Patent Grant
9494887
1. Field of the Invention
The present invention relates to a toner for developing electrostatic latent images used in image forming methods such as electrophotographic methods and electrostatic printing methods.
2. Description of the Related Art
As computers and multimedia become more advanced, there arises an increasing need to develop ways to output high-definition full color images that satisfy various needs in homes and offices.
In offices where large quantities of copies and printouts are made, image forming apparatuses desirably have high durability whereby degradation of image quality is suppressed even when a large number of copies and printouts are made.
In contrast, in small offices and homes, image forming apparatuses are desirably capable of producing high-quality images and are desirably small to save space and energy and reduce weight. To satisfy these needs, toners used therein desirably have improved properties, such as environmental stability, low-temperature fixability, development durability, and storage stability.
In particular, a full color image is formed by superimposing color toners. Unless all of the color toners are developed equally, the color reproducibility is degraded and color nonuniformity is generated. If a pigment or a dye used as a colorant of a toner is precipitated on the surfaces of toner particles, the developing performance is affected and color nonuniformity may result.
In forming a full color image, fixability and color mixing property during fixing are important. For example, in order to achieve high-speed image formation, a binder resin suitable for low temperature fixing is selected. The influence of this binder resin on the developing performance and durability is also large.
Moreover, a toner that can be used for a long time and is capable of forming high-definition full color images at various temperatures and humidity is in demand. In order to fulfill such need, several challenges are desirably addressed, such as suppressing changes in the toner surface properties and changes in the charge amount of toners caused by changes in the operation environment and minimizing soiling of parts such as a developing roller, a charging roller, a regulating blade, and a photosensitive drum. In this respect, development of a toner that exhibits stable chargeability despite being stored in a wide variety of environments for a long time and has stable development durability that does not cause soiling of parts has been eagerly anticipated.
One of the causes of changes in charge amount and storage stability of the toner due to temperature and humidity is a phenomenon called bleeding in which a release agent and a resin component in the toner ooze out from the interior of the toner particle to the surface of the toner particle, thereby altering the surface properties of the toner.
One way to address this challenge is to cover the surface of a toner particle with a resin.
Japanese Patent Laid-Open No. 2006-146056 discloses a toner that has good high-temperature storage stability and exhibits good printing durability when printing is conducted in a normal temperature, normal humidity environment or a high temperature, high humidity environment. This toner includes inorganic fine particles strongly fixed to toner particle surfaces.
However, even if inorganic fine particles are strongly fixed to toner particles, bleeding of a release agent and a resin component occurs through gaps between the inorganic fine particles and the inorganic fine particles may detach due to deterioration of durability. Accordingly, the durability in a severe environment is desirably further improved and the problem of soiling of parts is desirably addressed.
Japanese Patent Laid-Open No. 03-089361 discloses a method for producing a polymerized toner, in which a silane coupling agent is added to the reaction system to try to prevent colorants and polar substances from becoming exposed in the toner particle surfaces and to obtain a toner that has a narrow charge amount distribution and very low dependence of charge amount on humidity.
However, according to this method, the amount of precipitates of the silane compounds on the toner particle surfaces and hydrolytic polycondensation are insufficient. The environmental stability and the development durability are desirably further improved.
Japanese Patent Laid-Open No. 08-095284 discloses a way of controlling the charge amount of the toner and forming high-quality printed images irrespective of temperature and humidity in the environment. In particular, it discloses a polymerized toner in which a silane is used to coat surfaces of toner particles.
However, the polarity of organic functional groups is high and hydrolytic polycondensation and the amount of precipitates of the silane compound on the toner particle surfaces are insufficient. Further improvements are desired in order to enhance the storage stability, suppress soling of parts by toner fusion, and decrease the change in image density caused by changes in chargeability at high temperature and high humidity.
Japanese Patent Laid-Open No. 2001-75304 discloses a toner that improves fluidity, low temperature fixability, and blocking property and suppresses detachment of a fluidizer. This toner is a polymerized toner that includes a coating layer in which granular lumps containing a silicon compound are fixed to each other.
However, bleeding of a release agent and a resin component occurs through gaps between the granular lumps containing a silicon compound. The image density changes due to changes in chargeability in a high temperature, high humidity environment due to insufficient hydrolytic polycondensation and an insufficient amount of silane compound precipitates on the toner particle surfaces. Moreover, parts become soiled by toner fusion. These problems are desirably addressed and the storage stability is desirably further improved.
The present invention provides a toner that addresses the challenges described above and exhibits good environmental stability, low-temperature fixability, development durability, and storage stability.
The inventors of the present invention have conducted extensive studies and made the present invention based on the findings.
The present invention provides a toner that includes toner particles each including a surface layer containing an organic silicon polymer.
The organic silicon polymer is obtained by polymerizing a polymerizable monomer that contains a compound represented by formula (1) below:
(In formula (1), R1 represents (i) CH2═CH— or (ii) CH2═CH-L- (in formula (ii), L represents a methylene group, an ethylene group, or a phenylene group) and R2, R3, and R4 each independently represent a halogen atom, a hydroxy group, or an alkoxy group.).
An average thickness Dav. of the surface layers measured by observation of cross sections of the toner particles with a transmission electron microscope (TEM) is 5.0 nm or more and 150.0 nm or less.
In mapping measurement performed through time-of-flight secondary ion mass spectroscopy using a focused ion beam as a probe (FIB-TOF—SIMS), a ratio (ASi/AC) is 20.00 or more, where ASi is ISi/I, AC is IC/I, ISi represents an intensity of silicon ions released from the toner particles upon irradiation of toner particle surfaces with primary ions, IC represents an intensity of carbon ions released from the toner particles upon irradiation of the toner particle surfaces with the primary ions, and I represents a primary ion dose of irradiation.
Further features of the present invention will become apparent from the following description of exemplary embodiments (with reference to the attached drawings).
The present invention will now be described in detail.
A toner according to an embodiment of the present invention includes toner particles each including a surface layer that contains an organic silicon polymer.
The organic silicon polymer is a polymer prepared by polymerizing a polymerizable monomer that contains a compound represented by formula (1) below:
(In formula (1), R1 represents (i) CH2═CH— or (ii) CH2═CH-L- (in formula (ii), L represents a methylene group, an ethylene group, or a phenylene group) and R2, R3, and R4 each independently represent a halogen atom, a hydroxy group, or an alkoxy group.)
The average thickness Dav. of the surface layers measured by observation of cross sections of the toner particles with a transmission electron microscope (TEM) is 5.0 nm or more and 150.0 nm or less.
In mapping measurement performed through time-of-flight secondary ion mass spectroscopy using a focused ion beam as a probe (FIB-TOF—SIMS), the ratio (ASi/AC) is 20.00 or more, where ASi is ISi/I, AC is IC/I, ISi represents the intensity of silicon ions released from the toner particles upon irradiation of toner particle surfaces with primary ions, IC represents the intensity of carbon ions released from the toner particles upon irradiation of the toner particle surfaces with the primary ions, and I represents a primary ion dose of irradiation.
Compound Used for Obtaining Organic Silicon Polymer
The organic silicon polymer is obtained by polymerizing a polymerizable monomer containing a compound represented by formula (1) above.
Toner particles with surface layers containing the organic silicon polymer can exhibit improved hydrophobicity at the toner particle surfaces. As a result, the environmental stability of the toner is improved. To facilitate incorporation of the organic silicon polymer in the surface layers, the number of carbon atoms in R4 is preferably 5 or less, more preferably 3 or less, and most preferably 2 or less. From the viewpoints of the coatability of the surface layers of the toner particles and the chargeability and durability of the toner, R1 preferably represents a vinyl group or an allyl group and more preferably represents a vinyl group. R2, R3, and R4 each independently represent a halogen atom, a hydroxy group, or an alkoxy group (hereinafter R2, R3, and R4 may also be referred to as “reactive group” each). These reactive groups undergo hydrolysis, addition polymerization, or condensation polymerization to form a crosslinked structure. Since such a crosslinked structure is formed on the surfaces of toner particles, a toner having good development durability can be obtained. In particular R2, R3, and R4 preferably each independently represent an alkoxy group and more preferably each independently represent a methoxy group or an ethoxy group since hydrolysis proceeds slowly at room temperature, the organic silicon polymer can be smoothly precipitated at the surfaces of the toner particles, and the coatability on the surfaces of the toner particles is improved. Hydrolysis, addition polymerization, or condensation polymerization of R2, R3, and R4 can be controlled by adjusting the reaction temperature, reaction time, reaction solvent, and pH.
ASi/AC
For the purposes of the present invention, it is important that the ratio (ASi/AC) be 20.00 or more in mapping measurement performed through time-of-flight secondary ion mass spectroscopy using a focused ion beam as a probe (FIB-TOF—SIMS), where ASi is ISi/I, AC is IC/I, ISi represents the intensity (current value detected with a SIMS detector) of silicon ions (m/z=27.50 to 28.50) released from the toner particles upon irradiation of toner particle surfaces with primary ions, IC represents the intensity (current value detected with a SIMS detector) of carbon ions (m/z=11.50 to 12.50) released from the toner particles upon irradiation of the toner particle surfaces with the primary ions, and I represents a primary ion dose (the number of primary ions) of irradiation.
That the toner particles having surface layers containing the organic silicon polymer have ASi/AC of 20.00 or more means that the organic silicon polymer is abundantly contained in the surface layers. As a result, the surface free energy of the surfaces of the toner particles is decreased, soiling of parts can be suppressed, and thus development durability can be improved.
ASi/AC is preferably 40.00 or more and more preferably 60.00 or more.
ASi/AC can be controlled by adjusting the number of carbon atoms in the structure (i) or (ii) represented by R1 in formula (1), conditions of hydrolysis, and reaction temperature, reaction time, reaction solvent, and pH of addition polymerization and polycondensation. For example, the number of carbon atoms in R1 is preferably 5 or less, more preferably 3 or less, and most preferably 2 or less.
The compound represented by formula (1) is preferably polymerized at a polymerization temperature of 85° C. or higher for a reaction time of 5 hours or longer and more preferably at a reaction temperature of 100° C. or higher for a reaction time of 5 hours or longer. The pH of the reaction solvent used for the reaction of the compound represented by formula (1) is preferably 4.0 to 7.5 and more preferably 8.5 to 11.0. When the monomer composition containing the compound represented by formula (1) is polymerized under the aforementioned reaction conditions, it becomes easy to provide the organic silicon polymer on surfaces of the toner particles.
The organic silicon polymer is not only present on the surfaces of the toner particles but also contained in the surface layers of the toner particles. This can be confirmed by partly scraping the surface layers of the toner particles by focused ion beam etching and measuring ASi/AC at the section.
In particular, ASi/AC is preferably 20.00 or more and more preferably 40.00 or more when the accumulated dose rate of the toner particles, which indicates the total quantity of primary ions applied to the toner particles by focused ion beam etching, is 1.66×1019 (ions/m2). When the toner particles have surface layers that contain an organic silicon polymer, bleeding of the resin components and release agent can be suppressed and a toner having good development durability, storage stability, and environmental stability can be obtained. Note that for the accumulated dose rate of the toner particles, the extent to which the toner particles are etched differs depending on the hardness of the toner particle surfaces and the composition of the material.
Average thickness Dav. of surface layers of toner particles and percentage (existing ratio) of surface layer thicknesses that are 5.0 nm or less out of surface layer thicknesses FRAn
The average thickness Dav. of the surface layers of the toner particles containing the organic silicon polymer and determined by observation of cross sections of the toner particles by using a transmission electron microscope (TEM) is 5.0 nm or more and 150.0 nm or less. At this average thickness, bleeding of the release agent and the resin components can be suppressed and a toner having good storage stability, environmental stability, and development durability can be obtained. From the viewpoint of storage stability, the average thickness Dav. of the surface layers of the toner particles is preferably 10.0 nm or more and 150.0 nm or less and more preferably 10.0 nm or more and 125.0 nm or less, and most preferably 15.0 nm or more and 100.0 nm or less.
The average thickness Dav. of the surface layers of the toner particles containing the organic silicon polymer can be controlled by adjusting the number of carbon atoms in R1 of formula (1), the reaction temperature, reaction time, reaction solvent, and pH of the addition polymerization and condensation polymerization, and the organic silicon polymer content.
In order to increase the average thickness Dav. of the surface layers of the toner particles, the number of carbon atoms in R1 is preferably 5 or less, more preferably 3 or less, and most preferably 2 or less. When the number of carbon atoms in R1 is 5 or less, it becomes easier to provide the organic silicon polymer on the surface layer side of the toner particles.
The organic silicon polymer may be arranged such that the highest ASi/AC is observed at the outermost surface layer of a toner particle. When toner particles have such a structure, bleeding of the resin components and the release agent is further suppressed, and a toner having good storage stability, environmental stability, and development durability can be obtained.
For the purposes of the present invention, the “outermost surface layer of a toner particle” refers to a part of a toner particle that extends from the surface (depth: 0.00 nm) to a depth of 10.0 nm toward the center of the particle.
In a cross section of a toner particle observed with a transmission electron microscope (TEM), sixteen straight lines that pass through the midpoint of a long axis L, which is a maximum diameter of the cross section, and extend across the cross section are drawn with reference to the long axis L such that the intersectional angles between adjacent straight lines at the midpoint are equal to each other (namely, 11.25°) and that thirty-two line segments An (n=1 to 32) that extend from the midpoint to the surface of the toner particle are formed. Assuming the length of each line segment to be RAn (n=1 to 32) and the thickness of the surface layer on a line segment An to be FRAn (n=1 to 32), the percentage (existing ratio) of the surface layer thicknesses that are 5.0 nm or less out of surface layer thicknesses FRAn may be 20.0% or less.
In the case where the percentage that the surface layer thicknesses that are 5.0 nm or less out of the surface layer thicknesses FRAn is 20.0% or less, a toner having good image density stability and causes less fogging in a wide variety of environments can be obtained.
The average thickness Dav. of the surface layers of the toner particles and the percentage that the surface layer thickness is 5.0 nm or less can be controlled by adjusting the number of carbon atoms in R1 of formula (1) above, reaction temperature, reaction time, reaction solvent, pH, and the organic silicon polymer content.
Silicon Concentration at Surfaces of Toner Particles
In the toner according to an embodiment of the present invention, a silicon concentration dSi relative to a total of the silicon concentration dSi, an oxygen concentration dO, and a carbon concentration dC (dSi+dO+dC) determined by electron spectroscopy for chemical analysis (ESCA) performed at surfaces of the toner particles is preferably 2.5 atomic % or more, more preferably 5.0 atomic % or more, and most preferably 10.0 atomic % or more.
ESCA is an element analysis technique of the outermost surface several nanometers in depth. When the silicon concentration in the outermost surface layers of the toner particles is 2.5 atomic % or more, the surface free energy of the outermost surface layers can be lowered. The fluidity can be further improved and the soiling of parts and fogging can be further suppressed by adjusting the silicon concentration to 2.5 atomic % or more.
The silicon concentration in the outermost surface layers of the toner particles can be controlled by adjusting the structure of R1 in formula (1) above, reaction temperature, reaction time, reaction solvent, pH, and the organic silicon polymer content.
Method for Preparing Organic Silicon Polymer
A representative example of a method for preparing an organic silicon polymer according to an embodiment of the invention is a sol-gel method.
In a sol-gel method, a metal alkoxide M(OR)n (M: metal, O: oxygen, R: hydrocarbon, n: oxidation number of metal) is used as a starting material, is hydrolyzed and condensation polymerized in a solvent to form a sol, and is formed into a gel. A sol-gel method is used to synthesize glass, ceramics, organic-inorganic hybrid materials, and nano-composites. According to this method, functional materials of various forms, such as surface layers, fibers, bulks and fine particles, can be synthesized from a liquid phase at a low temperature.
In particular, surface layers of the toner particles are formed by hydrolytic polycondensation of a silicon compound such as alkoxysilane. When a surface layer is uniformly provided on the surface of each toner particle, the environmental stability is improved without fixing or adhering inorganic fine particles as in the toners of the related art. Moreover, the performance of the toner is rarely degraded in long-term use and a toner having good storage stability can be obtained.
In a sol-gel method, a solution is used in the initial stage and this solution is gelled to form a material. Thus, various fine structures and shapes can be fabricated. In particular, for toner particles formed in an aqueous medium, it is easy to provide an organic silicon compound on surfaces of toner particles due to the hydrophilicity exhibited by hydrophilic groups such as silanol groups in the organic silicon compound.
However, if the hydrophobicity of the organic silicon compound is excessively high (for example, when the organic silicon compound contains functional groups that are highly hydrophobic), it becomes difficult to precipitate the organic silicon compound at the surface layers of the toner particles. Accordingly, it becomes difficult to form a toner particle that has a surface layer containing the organic silicon polymer.
In contrast, if the hydrophobicity of the organic silicon compound is excessively low, the charge stability of the toner tends to be degraded despite the incorporation of the organic silicon polymer in the surface layers of the toner particles. The fine structures and shapes of the toner particles can be controlled by adjusting the reaction temperature, reaction time, reaction solvent, pH, the type of the organic silicon compound, and the amount of the organic silicon compound added, for example.
In order to obtain the organic silicon polymer, at least one organic silicon compound (hereinafter may be referred to as “trifunctional silane”) represented by formula (1) above is used.
Examples of the organic silicon compound represented by formula (Z) above (hereinafter may be referred to as “trifunctional silane”) include trifunctional vinylsilanes such as vinyltrimethoxysilane, vinyltriethoxysilane, vinyldiethoxymethoxysilane, vinylethoxydimethoxysilane, vinyltrichlorosilane, vinylmethoxydichlorosilane, vinylethoxydichlorosilane, vinyldimethoxychlorosilane, vinylmethoxyethoxychlorosilane, vinyldiethoxychlorosilane, vinyltriacetoxysilane, vinyldiacetoxymethoxysilane, vinyldiacetoxyethoxysilane, vinylacetoxydimethoxysilane, vinylacetoxymethoxyethoxysilane, vinylacetoxydiethoxysilane, vinyltrihydroxysilane, vinylmethoxydihydroxysilane, vinylethoxydihydroxysilane, vinyldimethoxyhydroxysilane, vinylethoxymethoxyhydroxysilane, and vinyldiethoxyhydroxysilane; and trifunctional allylsilanes such as allyltrimethoxysilane, allyltriethoxysilane, allyldiethoxymethoxysilane, allylethoxydimethoxysilane, allyltrichlorosilane, allylmethoxydichlorosilane, allylethoxydichlorosilane, allyldimethoxychlorosilane, allylmethoxyethoxychlorosilane, allyldiethoxychlorosilane, allyltriacetoxysilane, allyldiacetoxymethoxysilane, allyldiacetoxyethoxysilane, allylacetoxydimethoxysilane, allylacetoxymethoxyethoxysilane, allylacetoxydiethoxysilane, allyltrihydroxysilane, allylmethoxydihydroxysilane, allylethoxydihydroxysilane, allyldimethoxyhydroxysilane, allylethoxymethoxyhydroxysilane, and allyldiethoxyhydroxysilane.
These organic silicon compounds may be used alone or in combination.
The content of the organic silicon compound represented by formula (1) is preferably 50 mol % or more and more preferably 60 mol % or more in the organic silicon polymer. The environmental stability of the toner can be further improved when the content of the organic silicon compound represented by formula (1) is 50 mol % or more.
An organic silicon polymer obtained by using an organic silicon compound having three functional group per molecule (trifunctional silane), an organic silicon compound having two functional groups per molecule (difunctional silane), or an organic silicon compound having one reactive group per molecule (monofunctional silane) in combination with the organic silicon compound represented by formula (1) may also be used.
Examples of the organic silicon compound that can be used in combination with the organic silicon compound represented by formula (1) include dimethyldiethoxysilane, tetraethoxysilane, hexamethyldisilazane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, 3-glycidoxypropyltriethoxysilane, p-styryltrimethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropylmethyldiethoxysilane, 3-methacryloxypropyltriethoxysilane, 3-acryloxypropyltrimethoxysilane, N-2-(aminoethyl)-3-aminopropylmethyldimethoxysilane, N-2-(aminoethyl)-3-aminopropyltrimethoxysilane, N-2-(aminoethyl)-3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, N-phenyl-3-aminopropyltrimethoxysilane, 3-ureidopropyltriethoxysilane, 3-chloropropyltrimethoxysilane, 3-mercaptopropylmethyldimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane, bis(triethoxysilylpropyl)tetrasulfide, 3-isocyanatepropyltriethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, trimethylsilyl chloride, N,N′-bis(trimethylsilyl)urea, N,N′-bis(trimethylsilyl)urea, N,O-bis(trimethylsilyl)trifluoroacetamide, trimethylsilyltrifluoromethane sulfonate, triethylsilyl chloride, t-butyldimethylsilyl chloride, tri-i-propylsilyl chloride, 1,3-dichloro-1,1,3,3-tetra-tri-i-propyldisiloxane, trimethylsilylacetylene, hexamethyldisilane, tetraisocyanatesilane, methyl triisocyanatesilane, and vinyl triisocyanatesilane.
It is generally known that, in a sol-gel reaction, the bonding state of the siloxane bonds generated differs depending on the acidity of the reaction medium. To be more specific, when the reaction medium is acidic, a hydrogen ion is electrophilically added to an oxygen atom of one functional group (for example, an alkoxy group (—OR group)). Then oxygen atoms in the water molecules coordinate to a silicon atom, thereby forming a hydrosilyl group by substitution reaction. If there is enough water present, one H+ attacks one oxygen atom of a reactive group (for example, an alkoxy group (—OR group)) and thus the speed of substitution reaction to hydroxy groups is low if the H+ content in the reaction medium is low. As a result, polycondensation reaction occurs before all of the reactive groups attached to the silane are hydrolyzed and one-dimensional linear polymers and two-dimensional polymers are relatively easily generated.
In contrast, when the reaction medium is alkaline, hydroxide ions are added to the silicon atom and a 5-coordinated intermediate is produced during the course of the reaction. Accordingly, all of the reactive groups (for example, alkoxy groups (—OR groups)) can easily be eliminated and easily substituted into silanol groups. In particular, when a silicon compound having three or more reactive groups is used for the same silane, hydrolysis and polycondensation occurs three dimensionally and an organic silicon polymer having many three-dimensional crosslinks is formed. Moreover, the reaction ends in a short time.
In view of the above, an organic silicon polymer is preferably prepared by a sol-gel reaction in an alkaline reaction medium. In order to form the polymer in an aqueous medium, the pH may be 8.0 or more. In this manner, an organic silicon polymer that has a higher strength and higher durability can be formed. The sol-gel reaction may be performed for 5 hours or longer at a reaction temperature of 85° C. or higher. When a sol-gel reaction is performed at this reaction temperature for this reaction time, formation of coalesced particles in which silane compounds in a sol state or a gel state on the surfaces of the toner particles are bonded to each other can be suppressed.
The organic silicon compound may be used in combination with an organic titanium compound or an organic aluminum compound.
Examples of the organic titanium compound include o-allyloxy(polyethylene oxide)triisopropoxytitanate, titanium allylacetoacetate triisopropoxide, titanium bis(triethanolamine)diisopropoxide, titanium tetra-n-butoxide, titanium tetra-n-propoxide, titanium chloride triisopropoxide, titanium chloride triisopropoxide, titanium di-n-butoxide(bis-2,4-pentanedionate), titanium chloride diethoxide, titanium diisopropoxide(bis-2,4-pentanedionate), titanium diisopropoxide bis(tetramethylheptanedionate), titanium diisopropoxide bis(ethyl acetoacetate), titanium tetraethoxide, titanium 2-ethylhexyloxide, titanium tetraisobutoxide, titanium tetraisopropoxide, titanium lactate, titanium methacrylate isopropoxide, titanium methacryloxyethyl acetoacetate triisopropoxide, (2-methacryloxyethoxy)triisopropoxy titanate, titanium tetramethoxide, titanium methoxypropoxide, titanium methylphenoxide, titanium n-nonyloxide, titanium oxide bis(pentanedionate), titanium n-propoxide, titanium stearyloxide, titanium tetrakis(bis-2,2-(allyloxymethyl)butoxide), titanium triisostearoylisopropoxide, titanium methacrylate methoxyethoxide, tetrakis(trimethylsiloxy)titanium, titanium tris(dodecylbenzenesulfonate) isopropoxide, and titanocene diphenoxide.
Examples of the organic aluminum compound include aluminum(III) tri-n-butoxide, aluminum(III) tri-s-butoxide, aluminum(III) di-s-butoxide bis(ethyl acetoacetate), aluminum(III) tri-t-butoxide, aluminum(III) di-s-butoxide ethyl acetoacetate, aluminum(III) diisopropoxide ethyl acetoacetate, aluminum(III) triethoxide, aluminum hexafluoropentanedioanate, aluminum(III) 3-hydroxy-2-methyl-4-pyronate, aluminum(III) isopropoxide, aluminum-9-octadecenyl acetoacetate diisopropoxide, aluminum(III) 2,4-pentanedionate, aluminum triphenoxide, and aluminum(III) 2,2,6,6-tetramethyl-3,5-heptanedionate.
Two or more of these organic titanium compounds and two or more of the organic aluminum compounds may be used. The amount of charges can be controlled by appropriately selecting a combination of these compounds and adjusting the amount added.
The organic silicon polymer may be obtained by polymerizing the vinyl-based polymerizable monomer and the compound represented by formula (1) above.
Method for Producing Toner Particles
A method for producing toner particles will now be described.
The description below provides specific embodiments of having an organic silicon polymer incorporated in surface layers of toner particles. However, the present invention is not limited to these embodiments.
A first production method includes forming particles in an aqueous medium from a polymerizable monomer composition containing a polymerizable monomer, a colorant, and an organic silicon compound and polymerizing the polymerizable monomer to obtain toner particles (hereinafter this method may also be referred to as a “suspension polymerization method”).
A second production method includes preparing toner base bodies first, placing the toner base bodies in an aqueous medium, and forming surface layers of an organic silicon polymer on the toner base bodies in the aqueous medium.
The toner base bodies may be obtained by melt kneading a binder resin and a colorant and pulverizing the resulting product. Alternatively, the toner base bodies may be obtained by agglomerating and associating the binder resin particles and the colorant particles in an aqueous medium, or by suspending in an aqueous medium an organic phase dispersion, which is prepared by dissolving a binder resin, a silane compound, and a colorant in an organic solvent, so as to form particles and conduct polymerization and then removing the organic solvent.
A third production method includes suspending in an aqueous medium an organic phase dispersion, which is prepared by dissolving a binder resin, a silane compound, and a colorant in an organic solvent, so as to form particles and conduct polymerization, and then removing the organic solvent to obtain toner particles.
A fourth production method includes agglomerating and associating binder resin particles, colorant particles, and organic silicon compound-containing particles in a sol or gel state in an aqueous medium to form toner particles.
A fifth production method includes spraying a solvent containing an organic silicon compound onto surfaces of toner base bodies by a spray drying method and polymerizing or drying the surfaces by blowing hot air or by cooling so as to form surface layers containing the organic silicon compound.
The toner base bodies may be obtained by melt kneading a binder resin and a colorant and pulverizing the resulting product, or by agglomerating and associating binder resin particles and colorant particles in an aqueous medium, or by suspending in an aqueous medium an organic phase dispersion, which is prepared by dissolving a binder resin, a silane compound, and a colorant in an organic solvent, so as to form particles and conduct polymerization and then removing the organic solvent.
Toner particles produced by these production methods include surface layers that contain an organic silicon polymer and thus exhibit good environmental stability (in particular, the chargeability in a severe environment). Moreover, changes in the surface state of the toner particles caused by bleeding of the release agent and the resin in the toner interior are suppressed even in a severe environment.
The toner particles obtained by these production methods may be surface-treated by applying hot air. When toner particles are surface-treated by applying hot air, condensation polymerization of the organic silicon polymer near the surfaces of the toner particles is accelerated and the environmental stability and the development durability can be improved.
A technique capable of treating surfaces of toner particles or a toner with hot air and cooling the treated toner particles by using cool air may be employed as the surface treatment that uses hot air described above. Examples of the machines used to conduct a surface treatment using hot air include HYBRIDIZATION System (produced by Nara Machinery Co., Ltd.), MECHANOFUSION System (produced by Hosokawa Micron Corporation), FACULTY (produced by Hosokawa Micron Corporation), and METEORAINBOW MR type (produced by Nippon Pneumatic MFG., Co., Ltd.).
Examples of the aqueous medium used in the production methods described above include water, alcohols such as methanol, ethanol, and propanol, and mixed solvents of these.
Among the production methods described above, the first production method (suspension polymerization method) may be employed to produce toner particles. According to the suspension polymerization method, it is easy to have an organic silicon polymer uniformly precipitated in surfaces of the toner particles, good adhesion is achieved between the surface layers and the interiors of the toner particles, and the storage stability, the environmental stability, and the development durability are enhanced. The suspension polymerization method is described in further detail below.
If needed, a release agent, a polar resin, and a low-molecular-weight resin may be added to the polymerizable monomer composition described above. Upon completion of the polymerization step, the particles generated may be washed and recovered by filtration, and dried to obtain toner particles. Heating may be conducted in the latter half of the polymerization step. In order to remove unreacted polymerizable monomer and by-products, part of the dispersion medium may be distilled away from the reaction system in the latter half of the polymerization step or after completion of the polymerization step.
Low-Molecular-Weight Resin
The following resins can be used as the low-molecular-weight resin as long as the effects of the invention are not impaired: homopolymers of styrene or its substitutes such as polystyrene and polyvinyl toluene; styrene-based copolymers such as a styrene-propylene copolymer, a styrene-vinyl toluene copolymer, a styrene-vinyl naphthalene copolymer, a styrene-methyl acrylate copolymer, a styrene-ethyl acrylate copolymer, a styrene-butyl acrylate copolymer, a styrene-octyl acrylate copolymer, a styrene-dimethylaminoethyl acrylate copolymer, a styrene-methyl methacrylate copolymer, a styrene-ethyl methacrylate copolymer, a styrene-butyl methacrylate copolymer, a styrene-dimethylaminoethyl methacrylate copolymer, a styrene-vinyl methyl ether copolymer, a styrene-vinyl ethyl ether copolymer, a styrene-vinyl methyl ketone copolymer, a styrene-butadiene copolymer, a styrene-isoprene copolymer, a styrene-maleic acid copolymer, and a styrene-maleic acid ester copolymer; and polymethyl methacrylate, polybutyl methacrylate, polyvinyl acetate, polyethylene polypropylene, polyvinyl butyral, silicone resin, polyester resin, polyamide resin, epoxy resin, polyacrylic resin, rosin, modified rosin, terpene resin, phenolic resin, aliphatic or alicyclic hydrocarbon resin, and aromatic petroleum resin.
These resins may be used alone or in combination.
In order to address changes in viscosity of the toner at high temperature, the binder resin may contain a polymerizable functional group. Examples of the polymerizable functional group include a vinyl group, an isocyanate group, an epoxy group, an amino group, a carboxylic acid group, and a hydroxy group.
The weight-average molecular weight (Mw) of the THF soluble of the low-molecular-weight resin determined by GPC may be 2000 to 6000.
Polar Resin
The polar resin may be a saturated or unsaturated polyester-based resin.
Examples of the polyester-based resin include those obtained by condensation polymerization of an acid component monomer and an alcohol component monomer.
Examples of the acid component monomer include terephthalic acid, isophthalic acid, phthalic acid, cyclohexanedicarboxylic acid, and trimellitic acid.
Examples of the alcohol component monomer include bisphenol A, hydrogenated bisphenol, ethylene oxide adducts of bisphenol A, propylene oxide adducts of bisphenol A, glycerin, trimethylol propane, and pentaerythritol.
Release Agent
Examples of the release agent include petroleum-based wax and derivatives thereof such as paraffin wax, microcrystalline wax, and petrolatum, montan wax and derivatives thereof, Fisher-Tropsch hydrocarbon wax and derivatives thereof, polyolefin wax and derivatives thereof such as polyethylene and polypropylene, natural wax and derivatives thereof such as carnauba wax and candelilla wax, higher aliphatic alcohols, fatty acids and compounds thereof such as stearic acid and palmitic acid, acid amide wax, ester wax, ketone, hydrogenated castor oil and derivatives thereof, vegetable wax, animal wax, and silicone resin. The derivatives also refer to oxides, block copolymers with vinyl-based monomers, and graft modified products.
Polymerizable Monomer
The following vinyl-based polymerizable monomers can be used in addition to the compound represented by formula (1) above as the polymerizable monomer used in the suspension polymerization method: styrene; styrene derivatives such as α-methylstyrene, β-methylstyrene, o-methylstyrene, m-methylstyrene, p-methylstyrene, 2,4-dimethylstyrene, p-n-butylstyrene, p-tert-butylstyrene, p-n-hexylstyrene, p-n-octylstyrene, p-n-nonylstyrene, p-n-decylstyrene, p-n-dodecylstyrene, p-methoxystyrene, and p-phenylstyrene; acryl-based polymerizable monomers such as methyl acrylate, ethyl acrylate, n-propyl acrylate, iso-propyl acrylate, n-butyl acrylate, iso-butyl acrylate, tert-butyl acrylate, n-amyl acrylate, n-hexyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, n-nonyl acrylate, cyclohexyl acrylate, benzyl acrylate, dimethyl phosphate ethyl acrylate, diethyl phosphate ethyl acrylate, dibutyl phosphate ethyl acrylate, and 2-benzoyloxy ethyl acrylate; methacryl-based polymerizable monomers such as methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, iso-propyl methacrylate, n-butyl methacrylate, iso-butyl methacrylate, tert-butyl methacrylate, n-amyl methacrylate, n-hexyl methacrylate, 2-ethylhexyl methacrylate, n-octyl methacrylate, n-nonyl methacrylate, diethyl phosphate ethyl methacrylate, and dibutyl phosphate ethyl methacrylate; esters of methylene aliphatic monocarboxylic acids; vinyl esters such as vinyl acetate, vinyl propionate, vinyl benzoate, vinyl butyrate, and vinyl formate; vinyl ethers such as vinyl methyl ether, vinyl ethyl ether, and vinyl isobutyl ether; and vinyl methyl ketone, vinyl hexyl ketone, and vinyl isopropyl ketone.
Among these vinyl-based polymers, styrene-based polymers, styrene-acryl-based copolymers, and styrene-methacryl-based copolymers are preferable. The adhesion with the organic silicon polymer is improved and the storage stability and the development durability are enhanced.
Other Additives
In polymerizing the polymerizable monomer, a polymerization initiator may be added.
Examples of the polymerization initiator include azo- or diazo-based polymerization initiators such as 2,2′-azobis-(2,4-divaleronitrile), 2,2′-azobisisobutyronitrile, 1,1′-azobis(cyclohexane-1-carbonitrile), 2,2′-azobis-4-methoxy-2,4-dimethylvaleronitrile, azobisisobutyronitrile; and peroxide-based polymerization initiators such as benzoyl peroxide, methyl ethyl ketone peroxide, diisopropyloxy carbonate, cumene hydroperoxide, 2,4-dichlorobenzoyl peroxide, and lauroyl peroxide.
The amount of the polymerization initiator added may be 0.5 to 30.0 mass % relative to the polymerizable monomer. Two or more polymerization initiators may be used in combination.
In order to control the molecular weight of the binder resin contained in the toner particles, a chain transfer agent may be added in polymerizing the polymerizable monomer. The amount of the chain transfer agent added may be 0.001 to 15.000 mass % of the polymerizable monomer.
In order to control the molecular weight of the binder resin contained in the toner particles, a crosslinking agent may be added in polymerizing the polymerizable monomer.
Examples of the crosslinking agent include divinylbenzene, bis(4-acryloxypolyethoxyphenyl)propane, ethylene glycol diacrylate, 1,3-butylene glycol diacrylate, 1,4-butanediol diacrylate, 1,5-pentanediol diacrylate, 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, diethylene glycol diacrylate, triethylene glycol diacrylate, tetraethylene glycol diacrylate, #200, #400, and #600 diacrylates of polyethylene glycol, dipropylene glycol diacrylate, polypropylene glycol diacrylate, polyester-type diacrylate (MANDA produced by Nippon Kayaku Co., Ltd.), and methacrylates of the foregoing.
Examples of a polyfunctional crosslinking agent include pentaerythritol triacrylate, trimethylol ethane triacrylate, trimethylol propane triacrylate, tetramethylol methane tetraacrylate, oligo ester acrylate and methacrylate, 2,2-bis(4-methacryloxy.polyethoxyphenyl)propane, diacryl phthalate, triallyl cyanurate, triallyl isocyanurate, triallyl trimellitate, and diallyl chlorendate.
The amount of the crosslinking agent added may be 0.001 to 15.000 mass % relative to the polymerizable monomer.
Binder Resin
The binder resin contained in the toner particles is preferably a vinyl-based resin and more preferably a styrene-based resin, a styrene-acryl-based resin, or a styrene-methacryl-based resin. A vinyl-based resin is synthesized as a result of polymerization of the vinyl-based polymerizable monomer described above. Vinyl-based resins have excellent environmental stability. Vinyl-based resins are also advantageous since they give highly uniform surfaces and cause an organic silicon polymer obtained by polymerization of a polymerizable monomer containing a compound represented by formula (1) to precipitate in the surfaces of the toner particles.
Dispersion Stabilizer
In the case where the medium used in polymerizing the polymerizable monomer is an aqueous medium, the following can be used as the dispersion stabilizer for particles of the polymerizable monomer composition: hydroxyapatite, tricalcium phosphate, magnesium phosphate, zinc phosphate, aluminum phosphate, calcium carbonate, magnesium carbonate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, calcium metasilicate, calcium sulfate, barium sulfate, bentonite, silica, and alumina.
Examples of the organic dispersion stabilizer include polyvinyl alcohol, gelatin, methyl cellulose, methyl hydroxypropyl cellulose, ethyl cellulose, carboxymethyl cellulose sodium salt, and starch.
Commercially available nonionic, anionic, and cationic surfactants can also be used.
Examples of the surfactant include sodium dodecyl sulfate, sodium tetradecyl sulfate, sodium pentadecyl sulfate, sodium octyl sulfate, sodium oleate, sodium laurate, and potassium stearate.
In the case where a slightly water-soluble inorganic dispersion stabilizer is used to prepare an aqueous medium, the amount of the dispersion stabilizer added may be 0.2 to 2.0 parts by mass per 100 parts by mass of the polymerizable monomer. The aqueous medium may be prepared by using 300 to 3,000 parts by mass of water per 100 parts by mass of the polymerizable monomer composition.
A commercially available dispersion stabilizer can be directly used in preparing an aqueous medium in which the slightly water-soluble inorganic dispersion stabilizer is dispersed. In order to obtain a dispersion stabilizer having fine and uniform particle size, a slightly water-soluble inorganic dispersion stabilizer may be generated in a liquid medium such as water under stirring at high speed. In particular, in the case where tricalcium phosphate is used as the dispersion stabilizer, an aqueous solution of sodium phosphate and an aqueous solution of calcium chloride may be mixed under stirring at high speed so as to form fine particles of tricalcium phosphate and to obtain a desirable dispersion stabilizer.
Colorant
Examples of the colorant used in the toner are as follows.
Examples of the yellow pigment include iron oxide yellow, Naples Yellow, Naphthol Yellow S, Hansa yellow G, Hansa Yellow 10G, Benzidine Yellow G, Benzidine Yellow GR, Lake Quinoline Yellow, Permanent Yellow NCG, Lake Tartrazine, isoindolinone compounds, anthraquinone compounds, azo metal complexes, methine compounds, and allylamide compounds.
Specific examples thereof include C.I. Pigment Yellow 12, C.I. Pigment Yellow 13, C.I. Pigment Yellow 14, C.I. Pigment Yellow 15, C.I. Pigment Yellow 17, C.I. Pigment Yellow 62, C.I. Pigment Yellow 74, C.I. Pigment Yellow 83, C.I. Pigment Yellow 93, C.I. Pigment Yellow 94, C.I. Pigment Yellow 95, C.I. Pigment Yellow 109, C.I. Pigment Yellow 110, C.I. Pigment Yellow 111, C.I. Pigment Yellow 128, C.I. Pigment Yellow 129, C.I. Pigment Yellow 147, C.I. Pigment Yellow 155, C.I. Pigment Yellow 168, and C.I. Pigment Yellow 180.
Examples of an orange pigment includes Permanent Orange GTR, Pyrazolone Orange, Vulcan Orange, Benzidine Orange G, Indanthrene Brilliant Orange RK, and Indanthrene Brilliant Orange GK.
Examples of a red pigment include red iron oxide, Permanent Red 4R, Lithol Red, Pyrazolone Red, Watching Red Calcium Salt, Lake Red C, Lake Red D, Brilliant Carmine 6B, Brilliant Carmine 3B, Eosine Lake, Rhodamine B Lake, Alizarin Lake, condensed azo compounds, diketopyrrolopyrrole compounds, anthraquinone, quinacridone compounds, basic dye lake compounds, naphthol compounds, benzimidazolone compounds, thioindigo compounds, and perylene compounds.
Specific examples thereof include C.I. Pigment Red 2, C.I. Pigment Red 3, C.I. Pigment Red 5, C.I. Pigment Red 6, C.I. Pigment Red 7, C.I. Pigment Red 23, C.I. Pigment Red 48:2, C.I. Pigment Red 48:3, C.I. Pigment Red 48:4, C.I. Pigment Red 57:1, C.I. Pigment Red 81:1, C.I. Pigment Red 122, C.I. Pigment Red 144, C.I. Pigment Red 146, C.I. Pigment Red 166, C.I. Pigment Red 169, C.I. Pigment Red 177, C.I. Pigment Red 184, C.I. Pigment Red 185, C.I. Pigment Red 202, C.I. Pigment Red 206, C.I. Pigment Red 220, C.I. Pigment Red 221, and C.I. Pigment Red 254.
Examples of a blue pigment include Alkali Blue Lake, Victoria Blue Lake, Phthalocyanine Blue, Metal-free Phthalocyanine Blue, Phthalocyanine Blue partial chlorides, Fast Sky Blue, Indanthrene Blue BG, and other copper phthalocyanine compounds and derivatives thereof, anthraquinone compounds, and basic dye lake compounds.
Specific examples thereof include C.I. Pigment Blue 1, C.I. Pigment Blue 7, C.I. Pigment Blue 15, C.I. Pigment Blue 15:1, C.I. Pigment Blue 15:2, C.I. Pigment Blue 15:3, C.I. Pigment Blue 15:4, C.I. Pigment Blue 60, C.I. Pigment Blue 62, and C.I. Pigment Blue 66.
Examples of a purple pigment include Fast Violet B and Methyl Violet Lake.
Examples of a green pigment include Pigment Green B, Malachite Green Lake, and Final Yellow Green G.
Examples of a white pigment include zinc oxide, titanium oxide, antimony white, and zinc sulfide.
Examples of a black pigment include carbon black, aniline black, nonmagnetic ferrite, magnetite, and those pigments adjusted to have a black color by using the yellow colorants, the red colorants, and the blue colorants described above.
These colorants can be used alone, in combination as a mixture, or in a solid solution form.
Care should be paid to the polymerization inhibiting effect of the colorant and the colorant's tendency to make transition into a dispersion medium depending on the toner production method. If needed, the colorant may be surface treated with a substance that does not inhibit polymerization so as to modify the surface. In particular, many dyes and carbon black exhibit polymerization inhibiting effects and care should be taken in using these.
An example of a method suitable for treating a dye include polymerizing a Polymerizable monomer in the presence of a dye in advance, and adding a polymerizable monomer composition to the resulting colored polymer. In the case where carbon black is used, the carbon black can be treated in the same way as the dye or can be treated with a substance (for example, organosiloxanes) that reacts with surface functional groups of the carbon black.
The colorant content may be 3.0 to 15.0 parts by mass per 100 parts by mass of the binder resin or the polymerizable monomer.
Charge Control Agent
The toner may contain a charge control agent. The charge control agent may be any available charge control agent. In particular, a charge control agent that exhibits a high charging speed and can stably maintain a particular amount of charges may be used. In the case where toner particles are produced by a direct polymerization method, a charge control agent that has a low polymerization inhibition effect and is substantially free of substances soluble in the aqueous medium may be used.
Examples of the charge control agent capable of forming negative charge toners include organic metal compounds and chelating compounds such as monoazo metal compounds, acetylacetone metal compounds, and metal compounds based on aromatic oxycarboxylic acids, aromatic dicarboxylic acids, oxycarboxylic acids, and dicarboxylic acids. Other examples include aromatic oxycarboxylic acids, aromatic mono- and poly-carboxylic acids and metal salts thereof, anhydrides, esters, and phenol derivatives such as bisphenol. Yet other examples include urea derivatives, metal-containing salicylic acid-based compounds, metal-containing naphthoic acid-based compounds, boron compounds, quaternary ammonium salts, and calixarene.
Examples of the charge control agent capable of forming positive charge toners include nigrosin and modified nigrosin such as fatty acid metal salts; guanidine compounds; imidazole compounds; quaternary ammonium salts, onium salts thereof such as phosphonium salts which are analogs of these, and lake pigments thereof such as tributylbenzyl ammonium-1-hydroxy-4-naphthosulfonic acid salt and tetrabutyl ammonium tetrafluoroborate; triphenyl methane dyes and lake pigments thereof (examples of the laking agent include phosphotungstic acid, phosphomolybdic acid, phosphotungstomolybdic acid, tannic acid, lauric acid, gallic acid, ferricyanide, and ferrocyanide); metal salts of higher aliphatic acids; and resin-based charge control agents.
These charge control agents may be used alone or in combination.
Among these charge control agents, metal-containing salicylic acid-based compounds are preferable and more preferably the metal is aluminum or zircon. Of these, 3,5-di-tert-butyl salicylic acid aluminum compound is most preferable as the charge control agent.
The charge control resin may be a polymer having a sulfonic acid-based functional group. A polymer having a sulfonic acid-based functional group refers to a polymer or copolymer that has a sulfonic acid group, a sulfonic acid base, or a sulfonic acid ester group.
Examples of the polymer or copolymer that has a sulfonic acid group, a sulfonic acid base, or a sulfonic acid ester group include polymer-type compounds having sulfonic acid groups in the side chains. From the viewpoint of improving the charge stability at high humidity, a polymer-type compound which is a styrene and/or styrene (meth)acrylic acid ester copolymer that has a glass transition temperature (Tg) of 40° C. to 90° C. and contains 2 mass % or more and preferably 5 mass % or more of a sulfonic acid group-containing (meth)acrylamide-based monomer in terms of a copolymerization ratio may be used. With this compound, the charge stability at high humidity is improved.
The sulfonic acid group-containing (meth)acrylamide-based monomer may be a compound represented by general formula (X) below. Examples thereof include 2-acrylamide-2-methyl propanoic acid and 2-methacrylamide-2-methyl propanoic acid.
(In formula (X), R11 represents a hydrogen atom or a methyl group, R12 and R13 each independently represents a hydrogen group or an alkyl group, alkenyl group, aryl group, or alkoxy group having 1 to 10 carbon atoms, and n represents an integer in the range of 1 to 10.)
The polymer having a sulfonic acid group may be contained in an amount of 0.1 to 10.0 parts by mass per 100 parts by mass of the binder resin in the toner particles so that the charge state of the toner can be further improved when used in combination with a water-soluble initiator.
The amount of the charge control agent added may be 0.01 to 10.00 parts by mass per 100 parts by mass of the binder resin or the polymerizable monomer.
Organic Fine Particles and Inorganic Fine Particles
Various types of organic fine particles and/or inorganic fine particles may be externally added to the toner particles so as to impart various properties to the toner. The organic fine particles and the inorganic fine particles may have a particle size equal to or smaller than 1/10 of the weight-average particle size of the toner particles considering the durability of these particles added to the toner particles.
Examples of the organic fine particles and inorganic fine particles are as follows:
(1) Fluidity imparting agent: silica, alumina, titanium oxide, carbon black, and fluorinated carbon;
(2) Abrasives: metal oxides such as strontium titanate, cerium oxide, alumina, magnesium oxide, and chromium oxide; nitrides such as silicon nitride; carbide such as silicon carbide; and metal salts such as calcium sulfate, barium sulfate, and calcium carbonate;
(3) Lubricant: fluorine-based resin powders such as vinylidene fluoride and polytetrafluoroethylene and aliphatic acid metal salts such as zinc stearate and calcium stearate; and
(4) Charge control particles: metal oxides such as tin oxide, titanium oxide, zinc oxide, silica, and alumina, and carbon black.
The organic fine particles or inorganic fine particles are used as the material for treating the surfaces of the toner particles in order to improve the fluidity of the toner and make the charges of the toner uniform. Since the chargeability of the toner can be controlled and the charge properties in a high humidity environment can be improved by hydrophobing the organic fine particles or the inorganic fine particles, hydrophobized organic or inorganic fine particles may be used. If organic fine particles or inorganic fine particles added to the toner absorb humidity, the chargeability of the toner is degraded and the developing performance and the transfer property tend to be lowered.
Examples of the treating agent used for hydrophobing the organic fine particles or inorganic fine particles include unmodified silicone varnishes, various modified silicone varnishes, unmodified silicone oils, various modified silicone oils, silane compounds, silane coupling agents, other silicon compounds, and organic titanium compounds. These treating agents may be used alone or in combination.
In particular, inorganic fine particles treated with a silicone oil are preferably used. More preferably, inorganic fine particles are hydrophobized with a coupling agent and, at the same time or after this treatment, treated with a silicone oil. Hydrophobized inorganic fine particles treated with a silicone oil help maintain the charge amount of the toner high even in a high humidity environment and reduce the selective developing performance.
The amount of the organic fine particles or the inorganic fine particles added is preferably 0.01 to 10.00 parts by mass, more preferably 0.02 to 1.00 parts by mass, and most preferably 0.03 to 1.00 parts by mass per 100 parts by mass of the toner particles. At this amount, penetration of organic fine particles or inorganic fine particles into interior of the toner particles is suppressed and non-soiling property is enhanced. The organic fine particles or the inorganic fine particles may be used alone of in combination.
The BET specific surface area of the organic fine particles or the inorganic fine particles may be 10 m2/g or more and 450 m2/g or less.
The BET specific surface area of the organic fine particles or the inorganic fine particles can be determined in accordance with a BET method (preferably a BET multipoint method) through a dynamic flow method and a low-temperature gas adsorption method. For example, a specific surface area meter “GEMINI 2375 Ver. 5.0” (product of Shimadzu Corporation) is used to allow nitrogen gas to adsorb onto surfaces of samples and conduct measurement by a BET multipoint method so as to calculate the BET specific surface area (m2/g).
The organic fine particles or the inorganic fine particles may be strongly fixed or attached to the surfaces of the toner particles. This can be achieved by using a HENSCHEL MIXER, MECHANOFUSION, CYCLOMIX, TURBULIZER, FLEXOMIX, HYBRIDIZATION, MECHANOHYBRID, or NOBIILTA, for example.
The organic fine particles or the inorganic fine particles can be strongly fixed or attached to the surfaces of the toner particles by increasing the rotation peripheral speed or extending the treatment time.
Physical Properties of Toner
The physical properties of the toner will now be described.
80° C. Viscosity
The 80° C. viscosity of the toner measured with a constant-pressure extrusion system capillary rheometer may be 1,000 Pa·s or more and 40,000 Pa·s or less. When the 80° C. viscosity is within the range of 1,000 to 40,000 Pa·s, the toner exhibits good low-temperature fixability. The 80° C. viscosity is more preferably in the range of 2,000 Pa·s to 20,000 Pa·s. The 80° C. viscosity can be controlled by adjusting the amount of the low-molecular-weight resin added, the type of monomer used for producing the binder resin, the amount of the initiator, the reaction temperature, and the reaction time.
The 80° C. viscosity of the toner measured with the constant-pressure extrusion system capillary rheometer can be determined through the following procedure.
FLOW TESTER CFT-500D (produced by Shimadzu Corporation) is used as a measurement instrument, for example, and measurement is conducted under the following conditions.
The viscosity (Pa·s) of the toner in the temperature range of 30° C. to 200° C. is measured by the above-described procedure and the 80° C. viscosity (Pa·s) is determined. The resulting value is assumed to be the 80° C. viscosity measured with a constant-pressure extrusion system capillary rheometer.
Weight-Average Particle Size (D4)
The weight-average particle size (D4) of the toner is preferably 4.0 to 9.0 μm, more preferably 5.0 to 8.0 μm, and most preferably 5.0 to 7.0 μm.
Glass Transition Temperature (Tg)
The glass transition temperature (Tg) of the toner is preferably 35° C. to 100° C., more preferably 40° C. to 80° C., and most preferably 45° C. to 70° C. When the glass transition temperature is within this range, blocking resistance, low-temperature offset resistance, and transparency of the projection images on the films for overhead projectors can be further improved.
THF Insoluble Content
The content of substances insoluble in tetrahydrofuran (THF) (hereinafter referred to as THF insoluble content) is preferably less than 50.0 mass %, more preferably 0.0 mass % or more and less than 45.0 mass %, and most preferably 5.0 mass % or more and less than 40.0 mass % relative to the toner components in the toner other than the colorant and the inorganic fine particles. When the THF insoluble content is less than 50.0 mass %, the low-temperature fixability can be improved.
The THF insoluble content of the toner refers to the mass ratio of the ultra high molecular weight polymer (substantially a crosslinked polymer) which became insoluble in the THF solvent. For the purposes of the present invention, the THF insoluble content is the value measured by the following procedure.
One gram of the toner is weighed (W1 g), placed in a cylindrical filter (for example, No. 86R produced by Toyo Roshi Kaisha, Ltd.), and loaded in a Soxhlet extractor. Extraction is conducted for 20 hours by using 200 mL of THF as a solvent and the soluble components extracted with the solvent are condensed and vacuum dried for several hours at 40° C. Then the THF soluble resin components are weighed (W2 g). The weight of components, such as a pigment, other than the resin components in the toner is assumed to be W3 g. The THF insoluble content can be determined from the following equation:
THF insoluble content (mass %)={(W1−(W3+W2))/(W1−W3)}×100
The THF insoluble content of the toner can be controlled by adjusting the degree of polymerization and degree of crosslinking of the binder resin.
Weight-Average Molecular Weight (Mw) and Weight-Average Molecular Weight (Mw)/Number-Average Molecular Weight (Mn)
The weight-average molecular weight (Mw) of the toner measured by gel permeation chromatography (GPC) performed on the tetrahydrofuran (THF) soluble components (hereinafter also referred to as “weight-average molecular weight of the toner”) may be in the range of 5,000 to 50,000. When the weight-average molecular weight (Mw) of the toner is in this range, blocking resistance, development durability, and low-temperature fixability can be improved and high-gloss images can be produced. The weight-average molecular weight (Mw) of the toner can be controlled by adjusting the amount and the weight-average molecular weight (Mw) of the low-molecular-weight resin added, the reaction temperature and reaction time for toner production, and the amount of initiator, the amount of the chain transfer agent, and the amount of the crosslinking agent used for toner production.
The ratio (Mw/Mn) of the weight-average molecular weight (Mw) to the number-average molecular weight (Mn) of the toner determined by GPC performed on the tetrahydrofuran (THF) soluble components is preferably in the range of 5.0 to 100.0 and more preferably in the range of 5 to 30. When the Mw/Mn is within this range, the temperature range in which fixing is possible can be widened.
Method for Measuring and Evaluating Physical Properties of Toner Particles or Toner
Methods for measuring and evaluating physical properties of the toner particles or toner will now be described.
Mapping Measurement Through Focused Ion Beam Time-of-Flight Secondary Ion Spectrometry (FIB-TOF—SIMS)
FIB-TOF—SIMS measurement is performed by using a secondary ion mass spectrometer having FIB processing function, “FIB-TOF—SIMS” produced by Toyama Co., Ltd. (commercial version of single particle history analyzer).
The analytical conditions are as follows.
Sample preparation: An indium plate is placed on a sample holder and toner particles are placed on the indium place. In order to prevent toner particles from moving on the sample holder, carbon paste may be applied to the indium plate on the sample holder to immobilize the toner particles. When an immobilization aid such as carbon paste or a silicon wafer is used, the background is measured under the same conditions but without toner particles and the results are used in conversion.
Pretreatment of sample: not performed
Measurement method: Surfaces of toner particles are scraped by FIB etching and SIMS is performed under the following analytical conditions for every equal ratio spacing.
Analytical conditions: secondary ion mass spectroscopy (SIMS, 1 step)
Primary ion source information: ion species (natural isotope) Ga+
Acceleration voltage (keV): 30
Beam current (pA): 180
Mapping time (min): 12
No. of pixels (pixel): 65536
Charge neutralization mode: ON
Measurement mode: positive
Analytic area: 10.0 μm×14.1 μm
No. of pulses (sweep/pix): 5
No. of pixels (pixel/map): 65536
No. of repetition (/map): 10
No. of times of ion irradiation (No. of pulses×No. of repetition=sweep): 50
Pulse width (sec): 2.00×10−7
Irradiation ion dose (ions): 7.37×108
Dose rate (ions/m2): 5.2×1018
Frequency (Hz): 16000
Calculation of primary ion dose Ia applied to entire area of view in one mapping
The primary ion dose applied to the entire area of view in one mapping is assumed to be Ia.
Ia=(beam current (A)×pulse width (sec)×number of pixels×number of times ions are applied)/elementary charge (C)
Under the aforementioned analytical conditions, the primary ion dose Ia is as shown below, where the elementary charge is assumed to be 1.6×10−19 (C).
(180×1.0×10−12×2.00×10−7×65536×50)/1.6×10−19)=7.37×108
Calculation of primary ion dose (number of ions) Imp applied to particles in one mapping
Ap: particle projection area (m2) of number of pixels of particle image
The particle projection area is calculated by determining the average particle size Dmp (μm) of particles present in an area in which mapping is conducted with SEM.
Am denotes the mapping area (m2) or number of pixels in the area of view for mapping
Ap/Am is a ratio of the particle projection area to the mapping area.
Ap/Am may be calculated on a basis of area or determined as pixel-based Ap/Am=(number of pixels where particle image is present)/(number of pixels in area of view for mapping).
The primary ion dose (number of ions) Imp applied to the particles in one mapping is calculated by the following equation.
Imp=Ia×(Ap/Am)
Calculation of silicon atom intensity ISi relative to the primary ion dose Imp applied to the particles in one mapping
In a mass spectrum measured under the aforementioned conditions, the total ISi of the intensity counts at M/Z=27.5 to 28.5 is divided by the primary ion dose (Imp) applied to the particles in one mapping.
ASi=ISi/Imp
In the case where the background of the sample holder is measured as in the present invention and the total of the intensity counts at M/Z=27.5 to 28.5 in a mass spectrum is assumed to be ISiB, ISiB is divided by the primary ion dose Ia applied to the entire area of view for one mapping and the following correction is made:
ASi=(ISi/Imp)−(ISiB/Ia)
Intensity AC of carbon atom relative to primary ion dose Imp applied to particles in one mapping
The total IC of intensity counts at M/Z=11.5 to 12.5 in a mass spectrum detected under the aforementioned conditions is divided by the primary ion dose (Imp) applied to the particles in one mapping:
AC=IC/Imp
In the case where the background of the sample holder is measured as in the present invention and the total of the intensity counts at M/Z=11.5 to 12.5 in a mass spectrum is assumed to be ICB, ICBB is divided by the primary ion dose Ia applied to the entire area of view for one mapping and the following correction is made:
AC=(IC/Imp)−(ICB/Ia)
Proportion of particles in area of view for etching
Ae denotes the etching area (m2).
Ap/Ae denotes the ratio of the toner particle projection area to the etching area.
Assume that the above-described calculation has found Ia=7.37×108 and the analytical results have found Ap/Am=0.3, ISi=20000, IC=15000, ISiB=0, and ICB=0. Then, Imp=7.37×108×0.3=2.21×108
Thus, ASi/AC=86.10
Calculation of accumulated dose rate EDRt per etching area in elapsed irradiation time T
The accumulated dose rate EDRt per etching area in an elapsed irradiation time T (sec), in other words, the total counts of primary ions applied to a unit area during etching in an elapsed irradiation time T (sec), is determined as follows.
Etching Conditions
Beam current (pA): 180
Etching area: 10.0 (μm)×14.0 (μm)
Number of steps: eight at elapsed irradiation time T (sec)=0.00, 2.07, 4.13, 8.27, 16.53, 33.07, 66.13, 529.07.
EDRt={beam current (A)×elapsed irradiation time (sec)}/{elementary charge (C) (1.6×10−19)×etching area (m2)}=180 (pA)×1.0×10−12×T (sec)/{1.6×10−19×10.0×1.0×10−6×14.0×1.0×10−6}
Etching is conducted in the following eight stages. T: elapsed irradiation time (sec), EDRt: accumulated dose rate (ions/m2)
Stage 0: T=0.00 (sec), EDRt=0.00 (ions/m2)
Stage 1: T=2.07 (sec), EDRt=1.66×1019 (ions/m2)
Stage 2: T=4.13 (sec), EDRt=3.11×1019 (ions/m2)
Stage 3: T=8.27 (sec), EDRt=6.64×1019 (ions/m2)
Stage 4: T=16.53 (sec), EDRt=1.33×1020 (ions/m2)
Stage 5: T=33.07 (sec), EDRt=2.65×1020 (ions/m2)
Stage 6: T=66.13 (sec), EDRt=5.31×1020 (ions/m2)
Stage 7: T=529.07 (sec), EDRt=4.25×1021 (ions/m2)
Calculation of Accumulated Dose Rate PDRt Per Toner Projection Area for Elapsed Irradiation Time T
The accumulated dose rate PDRt per toner projection area for the elapsed irradiation time T is determined as follows.
PDRt=(accumulated dose rate per etching area for elapsed irradiation time T (sec))×Ap/Ae
Average thickness Dav. of surface layers of toner particles measured by observation of cross sections of toner particles with transmission electron microscope (TEM) and determining percentage of surface layer with a thickness of 5.0 nm or less
The cross sections of the toner particles can be observed by the following procedure.
First, toner particles are dispersed in an epoxy resin curable at room temperature. The resulting dispersion is left in a 40° C. atmosphere for 2 days to cure the epoxy resin. Thin samples are cut out from the resulting cured product by using a microtome equipped with diamond knives. The cross section of each sample is observed with a transmission electron microscope (TEM) at a magnification of ×10,000 to ×100,000. For the purposes of the present invention, observation is performed by utilizing the difference in atomic weight between the binder resin used and the organic silicon polymer since a portion with a higher atomic weight appears in light color. Moreover, in order to enhance the contrast between different materials, a ruthenium tetraoxide staining method or an osmium tetraoxide staining method may be employed.
A TEM bright field image is acquired by using an electron microscope, TECNAI TF20XT produced by FEI Company at an acceleration voltage of 200 kV. Then an EF mapping image of a Si-K edge (99 eV) is acquired by a three window method by using an EELS detector, GIF TRIDIEM produced by Gatan Inc., so as to confirm presence of the organic silicon polymer at the surface layer.
The toner particles used as the subject of the measurement for determining the average thickness Dav. of the surface layers of the toner particles and the percentage of the surface layer with a thickness of 5.0 nm or less by using a TEM are the particles which have an equivalent circle diameter Dtem within the range of ±10% of the weight-average particle diameter of the toner determined with a Coulter counter by the procedure described below, where the equivalent circle diameter Dtem is determined from the cross sections of the toner particles in the TEM image.
A long axis L, which is a maximum diameter of a cross section of a toner particle, is drawn on each toner particle to be measured. Then sixteen straight lines that pass through the midpoint of the long axis L and extend across the cross section are drawn such that the angles between adjacent straight lines at the intersection at the midpoint are equal (the intersectional angle is 11.25°) (refer to
The equivalent circle diameter Dtemav. is determined from a cross section of the toner in a TEM image through the following procedure.
First, the equivalent circle diameter Dtem of one toner particle is determined from the following formula from a toner cross section observed in a TEM image.
Dtem=(RA1+RA2+RA3+RA4+RA5+RA6+RA7+RA8+RA9+RA10+RA11+RA12+RA13+RA14+RA15+RA16+RA17+RA18+RA19+RA20+RA21+RA22+RA23+RA24+RA25+RA26+RA27+RA28+RA29+RA20+RA31+RA22)/16
This measurement and calculation are conducted on ten toner particles. The observed equivalent circle diameters are averaged and the result is assumed to be the equivalent circle diameter Dtemav. determined from cross sections of the toner particles.
Average Thickness Dav. Of Surface Layer of Toner Particle
The average thickness Dav. of the toner particle surface layer is determined by the following procedure.
First, the average thickness D(n) of a surface layer of one toner particle is determined by the following equation:
Dm=Total of surface layer thicknesses at thirty-two positions on the line segments/32
This calculation is conducted on ten toner particles. The resulting average thicknesses D(n) (n=1 to 10) of the toner particles are averaged in accordance with the equation below to determine the average thickness Dav. of the surface layers of the toner particles.
Dav.={D(1)+D(2)+D(3)+D(4)+D(5)+D(6)+D(7)+D(8)+D(9)+D(10)}/10
Percentage of Surface Layer Thicknesses that are 5.0 nm or Less Out of Thicknesses FRAn of the Surface Layer of the Toner Particle
The percentage of the surface layer thicknesses that are 5.0 nm or less out of the thicknesses FRAn of the surface layer is determined by the following procedure.
First, the percentage of the surface layer having a thickness of 5.0 nm or less is determined by using the equation below for one toner particle.
(Percentage of surface layer having a thickness of 5.0 nm or less)=((Number of surface layer thicknesses FRAn that are 5.0 nm or less)/32)×100
This calculation is conducted on ten toner particles. The obtained results are averaged and the result is assumed to be the percentage of the surface layer thicknesses that are 5.0 nm or less out of the thicknesses FRAn of the surface layer of the toner particle.
Concentration (Atomic %) of Silicon Present at Surfaces of Toner Particles
Surface composition analysis is conducted by electron spectroscopy for chemical analysis (ESCA) to determine the content (atomic %) of silicon present at the surfaces of the toner particles.
The system used for ESCA and the measurement conditions are as follows.
System used: QUANTUM 2000 produced by ULVAC-PHI Incorporated
ESCA measurement conditions: X-ray source: AlKα
X ray: 100 μm, 25 W, 15 kV
Raster: 300 μm×200 μm
Pass energy: 58.70 eV
Step size: 0.125 eV
Neutralizing electron gun: 20 μA, 1 V
Ar ion gun: 7 mA, 10 V
Number of sweeps: 15 for Si, 10 for C, 5 for O
The observed peak intensities of the respective elements are used to calculate the surface atomic concentrations (atomic %) by using relative sensitivity factors provided by ULVAC-PHI Incorporated.
Method for Measuring Weight-Average Molecular Weight (Mw), Number-Average Molecular Weight (Mn), and Main Peak Molecular Weight (Mp) of Toner and Various Resins
The weight-average molecular weight (Mw), number-average molecular weight (Mn), and main peak molecular weight (Mp) of the toner and various resins are determined by gel permeation chromatography (GPC) under the following conditions.
Measurement Conditions
Columns (produced by Showa Denko K.K.): seven-column combination including Shodex GPC KF-801, KF-802, KF-803, KF-804, KF-805, KF-806, and KF-807 (diameter: 8.0 mm, length: 30 cm)
Eluent: tetrahydrofuran (THF)
Temperature: 40° C.
Flow rate: 0.6 mL/min
Detector: RI
Concentration and amount of sample: 10 μl of a 0.1 mass % sample
Sample Preparation
In 20 mL of tetrahydrofuran, 0.04 g of a subject of measurement (toner or resin) is dispersed and dissolved. The resulting mixture is left standing still for 24 hours and filtered with a 0.2 μm filter (Pretreatment Disk H-25-2 produced by Tosoh Corporation). The filtrate is used as a sample.
Molecular weight calibration curves prepared from monodisperse polystyrene standard samples are used as the calibration curves. The standard polystyrene samples used for plotting calibration curves are TSK standard polystyrene F-850, F-450, F-288, F-128, F-80, F-40, F-20, F-10, F-4, F-2, F-1, A-5000, A-2500, A-1000, and A-500 produced by Tosoh Corporation. At least ten standard polystyrene samples are to be used.
In determining the GPC molecular weight distribution, the measurement is started from the point where the chromatogram is rising from the baseline on the high-molecular-weight side and conducted up to a molecular weight of about 400 on the low-molecular-weight side.
Method for Measuring Glass Transition Temperature (Tg) of Toner and Various Resins
The glass transition temperature (Tg) of the toner and various resins is measured with a differential scanning calorimeter (DSC) M-DSC (trade name: Q1000, produced by TA-Instruments) by the following procedure. First, 6 mg of a sample to be measured (toner or resin) is accurately weighed and placed in an aluminum pan. While using an empty aluminum pan as a reference, measurement is conducted in the measurement temperature range of 20° C. to 200° C. at a heating rate of 1° C./min at normal temperature and normal humidity. The measurement is conducted at a modulation amplitude of ±0.5° C. and a frequency of 1/min. The glass transition temperature (Tg: ° C.) is calculated from the obtained reversing heat flow curve. The midpoint of a line connecting the intersections between the tangent line of the endothermic curve and the base lines before and after the endotherm is assumed to be the glass transition temperature Tg (° C.).
The integrated calorific value per gram of the toner (J/g) indicated by the peak area of the endothermic main peak in an endothermic chart during temperature elevation measured by DSC is measured. An example of a reversing flow curve obtained by DSC measurement on the toner is shown in
The integrated calorific value (J/g) is determined by using the reversing flow curve obtained by the above-mentioned measurement. Analytic software, Universal Analysis 2000 for Windows 2000/XP Version 4.3A (produced by TA Instruments) is used in calculation. The integrated calorific value (J/g) is determined from the region defined by the endothermic curve and a straight line connecting the measurement points at 35° C. and 135° C. by using Integral Peak Linear function.
Method for Measuring Weight-Average Particle Size (D4) and Number-Average Particle Size (D1) of Toner
The weight-average particle size (D4) and the number-average particle size (D1) of the toner are measured by using a precision particle size distribution analyzer equipped with a 100 μm aperture tube based on an aperture resistance method, namely, COULTER COUNTER Multisizer 3 (registered trade mark, product of Beckman Coulter Inc.) and bundled special software Beckman Coulter Multisizer 3 version 3.51 produced by Beckman Coulter Inc., for setting measurement conditions and analyzing the observed data. The number of effective measurement channels is 25,000. The observed data is analyzed to calculate D4 and D1.
The aqueous electrolytic solution used in the measurement is prepared by dissolving special grade sodium chloride in ion exchange water so that the concentration is about 1 mass %. An example of such a solution is ISOTON II produced by Beckman Coulter Inc.
Before conducting measurement and analysis, the setting of the special software is done as follows: Set the total count of the control mode appearing in a “Change standard operating method (SOM)” window of the bundled software to 50,000 particles. Set the number of runs to 1 and Kd value to a value obtained by using “Standard particles 10.0 μm” produced by Beckman Coulter Inc. Press “Threshold/Noise level measurement button” to automatically set the threshold and the noise level. Set the current to 1600 μA, gain to 2, and electrolyte to ISOTON II. Check the “Flush aperture tube after run” box. In the “Convert Pulse to Size Settings” window of the bundled software, set the bin spacing to log diameter, size bin to 256 size bin, and size range to 2 μm to 60 μm.
A specific measurement method is as follows:
(1) Into a 250 mL round-bottomed glass beaker specially prepared for Multisizer 3, about 200 mL of the aqueous electrolytic solution is placed, the beaker is set in the sample stand, and anticlockwise stirring using a stirrer rod is conducted at 24 rotations/second. The contaminants and bubbles inside the aperture tube are preliminarily removed by “aperture flush” function of the software.
(2) Into a 100 mL flat-bottomed glass beaker, about 30 mL of the aqueous electrolytic solution is placed and about 0.3 mL of a diluted solution of a dispersing agent, “Contaminon N” (a 10 mass % aqueous solution of a neutral detergent for washing precision measurement instruments having pH of 7 and containing a nonionic surfactant, an anionic surfactant, and an organic builder, produced by Wako Pure Chemical Industries) diluted about 3 fold with ion exchange water on a mass basis is added thereto.
(3) A particular quantity of ion exchange water is placed in a water tank of an ultrasonic disperser, Ultrasonic Dispersion System Tetora 150 produced by Nikkaki Bios Co., Ltd., equipped with two oscillators having an oscillation frequency of 50 kHz with a 180 degree phase shift and an electrical output of 120 W. To the water tank, about 2 mL of Contaminon N is added.
(4) The beaker prepared in (2) is set in a beaker securing hole of the ultrasonic disperser and the ultrasonic disperser is operated. The height position of the beaker is adjusted so that the resonant state of the liquid surface of the aqueous electrolytic solution in the beaker is maximum.
(5) While applying ultrasonic waves to the electrolyte aqueous solution in the beaker in (4), about 10 mg of the toner is added to the aqueous electrolytic solution in small divided portions to conduct dispersion. The ultrasonic dispersion treatment is continued further for 60 seconds. During the process of ultrasonic dispersion, the water temperature of the water tank is adjusted to be in a range of 10° C. or more and 40° C. or less.
(6) The ultrasonically dispersed aqueous electrolytic solution containing dispersed toner prepared in (5) is added dropwise using a pipette to the round-bottomed beaker prepared in (1) installed in the sample stand to adjust the measurement concentration to about 5%. Run is repeated until the count of particles reaches 50,000.
(7) The measurement data is analyzed with special software installed in the instrument to calculate the weight-average particle diameter (D4) and the number-average particle diameter (D1). The weight-average particle diameter (D4) is the number in “Average Diameter” of the “Analysis/volume statistic values (arithmetic mean)” window on Graph/Volume % setting, and the number-average particle diameter (D1) is the number in “Average Diameter” of the “Analysis/number statistic values (arithmetic mean)” window on Graph/Number % setting.
Method for Measuring Average Circularity and Mode Circularity of Toner
The average circularity of the toner is measured with a dynamic flow particle imaging instrument EPIA-3000 (produced by Sysmex Corporation) under the measurement and analytical conditions used in calibration operation.
To 20 mL of ion exchange water, an appropriate amount of a surfactant, which is preferably an alkyl benzene sulfonic acid salt, is added as a dispersant and then 0.02 g of the measurement sample is added thereto. The resulting mixture is dispersed for 2 minutes in a desktop-type ultrasonic cleaner disperser (for example, VS-150 produced by Velvo-Clear) at an oscillation frequency of 50 kHz and a power output of 150 W to prepare a dispersion for measurement. During this process, cooling is appropriately conducted so that the temperature of the dispersion is within the range of 10° C. or more and 40° C. or less.
In measurement, the above-mentioned dynamic flow particle imaging instrument equipped with a standard object lens (magnification of 10) is used and particle sheath PSE-900A (produced by Sysmex Corporation) is used as the sheath solution. The dispersion prepared by the above-mentioned procedure is introduced into the dynamic flow particle imaging instrument and 3000 toner particles are measured at a total count mode and HPF measurement mode. The binarization threshold during the particle analysis is set to 85% and the analytic particle diameter is limited to an equivalent circle diameter of 1.98 μm or more and 19.92 μm or less so as to determine the average circularity of the toner.
Prior to measurement, automatic focus adjustment is conducted by using standard latex particles (for example, 5100A produced by Duke Scientific Corporation diluted with ion exchange water). After the start of the measurement, focus adjustment may be performed every two hours.
In the circularity distribution of the toner, a mode circularity of 0.98 to 1.00 means that most of toner particles have a shape close to spherical. At this circularity, the adhesion force of the toner to the photosensitive member attributable to image force and Van der Waals force is significantly decreased and the transfer efficiency is significantly increased.
The circularity is divided into sixty-one circularity classes ranging from a circularity of 0.40 to 1.00 at 0.01 intervals (for example, one class ranges from 0.40 to less than 0.41, the next class ranges from 0.41 to less than 0.42, and the last class ranges from 0.99 to less than 1.00). The observed circularities of the respective particles measured are assigned to corresponding classes and one of these classes where the highest number of particles are allotted in the circularity frequency distribution is assumed to be the mode circularity.
The present invention will be explained further through Examples below which do not limit the scope of the present invention. The number of parts in the description below indicate parts by mass unless otherwise noted.
Production Examples of the charge control resin used in embodiments of the present invention are described.
To a reactor equipped with a reflux duct, a stirrer, a thermometer, a nitrogen duct, a dropper, and a decompressor, 255 parts by mass of methanol, 145 parts by mass of 2-butanone, and 100 parts by mass of 2-propanol were added as solvents and 88 parts by mass of styrene, 6.2 parts by mass of 2-ethylhexyl acrylate, and 6.6 parts by mass of 2-acrylamide-2-methylpropane sulfonic acid were added as monomers. The resulting mixture was heated while being stirred at normal pressure under refluxing. Thereto, a solution prepared by diluting 0.8 parts by mass of a polymerization initiator, 2,2′-azobisisobutyronitrile with 20 parts by mass of 2-butanone was added dropwise for 30 minutes and stirring was continued for 5 hours. A solution prepared by diluting 1.2 parts by mass of 2,2′-azobisisobutyronitrile with 20 parts by mass of 2-butanone was added thereto for 30 minutes and stirring was conducted for 5 hours at normal pressure under refluxing to terminate the polymerization.
Next, the polymer obtained by distilling away the polymerization solvents at a reduced pressure was roughly pulverized to 100 μm or less with a cutter mill equipped with a 150 mesh screen and then finely pulverized with a jet mill. The resulting fine particles were classified with a 250 mesh sieve, and particles having a size of 60 μm or under were obtained by the classification. These particles were dissolved in methyl ethyl ketone to a concentration of 10% and the resulting solution was slowly added to methanol in an amount 20 times greater than that of methyl ethyl ketone so as to perform reprecipitation. The precipitates obtained were washed with methanol in an amount half that used for reprecipitation and the filtered particles were vacuum dried at 35° C. for 48 hours.
The particles after vacuum drying was re-dissolved in methyl ethyl ketone to a concentration of 10% and the resulting solution was slowly added to n-hexane in an amount 20 times greater than that of methyl ethyl ketone so as to perform reprecipitation. The precipitates obtained were washed with n-hexane in an amount half that used for reprecipitation and the filtered particles were vacuum dried at 35° C. for 48 hours. The resulting charge control resin had a Tg of about 82° C., a main peak molecular weight (Mp) of 19,300, a number-average molecular weight (Mn) of 12,700, and a weight-average molecular weight (Mw) of 21,100. The acid value was 20.4 mgKOH/g. The obtained resin was named “charge control resin 1”.
The following monomers were charged in an autoclave along with an esterification catalyst:
A decompressor, a water separator, a nitrogen gas introducing system, a temperature measurement system, and a stirrer were attached to the autoclave and the reaction was conducted in a nitrogen atmosphere at a reduced pressure according to a normal procedure at 220° C. until Tg was 70° C. As a result, a polyester-based resin (1) was obtained. The weight-average molecular weight (Mw) was 8,200 and the number-average molecular weight (Mn) was 3,220.
The following materials were reacted at 220° C. for 7 hours under stirring:
bisphenol A ethylene oxide 2 mol adduct: 720 parts by mass phthalic acid: 280 parts by mass
dibutyl titanium oxide: 2.5 parts by mass
Then the reaction was continued at a reduced pressure for 5 hours. The resulting product was cooled to 80° C., reacted with 190 parts by mass of isophorone diisocyanate in ethyl acetate for 2 hours. As a result, an isocyanate group-containing polyester resin was obtained. The isocyanate group-containing polyester resin (26 parts by mass) and 1 part by mass of isophorone diamine were reacted at 50° C. for 2 hours. As a result, a polyester-based resin (2) containing a urea group-containing polyester as a main component was obtained. The resulting polyester-based resin (2) had a weight-average molecular weight (Mw) of 25000, a number-average molecular weight (Mn) of 3200, and a peak molecular weight of 6200.
To a four-necked container equipped with a reflux duct, a stirrer, a thermometer, and a nitrogen duct, 700 parts by mass of ion exchange water, 1000 parts by mass of a 0.1 mol/L Na3PO4 aqueous solution, and 24.0 parts by mass of a 1.0 mol/L HCl aqueous solution were added. The resulting mixture was held at 60° C. while being stirred at 12,000 rpm using a high-speed stirrer, TK-Homomixer. To the resulting mixture, 85 parts by mass of a 1.0 mol/L CaCl2 aqueous solution was slowly added to prepare an aqueous dispersion medium containing fine, slightly water-soluble dispersion stabilizer Ca3(PO4)2.
The following materials were dispersed for three hours using an attritor to prepare a polymerizable monomer composition 1:
styrene: 70.0 parts by mass
n-butyl acrylate: 30.0 parts by mass
divinylbenzene: 0.10 parts by mass
vinyltriethoxysilane: 15.0 parts by mass
copper phthalocyanine pigment (Pigment Blue 15:3 (P.B. 15:3)): 6.5 parts by mass
polyester-based resin (1): 5.0 parts by mass
charge control agent 1 (aluminum compound of 3,5-di-tert-butyl salicylic acid): 0.5 parts by mass
charge control resin 1: 0.5 parts by mass
release agent (behenyl behenate, endothermic main peak
temperature: 72.1° C.): 10.0 parts by mass
The polymerizable monomer composition 1 was held at 60° C. for 20 minutes. Subsequently, the polymerizable monomer composition 1 and 14.0 parts by mass (50% toluene solution) of t-butyl peroxypivalate serving as a polymerization initiator were placed in an aqueous medium. The resulting mixture was stirred with a high-speed stirrer at a rotation speed of 12,000 rpm for 10 minutes to form particles. The high-speed stirrer was changed to a propeller-type stirrer. The inner temperature was increased to 70° C. and the reaction was performed for 5 hours under slow stirring. The pH of the aqueous medium at this stage was 5.1. Next, 8.0 parts by mass of 1.0 N—NaOH was added to adjust the pH to 7.0. The temperature inside the reactor was increased to 85° C. and held thereat for 5 hours. Then 300 parts by mass of ion exchange water was added, the reflux duct was removed, and a distillator was attached. Distillation was conducted for 5 hours while maintaining the temperature inside the reactor to 100° C., and a polymer slurry 1 was obtained as a result. The amount of the distillate fraction was 310 parts by mass. Diluted hydrochloric acid was added to a reactor containing the polymer slurry 1 after being cooled to 30° C. so as to remove the dispersion stabilizer. Filtration, washing, and drying were performed on the resulting product and toner particles having a weight-average particle size of 5.6 μm were obtained as a result. These toner particles were assumed to be toner particles 1. The formulation and conditions of the toner particles 1 are shown in Table 1 and physical properties thereof are shown in Tables 3 and 5.
Toner particles 2 were obtained as in Production Example of toner particles 1 except that 15.0 parts by mass of allyltriethoxysilane was used instead of 15.0 parts by mass of vinyltriethoxysilane used in Production Example of toner particles 1. The formulation and conditions of the toner particles 2 are shown in Table 1 and the physical properties thereof are shown in Tables 3 and 5.
Toner particles 3 were obtained as in Production Example of toner particles 1 except that 23.2 parts by mass of vinyltriethoxysilane was used instead of 15.0 parts by mass of vinyltriethoxysilane used in Production Example of toner particles 1. The formulation and conditions of the toner particles 3 are shown in Table 1 and the physical properties thereof are shown in Tables 3 and 5.
Toner particles 4 were obtained as in Production Example of toner particles 1 except that 22.4 parts by mass of vinyltriethoxysilane was used instead of 15.0 parts by mass of vinyltriethoxysilane used in Production Example of toner particles 1. The formulation and conditions of the toner particles 4 are shown in Table 1 and the physical properties thereof are shown in Tables 3 and 5.
Comparative toner particles 1 were obtained as in Production Example of toner particles 1 except that 15.0 parts by mass of tetraethoxysilane was used instead of 15.0 parts by mass of vinyltriethoxysilane used in Production Example of toner particles 1. The formulation and conditions of the comparative toner particles 1 are shown in Table 2 and the physical properties thereof are shown in Tables 4 and 6.
Comparative toner particles 2 were obtained as in Production Example of toner particles 1 except that 6.0 parts by mass of vinyltriethoxysilane was used instead of 15.0 parts by mass of vinyltriethoxysilane used in Production Example of toner particles 1. The formulation and conditions of the comparative toner particles 2 are shown in Table 2 and the physical properties thereof are shown in Tables 4 and 6.
Comparative toner particles 3 were obtained as in Production Example of toner particles 1 except that 3.0 parts by mass of vinyltriethoxysilane was used instead of 15.0 parts by mass of vinyltriethoxysilane used in Production Example of toner particles 1. Moreover, instead of heating the temperature inside the reactor to 85° C. and holding temperature for 5 hours after 7.0 parts by mass of the 1.0 N—NaOH was added to adjust the pH to 7.0, the temperature was increased to 70° C. and held thereat for 10 hours. Moreover, the distillation was not conducted. The formulation and conditions of the comparative toner particles 3 are shown in Table 2 and the physical properties thereof is shown in Tables 4 and 6.
Comparative toner particles 4 were obtained as in Production Example of toner 1 except that the amount of vinyltriethoxysilane used was changed from 15.0 parts by mass used in Production Example of toner particle 1 to 0.0 parts by mass. The formulation and conditions of the comparative toner particles 4 are shown in Table 2 and the physical properties thereof are shown in Tables 4 and 6.
In a HENSCHEL MIXER (produced by Nippon Coke & Engineering Co., Ltd., formally known as Mitsui Mining Co., Ltd.), 100 parts by mass of the toner particles 1, 0.5 parts by mass of hydrophobic silica having a BET specific surface area of 210 m2/g and surfaces treated with 4 mass % of hexamethyldisilazane and 3 mass % of 100 cps silicone oil, and 0.2 parts by mass of aluminum oxide having a BET specific surface area of 70 m2/g were mixed to prepare a toner. This toner was used as a toner 1. The physical properties of the toner 1 are shown in Table 3.
Toners 2 to 4 were obtained as in Production Example of toner 1 except that the toner particles 1 used in Production Example of toner 1 were changed to toner particles 2 to 4. The physical properties of the toners 2 to 4 are shown in Table 3.
Comparative toners 1 to 4 were obtained as in Production Example of toner particles 1 except that the toner particles 1 used in Production Example of toner particles 1 were changed to the comparative toner particles 1 to 4. The physical properties of the comparative toners 1 to 4 are shown in Table 4.
Evaluation of Physical Properties of Toners 1 to 4 and Comparative Toners 1 to 4 after Washing
A mixed solution of 1.0 part by mass of the toner 1, 100 parts by mass of ion exchange water, and 0.01 parts by mass of sodium dodecylbenzenesulfonate was ultrasonically dispersed for 5 minutes to conduct centrifugal separation. The upper 20% fraction of the filtrate was sampled. The filtrate was dried and the physical properties of the toner 1 after washing were measured. The physical properties of the toner 1 were the same as those before washing (Tables 3 and 5).
The same operation was performed on the toners 2 to 4 and the comparative toners 1 to 4 and physical properties of the washed toners were measured. The same physical properties were exhibited as those before washing for all of the toners 2 to 4 and the comparative toners 1 to 4.
The following evaluations were performed on the toner 1. The evaluation results are shown in Table 7.
Evaluation of Storage Stability
Evaluation of Storage Property
In a 100 ml glass jar, 10 g of the toner 1 was placed and left at 55° C. and a humidity of 20% for 15 days. The toner was then observed with naked eye.
A: No changes were observed.
B: Some aggregates were observed but they were loose.
C: Aggregates that were not loose were found.
D: No fluidity was observed.
E: Clear caking occurred.
Evaluation of Long-Term Storage Property
In a 100 mL glass jar, 10 g of a toner 1 was placed and left at 45° C. and a humidity of 95% for three months. The toner was then observed with naked eye.
A: No changes were observed.
B: Some aggregates were observed but they were loose.
C: Aggregates that were not loose were found.
D: No fluidity was observed.
E: Clear caking occurred.
Evaluation of Environmental Stability and Development Durability
Toner cartridges of a tandem-type laser beam printer LBP7700C produced by Canon Kabushiki Kaisha having a structure illustrated in
The toner cartridges for the printer were respectively left in a low temperature, low humidity (L/L) (10° C./15% RH) environment, a normal temperature, normal humidity (N/N) (25° C./50% RH) environment, and a high temperature, high humidity (H/H) (32.5° C./85% RH) environment for 24 hours. Each toner cartridge after being left in the corresponding environment for 24 hours was attached to LBP7700C and an initial solid image (toner coverage: 0.40 mg/cm2) was printed. Then an image with a 1.0% printing rate was printed on 14,000 sheets. After 14,000 sheets were printed out, a solid image was again output. The density of the solid image and extent of fogging before and after 14,000 sheets of printouts were made and contamination of parts after 14,000 sheets of printouts were made were evaluated.
Another toner cartridge was loaded with 150 g of the toner 1. The toner cartridge was left in a severe environment (40° C./95%) for 168 hours and then in a super high temperature, high humidity (35.0° C./85% RH) environment (hereinafter may be referred to as “SHH”) for 24 hours. The toner cartridge after being left in the super high temperature, high humidity environment for 24 hours was attached to LBP7700C and an initial solid image was printed. Then an image with a 1.0% printing rate was printed on 14,000 sheets of paper. After 14,000 sheets were printed out, a solid image was again output. The density of the solid image and extend of fogging before and after 14,000 sheets of printouts were made and contamination of parts after 45,000 sheets of printouts were made were evaluated. A4-size paper having a weight of 70 g/m2 was used as the transfer paper and printing was conducted in a transverse direction of the A4-size paper.
Evaluation of Image Density
A Macbeth densitometer (RD-914 produced by Macbeth) equipped with an SPI auxiliary filter was used to measure the image density of a fixed image portion of the initial solid image and the solid image after 14,000 sheets of printouts. The evaluation standard for image density was as follows:
A: 1.45 or more
B: 1.40 or more and less than 1.45
C: 1.30 or more and less than 1.40
D: 1.25 or more and less than 1.30
E: 1.20 or more and less than 1.25
F: Less than 1.20
Evaluation of Fogging
The whiteness degree of background portions of an initial image with 0% printing rate and an image with 0% printing rate after 14,000 sheets of printouts were made was measured with a reflectometer (produced by Tokyo Denshoku Co., Ltd.). The observed values were compared with the whiteness degree of the transfer paper so as calculate the difference and the fogging density (%) was determined from the difference. Fogging was evaluated from the results of the fogging density based on the following standard:
A: less than 1.0%
B: 1.0% or more and less than 1.5%
C: 1.5% or more and less than 2.0%
D: 2.0% or more and less than 2.5%
E: 2.5% or more and less than 3.0%
F: 3.0% or more
Evaluation of Soiling of Parts
After 14,000 sheets of printouts were made, an image in which the upper half portion is a halftone image (toner coverage: 0.25 mg/cm2) and the lower half portion is a solid image (toner coverage: 0.40 mg/cm2) was printed out and evaluated according to the following standard.
A: Vertical streaks that extend in the sheet feeding direction are found on none of the developing roller, the halftone image portion, and the solid image portion.
B: One or two fine streaks extending in a circumferential direction are found on two ends of the developing roller, but vertical streaks that extend in the sheet feeding direction are found on none of the halftone image portion and the solid image portion.
C: Three to five fine streaks extending in a circumferential direction are found on two ends of the developing roller and few vertical streaks that extend in the sheet feeding direction are found on the halftone image portion and the solid image portion. However, these streaks can be erased by image processing.
D: Six to twenty fine streaks extending in a circumferential direction are found on two ends of the developing roller and several fine streaks are also found on the halftone image portion and the solid image portion. These streaks cannot be erased by image processing.
E: Twenty-one or more streaks are found on the developing roller and the halftone mage portion and these streaks cannot be erased by image processing.
Measurement of Triboelectric Charge Amount of the Toner
The triboelectric charge amount of the toner was determined by the following method. First, a toner and a standard carrier for a negatively chargeable toner (trade name: N-01 produced by The Imaging Society of Japan) were left in the following environments for particular lengths of time.
(1) In a low temperature, low humidity environment (LL) (10° C./15% RH), or a normal temperature, normal humidity (NN) environment (25° C./50% RH), or a high temperature, high humidity (HH) environment (32.5° C./85% RH), the toner and the standard carrier were left standing for 24 hours.
(2) The toner and the standard carrier were left standing for 168 hours in a severe environment (40° C./90% RH) and then in a super high temperature, high humidity environment (32.5° C./90% RH) for 24 hours.
The toner and the standard carrier after being left in the above-described environment were mixed with each other by using a turbula mixer for 120 seconds in the same environment so that the toner content is 5 mass %. As a result, a two-component developer was obtained. Within one minute after completion of mixing of the two-component developer, the two-component developer was placed in a metal container having a bottom equipped with a conductive screen having an aperture of 20 μm in a normal temperature, normal humidity (25° C./50% RH) environment. The container was suctioned with a suction machine. The difference in mass between before and after suction and the potential accumulated in a capacitor connected to the container was measured. The suction pressure was 4.0 kPa. The triboelectric charge amount of the toner was calculated by using the following equation based on the difference in mass between before and after suction, the potential accumulated, and the capacity of the capacitor.
The standard carrier for a negatively chargeable toner used for measurement (trade name: N-01 produced by The Imaging Society of Japan) was screened with a 250 mesh in advance and the undersize was used.
Q=(A×B)/(W1−W2)
Q (C/kg): triboelectric charge amount of charge control resin and toner
A (μF): capacity of capacitor
B (V): potential difference accumulated in capacitor
W1−W2 (g): difference in mass between before and after suction
Evaluation of Low-Temperature Fixability (Low-Temperature Offset End Temperature)
The fixing unit of the laser beam printer LBP7700C produced by Canon Kabushiki Kaisha was modified so that the fixing temperature could be adjusted. The modified LBP7700C was used to heat-press an unfixed toner image having a toner coverage of 0.4 mg/cm2 to an image-receiving sheet in an oil-less manner at a process speed of 230 mm/sec so as to form a fixed image on the image-receiving sheet.
The fixability was evaluated in terms of low-temperature offset end temperature at which the rate of decrease in density between before and after ten times of rubbing of a fixed image with Kimwipes (S-200 produced by NIPPON PAPER CRECIA Co., LTD.) under a 75 g/cm2 load was less than 5%. Evaluation was conducted at normal temperature and normal humidity (25° C./50% RH).
Evaluation was conducted as in Example 1 except that the toner 1 used in Example 1 was changed to toners 2 to 4. The results are shown in Table 7.
Evaluation was conducted as in Example 1 except that the toner 1 used in Example 1 was changed to comparative toners 1 to 4. The results are shown in Table 8.
Evaluation was conducted as in Example 1 except that the toner 1 used in Example 1 was changed to toner particles 1. The results are shown in Table 7.
In the tables below, pbm denotes parts by mass.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2012-288228 filed Dec. 28, 2012, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-288228 | Dec 2012 | JP | national |
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| Number | Date | Country | |
|---|---|---|---|
| 20140186762 A1 | Jul 2014 | US |
