is imposed on the carrier, and a well-known carrier may be used. Examples of the carrier include: a coated carrier prepared by coating the surface of a core material formed of a magnetic powder with a coating resin; a magnetic powder-dispersed carrier prepared by dispersing a magnetic powder in a matrix resin; and a resin-impregnated carrier prepared by impregnating a porous magnetic powder with a resin.
In each of the magnetic powder-dispersed carrier and the resin-impregnated carrier, the particles included in the carrier may be used as cores, and the cores may be coated with a coating resin.
Examples of the magnetic powder include: magnetic metal powders such as iron powder, nickel powder, and cobalt powder; and magnetic oxide powders such as ferrite powder and magnetite powder.
Examples of the coating resin and the matrix resin include polyethylene, polypropylene, polystyrene, polyvinyl acetate, polyvinyl alcohol, polyvinyl butyral, polyvinyl chloride, polyvinyl ether, polyvinyl ketone, vinyl chloride-vinyl acetate copolymers, styrene-acrylate copolymers, straight silicone resins having organosiloxane bonds and modified products thereof, fluorocarbon resins, polyesters, polycarbonates, phenolic resins, and epoxy resins.
The coating resin and the matrix resin may contain an additional additive such as electrically conductive particles.
Examples of the electrically conductive particles include: particles of metals such as gold, silver, and copper; and particles of carbon black, titanium oxide, zinc oxide, tin oxide, barium sulfate, aluminum borate, and potassium titanate.
One example of the method for coating the surface of the core material with the coating resin is a method in which the surface of the core material is coated with a coating layer-forming solution prepared by dissolving the coating resin and various optional additives in an appropriate solvent. No particular limitation is imposed on the solvent, and the solvent may be selected in consideration of the type of resin used, ease of coating, etc.
Specific examples of the resin coating method include: an immersion method in which the core material is immersed in the coating layer-forming solution; a spray method in which the coating layer-forming solution is sprayed onto the surface of the core material; a fluidized bed method in which the coating layer-forming solution is sprayed onto the core material floated by the flow of air; and a kneader-coater method in which the core material of the carrier and the coating layer-forming solution are mixed in a kneader coater and then the solvent is removed.
The mixing ratio (mass ratio) of the toner and the carrier in the two-component developer is preferably toner:carrier=1:100 to 30:100 and more preferably 3:100 to 20:100.
An image forming apparatus according to an exemplary embodiment/an image forming method according to an exemplary embodiment will be described.
The image forming apparatus according to the present exemplary embodiment includes: an image holding member; charging means for charging the surface of the image holding member; electrostatic image forming means for forming an electrostatic image on the charged surface of the image holding member; developing means that contains an electrostatic image developer and develops the electrostatic image formed on the surface of the image holding member with the electrostatic image developer to thereby form a toner image; transferring means for transferring the toner image formed on the surface of the image holding member onto a recording medium; and fixing means for fixing the toner image transferred onto the recording medium. The electrostatic image developer used is the electrostatic image developer according to the preceding exemplary embodiment.
The fixing means includes a fixing member and a pressing member that presses the outer circumferential surface of the fixing member to sandwich the recording medium having the unfixed toner image formed on its surface between the fixing member and the pressing member and may include no application mechanism for applying a release agent to the surface of the fixing member.
In the image forming apparatus according to the present exemplary embodiment, an image forming method (an image forming method according to the present exemplary embodiment) is performed. The image forming method includes: charging the surface of the image holding member; forming an electrostatic image on the charged surface of the image holding member; developing the electrostatic image formed on the surface of the image holding member with the electrostatic image developer according to the preceding exemplary embodiment to thereby form a toner image; transferring the toner image formed on the surface of the image holding member onto a recording medium; and fixing the toner image transferred onto the surface of the recording medium.
The image forming apparatus according to the present exemplary embodiment is applied to known image forming apparatuses such as: a direct transfer-type apparatus that transfers a toner image formed on the surface of the image holding member directly onto a recording medium; an intermediate transfer-type apparatus that first-transfers a toner image formed on the surface of the image holding member onto the surface of an intermediate transfer body and second-transfers the toner image transferred onto the surface of the intermediate transfer body onto the surface of a recording medium; an apparatus including cleaning means for cleaning the surface of the image holding member after the transfer of the toner image but before charging; and an apparatus including charge eliminating means for eliminating charges on the surface of the image holding member after transfer of the toner image but before charging by irradiating the surface of the image holding member with charge eliminating light.
In the intermediate transfer-type apparatus, the transferring means includes, for example: an intermediate transfer body having a surface onto which a toner image is to be transferred; first transferring means for first-transferring a toner image formed on the surface of the image holding member onto the surface of the intermediate transfer body; and second transferring means for second-transferring the toner image transferred onto the surface of the intermediate transfer body onto the surface of a recording medium.
In the image forming apparatus according to the present exemplary embodiment, for example, a portion including the developing means may have a cartridge structure (process cartridge) that is detachably attached to the image forming apparatus. The process cartridge used may be, for example, a process cartridge including the developing means containing the electrostatic image developer according to the preceding exemplary embodiment.
An example of the image forming apparatus according to the present exemplary embodiment will be described, but this is not a limitation. Major components shown in
The image forming apparatus shown in
An intermediate transfer belt 20 serving as the intermediate transfer body is disposed above the units 10Y, 10M, 10C, and 10K in
Four color toners including yellow, magenta, cyan, and black toners contained in toner cartridges 8Y, 8M, 8C, and 8K, respectively, are supplied to developing devices (examples of the developing means) 4Y, 4M, 4C, and 4K, respectively, of the units 10Y, 10M, 10C, and 10K.
The first to fourth units 10Y, 10M, 10C, and 10K have the same structure. Therefore, the first unit 10Y that is disposed upstream in the running direction of the intermediate transfer belt and forms a yellow image will be described as a representative unit. Description of the second to fourth units 10M, 10C, 10K will be omitted by replacing Y (yellow) in the reference symbol in the first unit 10Y with M (magenta), C (cyan), or K (black).
The first unit 10Y includes a photoconductor 1Y serving as an image holding member. A charging roller (an example of the charging means) 2Y, an exposure unit (an example of the electrostatic image forming means) 3, a developing device (an example of the developing means) 4Y, a first transfer roller 5Y (an example of the first transferring means), and a photoconductor cleaner (an example of the cleaning means) 6Y are disposed around the photoconductor 1Y in this order. The charging roller charges the surface of the photoconductor 1Y to a prescribed potential, and the exposure unit 3 exposes the charged surface to a laser beam 3Y according to a color-separated image signal to thereby form an electrostatic image. The developing device 4Y supplies a charged toner to the electrostatic image to develop the electrostatic image, and the first transfer roller 5Y transfers the developed toner image onto the intermediate transfer belt 20. The photoconductor cleaner 6Y removes the toner remaining on the surface of the photoconductor 1Y after the first transfer.
The first transfer roller 5Y is disposed on the inner side of the intermediate transfer belt 20 and placed at a position opposed to the photoconductor 1Y. Bias power sources (not shown) for applying a first transfer bias are connected to the respective first transfer rollers 5Y, 5M, 5C, and 5K. The bias power sources are controlled by an unillustrated controller to change the transfer biases applied to the respective first transfer rollers.
A yellow image formation operation in the first unit 10Y will be described.
First, before the operation, the surface of the photoconductor 1Y is charged by the charging roller 2Y to a potential of −600 V to −800 V.
The photoconductor 1Y is formed by stacking a photosensitive layer on a conductive substrate (with a volume resistivity of, for example, 1×10−6 Ωcm or less at 20° C.). The photosensitive layer generally has a high resistance (the resistance of a general resin) but has the property that, when irradiated with a laser beam 3Y, the specific resistance of a portion irradiated with the laser beam is changed. Therefore, the laser beam 3Y is outputted from the exposure unit 3 toward the charged surface of the photoconductor 1Y according to yellow image data sent from an unillustrated controller. The photosensitive layer of the photoconductor 1Y is irradiated with the laser beam 3Y, and an electrostatic image with a yellow image pattern is thereby formed on the surface of the photoconductor 1Y.
The electrostatic image is an image formed on the surface of the photoconductor 1Y by charging and is a negative latent image formed as follows. The specific resistance of the irradiated portions of the photosensitive layer irradiated with the laser beam 3Y decreases, and this causes charges on the surface of the photoconductor 1Y to flow. However, the charges in portions not irradiated with the laser beam 3Y remain present, and the electrostatic image is thereby formed.
The electrostatic image formed on the photoconductor 1Y rotates to a prescribed developing position as the photoconductor 1Y rotates. Then the electrostatic image on the photoconductor 1Y at the developing position is converted to a visible image (developed image) as a toner image by the developing device 4Y.
An electrostatic image developer containing, for example, at least a yellow toner and a carrier is contained in the developing device 4Y. The yellow toner is agitated in the developing device 4Y and thereby frictionally charged. The charged yellow toner has a charge with the same polarity (negative polarity) as the charge on the photoconductor 1Y and is held on a developer roller (an example of a developer holding member). As the surface of the photoconductor 1Y passes through the developing device 4Y, the yellow toner electrostatically adheres to charge-eliminated latent image portions on the surface of the photoconductor 1Y, and the latent image is thereby developed with the yellow toner. Then the photoconductor 1Y with the yellow toner image formed thereon continues running at a prescribed speed, and the toner image developed on the photoconductor 1Y is transported to a prescribed first transfer position.
When the yellow toner image on the photoconductor 1Y is transported to the first transfer position, a first transfer bias is applied to the first transfer roller 5Y, and an electrostatic force directed from the photoconductor 1Y toward the first transfer roller 5Y acts on the toner image, so that the toner image on the photoconductor 1Y is transferred onto the intermediate transfer belt 20. The transfer bias applied in this case has a (+) polarity opposite to the (−) polarity of the toner and is controlled to +10 μA in, for example, the first unit 10Y by the controller (not shown).
The toner remaining on the photoconductor 1Y is removed and collected by the photoconductor cleaner 6Y.
The first transfer biases applied to the first transfer rollers 5M, 5C, and 5K of the second unit 10M and subsequent units are controlled in the same manner as in the first unit.
The intermediate transfer belt 20 with the yellow toner image transferred thereon in the first unit 10Y is sequentially transported through the second to fourth units 10M, 10C and 10K, and toner images of respective colors are superimposed and multi-transferred.
Then the intermediate transfer belt 20 with the four color toner images multi-transferred thereon in the first to fourth units reaches a secondary transfer unit that is composed of the intermediate transfer belt 20, the support roller 24 in contact with the inner surface of the intermediate transfer belt, and a secondary transfer roller (an example of the second transferring means) 26 disposed on the image holding surface side of the intermediate transfer belt 20. A recording paper sheet (an example of the recording medium) P is supplied to a gap between the secondary transfer roller 26 and the intermediate transfer belt 20 in contact with each other at a prescribed timing through a supply mechanism, and a secondary transfer bias is applied to the support roller 24. The transfer bias applied in this case has the same polarity (−) as the polarity (−) of the toner, and an electrostatic force directed from the intermediate transfer belt 20 toward the recording paper sheet P acts on the toner image, so that the toner image on the intermediate transfer belt 20 is transferred onto the recording paper sheet P. In this case, the secondary transfer bias is determined according to a resistance detected by resistance detection means (not shown) for detecting the resistance of the secondary transfer portion and is voltage-controlled.
Then the recording paper sheet P is transported to a press contact portion (nip portion) of a pair of rollers (an example of the fixing member and the pressing member) in a fixing device (an example of the fixing means) 28, and the toner image is fixed onto the recording paper sheet P to thereby form a fixed image.
The fixing device 28 may include no application mechanism for applying a release agent to the surface of the fixing rollers.
Examples of the recording paper sheet P onto which a toner image is to be transferred include plain paper sheets used for electrophotographic copying machines, printers, etc. Examples of the recording medium include, in addition to the recording paper sheets P, transparencies.
To further improve the smoothness of the surface of a fixed image, it may be necessary that the surface of the recording paper sheet P be smooth. For example, coated paper prepared by coating the surface of plain paper with, for example, a resin, art paper for printing, etc. are suitably used.
The recording paper sheet P with the color image fixed thereon is transported to an ejection unit, and a series of the color image formation operations is thereby completed.
A process cartridge according to an exemplary embodiment will be described.
The process cartridge according to the present exemplary embodiment includes developing means that contains the electrostatic image developer according to the preceding exemplary embodiment and develops an electrostatic image formed on the surface of the image holding member with the electrostatic image developer to thereby form a toner image. The process cartridge is detachably attached to the image forming apparatus.
The structure of the process cartridge in the present exemplary embodiment is not limited to the above described structure. The process cartridge may include, in addition to the developing unit, at least one optional unit selected from other means such as an image holding member, charging means, electrostatic image forming means, and transferring means.
An example of the process cartridge according to the present exemplary embodiment will be described, but this is not a limitation. Major components shown in
The process cartridge 200 shown in
In
Next, a toner cartridge according to an exemplary embodiment will be described.
The toner cartridge according to the present exemplary embodiment contains the toner according to the preceding exemplary embodiment and is detachably attached to an image forming apparatus. The toner cartridge contains a replenishment toner to be supplied to the developing means disposed in the image forming apparatus.
The image forming apparatus shown in
Examples of the present disclosure will next be described. However, the present disclosure is not limited to these Examples. In the following description, “parts” and “%” are based on mass, unless otherwise specified.
The above materials are placed in a 5 L flask equipped with a stirrer, a nitrogen introduction tube, a temperature sensor, and a rectifying column. The temperature of the mixture is increased to 220° C. over 1 hour, and titanium tetraethoxide is added in an amount of 1 part with respect to 100 parts of the above materials. While water produced is removed by evaporation, the temperature is increased to 230° C. over 0.5 hours. A dehydration condensation reaction is continued at 230° C. for 1 hour, and the reaction product is cooled. An amorphous polyester resin (A1) having a weight average molecular weight of 20,000, an acid value of 13 mgKOH/g, and a glass transition temperature of 60° C. is thereby synthesized.
Next, a container equipped with temperature controlling means and nitrogen purging means is charged with 40 parts of ethyl acetate and 25 parts of 2-butanol to prepare a solvent mixture, and 100 parts of the amorphous polyester resin (A1) is gradually added to the solvent mixture and dissolved therein. Then a 10 mass % aqueous ammonia solution is added thereto (in a molar amount corresponding to three times the acid value of the resin), and the mixture is stirred for 30 minutes.
Next, the container is purged with dry nitrogen, and the temperature is held at 40° C. While the solution mixture is stirred, 400 parts of ion exchanged water is added dropwise at a rate of 2 parts/minute to emulsify the mixture. After completion of the dropwise addition, the temperature of the emulsion is returned to room temperature (20° C. to 25° C.), and dry nitrogen is bubbled into the emulsion for 48 hours under stirring to reduce the contents of ethyl acetate and 2-butanol to 1,000 ppm or less. A resin particle dispersion in which resin particles having a volume average particle diameter of 200 nm are dispersed is thereby obtained. Ion exchanged water is added to the resin particle dispersion to adjust the solid content to 20% by mass, and an amorphous polyester resin dispersion (A1) is thereby obtained.
An amorphous polyester resin particle dispersion (A2) is obtained using the same procedure as in the preparation of the amorphous polyester resin particle dispersion (A1) except that the amount of the ethylene oxide adduct of bisphenol A added is changed to 30 parts by mole, that the amount of the propylene oxide adduct of bisphenol A is changed to 70 parts by mole, and that the temperature of the materials charged into the flask is increased to 210° C. over 1 hour.
The amorphous polyester resin (A2) obtained has a weight average molecular weight of 16000, an acid value of 13.4 mgKOH/g, and a glass transition temperature of 49° C.
An amorphous polyester resin particle dispersion (A3) is obtained using the same procedure as in the preparation of the amorphous polyester resin particle dispersion (A1) except that the amount of the ethylene oxide adduct of bisphenol A added is changed to 40 parts by mole, the amount of the propylene oxide adduct of bisphenol A added is changed to 60 parts by mole, and that the temperature of the materials charged into the flask was increased to 200° C. over 1 hour.
The amorphous polyester resin (A3) obtained has a weight average molecular weight of 14000, an acid value of 14.1 mgKOH/g, and a glass transition temperature of 45° C.
An amorphous polyester resin particle dispersion (A4) is obtained using the same procedure as in the preparation of the amorphous polyester resin particle dispersion (A1) except that the period of time over which the temperature is increased to 230° C. while the water produced is removed is changed to 1.0 hours.
The amorphous polyester resin (A4) obtained has a weight average molecular weight of 21,000, an acid value of 13 mgKOH/g, and a glass transition temperature of 60° C.
The above monomer components are placed in a reaction vessel equipped with a stirrer, a thermometer, a condenser, and a nitrogen gas introduction tube, and the reaction vessel is purged with dry nitrogen gas. Then titanium tetrabutoxide (reagent) is added in an amount of 0.25 parts with respect to 100 parts of the monomer components. The mixture is allowed to react at 170° C. in a nitrogen gas flow for 3 hours. The resulting mixture is further heated to 210° C. over 1 hour, and the pressure inside the reaction vessel is reduced to 3 kPa. Then the mixture is allowed to react under the reduced pressure for 13 hours while stirred, and a crystalline polyester resin (A1) is thereby obtained.
The crystalline polyester resin (A1) obtained has a melting temperature Tm of 73.6° C. as measured by DSC, a mass average molecular weight Mw of 25,000 as measured by GPC, a number average molecular weight Mn of 10,500 as measured by GPC, and an acid value AV of 10.1 mgKOH/g.
Next, a jacketed 3 L reaction tank (BJ-30N manufactured by TOKYO RIKAKIKAI Co., Ltd.) equipping with a condenser, a thermometer, a water dropping unit, and an anchor blade is charged with 300 parts of the crystalline polyester resin (1), 160 parts of methyl ethyl ketone (solvent), and 100 parts of isopropyl alcohol (solvent), and the mixture is stirred at 100 rpm while the temperature of the mixture is maintained at 70° C. in a water-circulation thermostatic bath to thereby dissolve the resin (a solution preparing step).
Then the number of revolutions for stirring is changed to 150 rpm, and the temperature of the water-circulation thermostatic bath is set to 66° C. Then 17 parts of 10% ammonia water (reagent) is added over 10 minutes, and a total of 900 parts of ion exchanged water held at 66° C. is added dropwise at a rate of 7 parts/minute to perform phase inversion to thereby obtain an emulsion.
Immediately after the emulsification, 800 parts of the obtained emulsion and 700 parts of ion exchanged water are placed in a 2 L round bottom flask, and the round bottom flask is placed in an evaporator (TOKYO RIKAKIKAI Co., Ltd.) equipped with a vacuum control unit through a trap ball. While rotated, the round bottom flask is heated in a hot water bath at 60° C., and the pressure inside the flask is reduced to 7 kPa with attention to bumping to remove the solvent. When the amount of the solvent collected has reached 1,100 parts, the pressure is returned to normal pressure, and the round bottom flask is water-cooled to thereby obtain a dispersion. The obtained dispersion has no solvent odor. The resin particles in the dispersion have a volume average particle diameter D50v of 130 nm. Then ion exchanged water is added to adjust the solid concentration to 20%, and the resulting dispersion is used as a crystalline polyester resin particle dispersion (A1).
A crystalline polyester resin particle dispersion (A2) is obtained using the same procedure as in the preparation of the crystalline polyester resin particle dispersion (A1) except that the reaction is allowed to proceed in a nitrogen gas flow at 170° C. under stirring for 3 hours and then the temperature is further increased to 200° C. over 1 hour.
The crystalline polyester resin (A2) obtained has a melting temperature Tm of 69.0° C. as measured by DSC, a mass average molecular weight Mw of 23,000 as measured by GPC, a number average molecular weight Mn of 9,000 as measured by GPC, and an acid value AV of 10.5 mgKOH/g.
A crystalline polyester resin particle dispersion (A3) is obtained using the same procedure as in the preparation of the crystalline polyester resin particle dispersion (A1) except for the following. The reaction is allowed to proceed in a nitrogen gas flow at 170° C. under stirring for 3 hours, and then the temperature is further increased to 200° C. over 1 hour. Then the pressure inside the reaction vessel is reduced to 3 kPa, and the reaction is allowed to proceed under the reduced pressure for 10 hours while stirred.
The crystalline polyester resin (A3) obtained has a melting temperature Tm of 60.0° C. as measured by DSC, a mass average molecular weight Mw of 20,000 as measured by GPC, a number average molecular weight Mn of 8,500 as measured by GPC, and an acid value AV of 10.8 mgKOH/g.
A crystalline polyester resin particle dispersion (A4) is obtained using the same procedure as in the preparation of the crystalline polyester resin particle dispersion (A1) except for the following. The reaction is allowed to proceed in a nitrogen gas flow at 170° C. under stirring for 3 hours, and then the temperature is further increased to 220° C. over 1 hour. Then the pressure inside the reaction vessel is reduced to 3 kPa, and the reaction is allowed to proceed under the reduced pressure for 15 hours while stirred.
The crystalline polyester resin (A4) obtained has a melting temperature Tm of 80° C. as measured by DSC, a mass average molecular weight Mw of 27,000 as measured by GPC, a number average molecular weight Mn of 12,000 as measured by GPC, and an acid value AV of 9.8 mgKOH/g.
The above materials are mixed and dispersed for 10 minutes using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA). Ion exchanged water is added such that the content of the basic dye in the dispersion is 20% by mass, and a coloring agent dispersion (A1) with the basic dye dispersed therein is thereby obtained.
The above materials are mixed and dispersed for 10 minutes using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA). Ion exchanged water is added such that the content of the basic dye in the dispersion is 20% by mass, and a coloring agent dispersion (A2) with the basic dye dispersed therein is thereby obtained.
The above materials are mixed and dispersed for 10 minutes using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA). Ion exchange water is added such that the content of the acidic dye in the dispersion is 20% by mass, and a coloring agent dispersion (A3) with the acidic dye dispersed therein is thereby obtained.
The above materials are mixed and dispersed for 10 minutes using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA). Ion exchanged water is added such that the content of the basic dye in the dispersion is 20% by mass, and a coloring agent dispersion (A4) with the basic dye dispersed therein is thereby obtained.
The above materials are mixed and dispersed for 10 minutes using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA). Ion exchanged water is added such that the content of the basic dye in the dispersion is 20% by mass, and a coloring agent dispersion (A5) with the basic dye dispersed therein is thereby obtained.
The above materials are mixed, heated to 100° C., dispersed using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA), and subjected to dispersion treatment using a Manton-Gaulin high-pressure homogenizer (manufactured by Gaulin Corporation) to thereby obtain a release agent particle dispersion (A1) (solid content: 20%) containing dispersed therein release agent particles with a volume average particle diameter of 200 nm.
The above materials are placed in a stainless steel round flask. Then 0.1N nitric acid is added to adjust the pH to 3.5, and 30 parts of an aqueous nitric acid solution with a poly-aluminum chloride concentration of 10% by mass is added. Then a homogenizer (ULTRA-TURRAX T50 manufactured by IKA) is used to disperse the particles at 30° C., and the dispersion is heated to 40° C. in a heating oil bath and held for 30 minutes. Then 100 parts of the amorphous polyester resin particle dispersion (A1) used as an additional dispersion is added gently, and the resulting mixture is left to stand for 1 hour. Then a 0.1N aqueous sodium hydroxide solution is added to adjust the pH to 8.5, and the resulting mixture is heated to 100° C. under continuous stirring and held for 10 hours. Then the temperature of the system is set to 53° C. (annealing treatment) and held for 1 hour. Next, the system is cooled to room temperature. The mixture is filtered, washed sufficiently with ion exchanged water, and dried, and toner particles with a volume average particle diameter of 6.0 μm are thereby obtained. The obtained toner particles are used as toner particles (A1).
Toner particles are obtained using the same procedure as that for the toner particles (A1) except for the type of amorphous polyester resin particle dispersion used and its amount, the type of crystalline polyester resin particle dispersion used and its amount, the type of coloring agent dispersion used and its amount, the type of release agent particle dispersion used and its amount, and the temperature and holding time in the annealing treatment are changed as shown in Tables 1-1 to 3-2. The additional dispersion used is the same as the changed amorphous polyester resin particle dispersion.
The amount of the amorphous polyester resin particle dispersion used is the amount of the material first charged into the stainless steel round flask when the toner particles are produced.
Toner particles (AC3) are produced by a kneading-grinding method.
Specifically, 20 parts of a crystalline polyester resin (the crystalline polyester resin synthesized when the above-described crystalline polyester resin particle dispersion (1) is prepared), 1.0 parts of a basic dye rhodamine B (Basic Violet 10 manufactured by Nippon Kasei Chemical Co., Ltd.), and 9.0 parts of paraffin wax (HNP-9 manufactured by Nippon Seiro Co., Ltd.) used as a release agent are added to 40 parts of an amorphous polyester resin (the amorphous polyester resin synthesized when the above-described amorphous polyester resin particle dispersion (1) is prepared), and the mixture is kneaded using a pressure kneader. The kneaded product is coarsely pulverized to produce toner particles (AC3) having a volume average particle diameter of 6.0 μm.
A 5 L flask equipped with a stirrer, a nitrogen introduction tube, a temperature sensor, and a rectifying column is charged with 80.9 parts of fumaric acid and 46.3 parts of 1,10-decanediol, and then titanium tetraethoxide is added in an amount of 1 part with respect to 100 parts of the above materials (fumaric acid and 1,10-decanediol). While water produced is removed, a reaction is allowed to proceed at 150° C. for 4 hours. Then the temperature is increased to 180° C. in a nitrogen flow over 6 hours, and the reaction is allowed to proceed at 180° C. for 6 hours. Then the reaction is allowed to proceed for 1 hour under reduced pressure, and the product is cooled to thereby obtain an unmodified crystalline polyester resin (P1).
A 5 L flask equipped with a stirrer, a nitrogen introduction tube, a temperature sensor, and a rectifying column is charged with 30 parts of isophthalic acid, 70 parts of fumaric acid, 5 parts by mole of ethylene oxide adduct of bisphenol A, and 95 parts of propylene oxide adduct of bisphenol A, and the temperature of the mixture is increased to 220° C. over 1 hour. Then titanium tetraethoxide is added in an amount of 1 part with respect to 100 parts of the above materials (isophthalic acid, fumaric acid, ethylene oxide adduct of bisphenol A, and propylene oxide adduct of bisphenol A). While water produced is removed by evaporation, the temperature is increased to 230° C. over 0.5 hours. A dehydration condensation reaction is continued at 230° C. for 1 hour, and the reaction product is cooled. Then isophorone diisocyanate is added in an amount of 2 parts with respect to 1 part of the resin, and 5 parts of ethyl acetate is added to dissolve the resin. Then a reaction is allowed to proceed at 200° C. for 3 hours, and the reaction product was cooled to thereby obtain an amorphous polyester resin (P1) having a terminal isocyanate group.
100 Parts of paraffin wax (HNP-9 manufactured by Nippon Seiro Co., Ltd.), 1 part of an anionic surfactant (Neogen RK manufactured by DAI-ICHI KOGYO SEIYAKU Co., Ltd.), and 350 parts of ion exchanged water are mixed, heated to 100° C., dispersed using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA), and subjected to dispersion treatment using a Manton-Gaulin high-pressure homogenizer (manufactured by Gaulin Corporation) to thereby obtain a release agent particle dispersion (solid content: 20%) containing dispersed therein release agent particles with a volume average particle diameter of 200 nm.
150 Parts of the amorphous polyester resin (P1), 3.0 parts of a basic dye (rhodamine B (Basic Violet 10 manufactured by Nippon Kasei Chemical Co., Ltd.), and 20 parts of ion exchanged water are mixed using a Henschel mixer. The mixture obtained is pulverized to produce a master batch.
107 Parts of the amorphous polyester resin (P1), 75 parts of the release agent particle dispersion, 18 parts of the master batch, and 73 parts of ethyl acetate are placed in a homogenizer (ULTRA-TURRAX T50 manufactured by IKA), stirred, dissolved, and dispersed to obtain an oil phase (A). 990 Parts of ion exchanged water, 100 parts of an anionic surfactant, and 100 parts of ethyl acetate are mixed in a different flask and stirred to obtain a water phase.
100 Parts of a solution prepared by dissolving the crystalline polyester resin (P1) in ethyl acetate (solid concentration: 10%) and 3 parts of isophoronediamine are added to 450 parts of the oil phase (A), and the mixture is stirred using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA), dissolved, and dispersed at 50° C. to thereby obtain an oil phase (B). Next, 400 parts of the water phase is placed in an different container and stirred at 50° C. using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA). 50 Parts of the oil phase (B) is added to the water phase, and the mixture is stirred at 50° C. for 5 minutes using a homogenizer (ULTRA-TURRAX T50 manufactured by IKA) to thereby obtain an emulsified slurry. The solvent in the emulsified slurry is removed at 50° C. for 15 hours to obtain a toner slurry. The toner slurry is filtered under reduced pressure and subjected to washing treatment to obtain toner particles.
Then the toner particles are washed, and a 5 L flask equipped with a stirrer, a nitrogen introduction tube, a temperature sensor, and a rectifying column is charged with a dispersion prepared by adding 50 parts of the toner particles to 500 parts of ion exchanged water. Then the dispersion is stirred and heated to 85° C. After the heating, the dispersion is stirred for 24 hours while the increased temperature is maintained. The toner particles are thereby heated at 85° C. for 24 hours. Then liquid nitrogen is added to the dispersion to cool (quench) the toner particles to room temperature (25° C.) at 20° C./minute. Then the dispersion is reheated to 53° C., held for 1 hour, and then cooled to 20° C. at a rate of 20° C./minute.
The toner particles obtained are dried and sieved to produce toner particles with a volume average particle diameter of 6.0 μm.
The toner particles (P1) are obtained through the above steps.
100 Parts of one type of toner particles and 0.7 parts of silica particles treated with dimethyl silicone oil (RY200 manufactured by Nippon Aerosil Co., Ltd.) are mixed using a Henschel mixer to thereby obtain a toner in an Example or a Comparative Example.
Then 8 parts of the toner obtained and 100 parts of a carrier described below are mixed to obtain a developer in an Example or a Comparative Example.
The above components other than the ferrite particles are dispersed using a sand mill to prepare a dispersion, and the dispersion and the ferrite particles are placed in a vacuum degassing-type kneader, and the mixture is dried under reduced pressure while stirred to thereby obtain a carrier.
One of the developers obtained in the Examples and Comparative Examples is charged into a developing unit of an image forming apparatus “DocuCentre Color 400 manufactured by Fuji Xerox Co., Ltd.,” and this image forming apparatus is used to evaluate the following properties.
A blank image with an area coverage of 0% is outputted on 100 sheets of OS coated paper (product name: OS coated 127 manufactured by FUJIFILM Business Innovation Corp.) at a process speed of 228 mm/s in an environment of a temperature of 22° C. and a humidity of 55% RH. Then Imaging Society of Japan (ISJ) Test Chart No. 5-1 including solid images with an area coverage of 100% (images with a toner mass per unit area (TMA) of 14.4 g/m2) is outputted on 100 sheets of OS coated paper (product name: OS coated 127 manufactured by FUJIFILM Business Innovation Corp.) at a process speed of 228 mm/s.
The gloss of a green portion of each of the ISJ Test Chart No. 5-1 on the first OS coated paper sheet and the ISJ Test Chart No. 5-1 on the 100th OS coated paper sheet is measured by the following method.
The gloss is measured using a portable glossmeter (BYK Gardner micro-tri-gloss manufactured by Toyo Seiki Seisaku-sho, Ltd.). Specifically, the gloss at 60 degrees is measured at 5 points, and the measured values are averaged.
The difference in gloss is determined from the measured values and evaluated according to the following criteria.
A(└): The maximum value of the differences in gloss between the first outputted image and 2nd to 100th images is less than 2°.
B(◯): The maximum value of the differences in gloss between the first outputted image and 2nd to 100th images is 2° or more and less than 5°.
C(×): The maximum value of the differences in gloss between the first outputted image and 2nd to 100th images is 5° or more.
The strength of an fixed image is evaluated as follows. A solid image is formed on color paper (J paper) manufactured by Fuji Xerox Co., Ltd. with the toner mass per unit area adjusted to 13.5 g/m2. After the formation of the toner image, an external fixing device with a nip width of 6.5 mm is used to fix the image at a fixing rate of 180 mm/sec.
The toner image is fixed with the fixing temperature fixed at 130° C., and a valley fold line is formed substantially at the center of the solid portion of the fixed image on the paper sheet. A broken portion of the fixed image is wiped with tissue paper, and the line width of a white portion formed is measured and evaluated according to the following criteria.
A: The line width of the white portion is less than 0.5 mm.
B: The line width of the white portion is 0.5 mm or more and less than 1.0 mm.
C: The line width of the white portion is 1.0 mm or more.
The abbreviations in the tables are as follows.
(Cry/Lub)×100: The ratio of the percentage of the crystalline resin on the surface of the toner particles as measured by X-ray photoelectron spectroscopy to the percentage of the release agent on the surface of the toner particles as measured by X-ray photoelectron spectroscopy.
As can be seen from the above results, with the toners in the Examples, the difference in gloss that occurs when images are formed continuously can be reduced.
The foregoing description of the exemplary embodiments of the present disclosure has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the disclosure and its practical applications, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-013924 | Jan 2021 | JP | national |
