ELECTROPHOTOGRAPHIC TONER

Abstract: Disclosed is a process in which a spherical electrophoto­ graphic toner containing a colorant and having a particle size suitable for the electrophotography is directly formed in the polymerization process for formation of a binder resin. If a reac­ tion medium capable of dissolving a monomer but incapable of dissolving a formed polymer is used and polymerization is car­ ried out in the presence of a radical polymerization initiator in the state where the monomer, the colorant and other additives are dissolved or dispersed in the reaction medium, an elec­ trophotographic toner having a desired particle size is ob­ tained. According to this process, the particle size of the colored resin is stably controlled to 1 to 30 um suitable for a toner in the polymerization process, and the particle size distri­ bution is very sharp.

Description: The present invention relates to a process in which a spherical electrophotographic toner containing a colorant and having a particle size in a range suitable for a toner is directly prepared in the polymerization process for formation of a binder resin. Furthermore, the present invention relates to an electrophotographic toner which is excellent not only in the flowability but also in various photographic characteristics. (2) Description of the Prior Art In the electrophotographic process, a toner is used for visualizing an electrostatic image. Toner particles are composed of a composition comprising a binder resin and, incorporated therein, a colorant and other additives such as a charge controlling agent, and have a particle size adjusted to a certain level, for example, 1 to 30 µm. A resin having desirable electroscopic property and binding property, for example, a styrene resin, is used as the binder resin, and carbon black or other organic or inorganic coloring pigment is used as the colorant. A most typical process for the production of an electrophotographic toner comprises melt-kneading a binder resin as described above with a colorant, cooling and pulverizing the molten composition and classifying the pulverized composition to recover a fraction having a certain particle size. The yield of the toner obtained through pulverization and classification is low and a large equipment is necessary for these operations. Accordingly, the manufacturing cost of the toner is very high. Moreover, the shape of the obtained particles is irregular and the flowability of the toner is generally low, and the toner is defective in that blocking is readily caused. Various trials have been proposed to prepare toners directly in the polymerization process for formation of a binder resin. According to a typical instance, in a water-insoluble monomer is dissolved a polymerization initiator soluble in the monomer, additives such as a colorant are added to the solution, the resulting composition is suspended under high-speed shear stirring into an aqueous solution comprising an appropriate dispersant, for example, a water-soluble polymer, an inorganic powder and a surface active agent, and the suspension is subjected to polymerization to form colored polymer particles. According to this suspension polymerization process, however, the particle size of the final toner is determined by the state of suspension of the monomer composition in water, and the particle size distribution of the toner particles is very broad and readily influenced by the state of throwing of the monomer composition into water or by the stirring condition, and it is very difficult to obtain a toner uniform in the particle size. Furthermore, according to this suspension polymerization process, in general, only coarse particles having a size of scores of µm to several mm are formed, and particles having a size of 1 to 30 µm, suitable for a toner of a developer, can hardly be obtained. Of course, it is possible to reduce the particle size of the formed toner if the amount incorporated of the dispersant is increased. However, in this case, the dispersant is contained in the toner and the toner becomes sensitive to the moisture, and the electrophotographic characteristics are readily degraded. A particular post treatment is necessary to eliminate this disadvantage, and the step number is increased and the process cannot be practically worked. A so-called emulsion polymerization is known as the process for preparing polymer particles having a relatively uniform particle size. This emulsion polymerization process, however, is defective in that the obtained particles are too fine and have a particle size smaller than 1 µm and the step of removing the emulsifier after the polymerization is necessary. Therefore, according to this process, it is difficult to obtain a colored resin for a toner directly in the polymerization process. Furthermore, there is known a process in which a styrene type or acrylic monomer having a polar group such as an amino group or a hydroxyl group and a colorant are subjected to suspension polymerization in the presence of an acid-soluble inorganic compound and the formed suspension is treated with an acid to obtain a toner composed of colored polymer fine particles (see Japanese Patent Publication No. 51-14895). This process, however, is defective in that a troublesome operation of dissolving and removing the inorganic compound becomes necessary and a part of the monomer is polymerized in the state dissolved in the aqueous phase at the dispersing and polymerizing steps to form as by-products fine polymer particles having a size smaller than 1 µm, as in the so-called emulsion polymerization. It is a primary object of the present invention to provide a process for the preparation of an electrophotographic toner, in which a colored resin having a particulate structured suitable for use as the toner and being substantially free of a factor inhibiting electrophotographic characteristics of the toner can be directly prepared in the polymerization process for formation of the resin. Another object of the present invention is to provide a process for the preparation of a toner, in which in the polymerization process for formation of a colored resin, the particle size of the colored resin is controlled to 1 to 30µm, suitable for the toner, and uniform particle size distribution can be maintained. Still another object of the present invention is to provide an electrophotographic toner to which a good chargeability is efficiently given by using a small amount of a charge-controlling agent, and a process for the preparation of this toner. In accordance with the present invention, there is provided a process for the preparation of an electrophotographic toner comprising a binder resin and a colorant dispersed in the binder resin, which comprises dissolving at least one radical-polymerizable monomer (A) selected from aromatic hydrocarbons of formula (1) wherein R₁ is hydrogen, lower alkyl or halogen and R₂ is hydrogen, lower alkyl, halogen, alkoxy, amino, nitro, vinyl or carboxyl, and acrylic monomers of formula (2) wherein R₃ is hydrogen or lower alkyl and R₄ is hydrogen, a hydrocarbon group having up to 12 carbon atoms, a hydroxyalkyl group, a vinyl ester group or an aminoalkyl group; and a dispersion stabilizer; and dispersing 1 to 30% by weight, based on the charged weight of monomers, of a colorant in a reaction medium comprising an organic solvent selected from alcohols and cellosolves; the reaction medium being selected so that the monomer (A) is soluble in the reaction medium but the resultant polymer is insoluble in the reaction medium; polymerizing the monomer (A) in the presence of a radical polymerization initiator precipitating substantially spherical particles composed of the resultant resin and the colorant and having an average particle size of 1 to 30µm; and recovering the particles from the reaction medium. In the process of the invention the polymerization is carried out so that 30 to 99 mole% of the radical-polymerizable monomer (A) is converted to a polymer, and a radical-polymerizable monomer (B) having a charge-controlling group is added in an amount of 0.1 to 10 mole% based on the monomer (A) continuously or in one stage or a plurality of stages during the polymerization. According to this polymerization process, there is obtained an electrophotographic toner comprising a binder resin and a colorant dispersed in the binder resin, wherein the binder resin is composed of a mixture comprising a resin component I formed of a radical-polymerizable monomer (A) convertible to a fixing thermoplastic resin and a copolymer resin component II of said monomer (A) and a radical-polymerizable monomer (B) having a charge-controlling functional group, the monomer (B) is present in an amount of 0.1 to 10 mole% based on the monomer (A), 30 to 99 mole% of the monomer (A) is present in the resin component I and 1 to 70 mole% of the monomer (A) is present in the resin component II, and the toner consists of spherical particles having a uniform particle size. In the process of the invention, at least one radical-polymerizable monomer (A), a dispersion stabilizer and a colorant are respectively dissolved and dispersed in a reaction medium (solvent) and polymerization is carried out in the presence of a radical polymerization initiator. It is important that the radical-polymerizable monomer (A) and the reaction medium should be selected so that the monomer (A) is soluble in the reaction medium but the formed polymer is insoluble in the reaction medium. The present invention is based on the finding that if the so-selected monomer(s) and reaction medium are used, a colored resin having a particle size larger than the particle size of resin particles obtained by customary emulsion polymerization and smaller than the particle size of resin particles obtained by customary suspension polymerization, which is in a range suitable for toner particles can be obtained. Polymerization which is advanced in a solution is generally called solution polymerization. In this solution polymerization, the formed polymer is dissolved in the solvent. In the process of the present invention, the formed polymer is not dissolved in the solvent, that is, the reaction medium. In this point, the polymerization of the present invention is distinguished from the solution polymerization. The reasons why colored particles having a particle size within the above-mentioned specific range and a relatively sharp particles size distribution can be obtained according to the present invention are believed to be as follows, though the reasons are not limited to those described below. In the polymerization system of the present invention, at the initial stage, the polymerization is initiated and advanced in the reaction medium, and the formed polymer chain is dispersed in the polymerization mixture and is combined with dispersed particles of the colorant having a large specific surface area. It is believed that at the middle stage of the polymerization, the polymerization is advanced according to both the emulsion polymerization and the suspension polymerization. Namely, at the middle stage of the polymerization, that is, after formation of the polymer particles, the polymerization is initiated and the chain growth is effected on the interfaces of the polymer particles and in the interiors of the polymer particles under conditions where the monomer is easily included into the interiors of the polymer particles. Accordingly, it is believed that the formed colored polymer particles come to have a particle size intermediate between the particle size of resin particles obtained by emulsion polymerization and the particle size of resin particles obtained by suspension polymerization, which is in a range suitable for a toner. It is considered that supposing that the radius of polymer particles in the polymerization mixture is r, the speed of growth of the polymer particles is in inverse proportion to the surface area 4πr² thereof, while the volume (4/3)πr³ of the polymer particles is increased in proportion to the polymerization time. Accordingly, in case of fine polymer particles, the speed of increase of the particle size is large, and in case of coarse polymer particles, this speed is small, and as the result, polymer particles having a relatively sharp particle size distribution can be obtained. Furthermore, in the colored polymer particles growing with advance of the polymerization, a substantially spherical shape is maintained by the interfacial tension between the polymer particles and the reaction medium. This is another advantage. Accordingly, in the colored particles obtained according to the present invention, the loss of the starting materials can be reduced because the classifying operation is not necessary, and the productivity is therefore improved. Moreover, the colored particles are excellent in the flowability and anti-blocking property as the powder, and if the amount used of the dispersant or activating agent is controlled, factors inhibiting the electrophotographic characteristics of the toner can be substantially eliminated. This is another prominent advantage. Radical-Polymerizable Monomer (A) The monomer (A) used in the invention is radical-polymerizable and a polymer formed from this monomer has fixing and electroscopic properties required for a toner. Examples of the monovinyl aromatic hydrocarbons of formula(1) include styrene, α-methylstyrene, vinyltoluene, α-chlorostyrene, o-, m- and p-chlorostyrenes, p-ethylstyrene, sodium styrene-sulfonate and divinylbenzene. These monomers may be used singly or in the form of mixtures of two or more of them. Examples of the acrylic monomers of formula (2) include acrylic acid, methacrylic acid, methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate, phenyl acrylate, methyl methacrylate, hexyl methacrylate, 2-ethylhexyl methacrylate, ethyl β-hydroxyacrylate, propyl γ-hydroxyacrylate, butyl δ-hydroxyacrylate, ethyl β-hydroxymethacrylate, propyl γ-aminoacrylate, propyl γ-N,N-diethylaminoacrylate, ethylene glycol dimethacrylate and tetraethylene glycol dimethacrylate. In order to uniformalize the particle size in the colored resin particles, the radical-polymerizable monomer is capable of dissolving the formed polymer therein. Colorant A pigment or dye (hereinafter referred to as "coloring pigment") is used as the colorant for coloring the toner. As preferred examples of the coloring pigment, there can be mentioned black pigments such as carbon black, acetylene black, lamp black and aniline black, yellow pigments such as chrome yellow, zinc yellow, cadmium yellow, yellow iron oxide, Mineral Fast Yellow, nickel titanium yellow, naples yellow, Naphthol Yellow S, Hansa Yellow G, Hansa Yellow 10G, Benzidine Yellow G, benzidine Yellow GR, Quinoline Yellow Lake, Permanent Yellow NCG and Tartrazine Yellow Lake, orange pigments such as chrome orange, molybdenum orange, Permanent Orange GTR, Pyrazolone Orange, Vulcan Orange, Indanthrene Brilliant Orange RK, Benzidine Orange G and Indanthrene Brilliant Orange GK, red pigments such as red iron oxide, cadmium red, red lead, mercury cadmium sulfide, Permanent Red 4R, Lithol Red, Pyrazolone Red, Watchung Red calcium salt, Lake Red D, Brilliant Carmine 6B, eosine lake, Rhodamine Lake B, alizarin lake and Brilliant Carmine 3B, violet pigments such as manganese violet, Fast Violet B and Methyl Violet Lake, blue pigments such as prussian blue, cobalt blue, Alkali Blue Lake, Victoria Blue Lake, Phthalocyanine Blue, metal-free Phthalocyanine Blue, partially chlorinated Phthalocyanine Blue, Fast Sky Blue and Indanthrene Blue BC, green pigments such as chrome green, chromium oxide, Pigment Green B, Malachite Green Lake and Fanal Yellow Green G, white pigments such as zinc flower, titanium oxide, antimony white and zinc sulfide, and extender pigments such as baryte powder, barium carbonate, clay, silica, white carbon, talc and alumina white. As the magnetic pigment, there are known tri-iron tetraoxide (Fe₃O₄), di-iron trioxide (γ-Fe₂O₃), zinc iron oxide (ZnFe₂O₄), yttrium iron oxide (Y₂Fe₅O₁₂), cadmium iron oxide (CdFe₂O₄), gadolinium iron oxide (Gd₃Fe₅O₁₂), copper iron oxide (CuFe₂O₄), lead iron oxide (PbFe₁₂O₁₉), neodium iron oxide (NdFeO₃), barium iron oxide (BaFe₁₂O₁₉), magnesium iron oxide (MgFe₂O₄), manganese iron oxide (MnFe₂O₄), lanthanum iron oxide (LaFeO₃), iron powder (Fe), cobalt powder (Co) and nickel powder (Ni). In the present invention, fine powders of these known magnetic pigments may be used. Reaction Medium According to the present invention, an organic solvent capable of dissolving the monomer (A) but incapable of dissolving the formed polymer thereof is used as the reaction medium. In order to avoid bad influences of the solvent left in the toner, it is preferred that the organic solvent be easily volatile. The solvent actually used should be determined according to the kinds of the monomer and the polymer thereof. Alcohols and cellosolves are used. Mixtures of two or more of these solvents, or mixtures of these solvents with other compatible organic solvents including ketones and hydrocarbons or water may be used. As the alcohol, there can be mentioned lower alcohols such as methanol, ethanol and propanol. As the cellosolve, there can mentioned methylcellosolve and ethylcellosolve. As the ketone, there can be used acetone, methylethyl ketone and methylbutyl ketone. As the hydrocarbon, there can be used n-hexane, n-heptane and cyclohexane. Polymerization Initiator A polymerization initiator soluble in a liquid mixture of the monomer and reaction medium is used. For example, there can be mentioned azo compounds such as azobisisobutyronitrile and peroxides such as cumene hydroperoxide, t-butyl hydroperoxide, dicumyl peroxide, di-t-butyl peroxide, benzoyl peroxide and lauroyl peroxide. Moreover, combinations of ionizing rays such as γ-rays and accelerated electron beams or violet rays with photosensitizers may be used. Additives Additives desired to be incorporated into the toner besides the above-mentioned colorant may be added to the starting composition prior to the polymerization. For example, a charge-controlling agent known to be valuable as a component of a two-component type pigment may be incorporated. For instance, there can be mentioned oil-soluble dyes such as Nigrosine Base (CI 5045), Oil Black (CI 26150) and Spilon Black, and metal salts of naphthenic acid, metal soaps of fatty acids and soaps of resin acids. Moreover, in order to impart an offset-preventing effect to the toner, there may be incorporated parting agents such as low-molecular-weight polyethylene, low-molecular-weight polypropylene, waxes and silicone oils. Polymerization According to the present invention, the above-mentioned components are dissolved or dispersed in the reaction medium and polymerization is carried out. It is preferred that the amount charged of the monomer (A) be 1 to 50% by weight, especially 5 to 30% by weight, based on the reaction medium. The colorant is incorporated in an amount of 1 to 30% by weight, especially 3 to 20% by weight, based on the charged monomer in the toner resin. When the magnetic pigment is used, it is preferred that the magnetic pigment be incorporated in an amount of 5 to 300% by weight, especially 10 to 250% by weight, based on the charged monomer. The amount of the initiator such as an azo compound or a peroxide may be a so-called catalytic amount, and generally, the amount is 0.1 to 10 % by weight based on the charged monomer. Known polymerization temperature and time may be adopted, and generally, the polymerization is carried out at a temperature of 40 to 100°C for 1 to 50 hours. Stirring of the polymerization mixture may be such gentle stirring that homogeneous reaction is caused as a whole. In order to prevent inhibition of the polymerization by oxygen, the atmosphere of the reaction system may be replaced by an inert gas such as nitrogen. In the present invention, there may be adopted a method in which only a part of the monomer (A) is dissolved in the reaction medium, polymerization is initiated in this state, and the remainder of the monomer (A) is added in a plurality of stages or continuously during the polymerization. It is considered that while the polymerization is in the stationary state, the concentration growing polymer radicals is constant. If the additional amount of the monomer (A) is added stepwise or continuously when the concentration of the monomer (A) in the polymerization mixture is reduced, the above-mentioned stationary state can be maintained and the growth of colored polymer particles can be further promoted. Also in this preferred embodiment, by using the above-mentioned specific combination of the monomer (A) and reaction medium, the particle size distribution of the formed colored polymer particles is made sharper and the particle size is more uniformalized. In this preferred embodiment, the monomer-containing composition is added to the reaction medium continuously or intermittently. In case of intermittent addition, it is preferred that the monomer (A) in an amount at least 0.5 time, especially at least 1 time, the amount of the monomer (A) initially charged be added in at least two stages. The monomer added afterward may be the same as or different from the monomer initially charged. It should be understood that formation of a block copolymer is possible. It is preferred that the average addition speed of the monomer added afterward be substantially the same as the speed of polymerization of the monomer. In case of a certain colorant, for example, carbon black, growing polymer radicals are caught on the surfaces of particles of the colorant to stop the growth of the polymer chain, resulting in the defect of incorporation of very fine particles in the final product. This disadvantage can be eliminated if the radical polymerization initiator is added in a plurality of stages during the polymerization or is added continuously. In this case, polymerization is initiated again on the surfaces of the colorant particles where the growth of the polymer is stopped. According to this preferred embodiment, substantially all of the colorant can be combined and integrated with the formed polymer, and the process is advantageous in that screening or classification is not necessary at all. In this preferred embodiment, the additional amount of the radical polymerization initiator is added to the additional amount of the monomer and the mixture is added stepwise or continuously. It is preferred that the amount of the additional polymerization initiator be 0.1 to 10 times, especially 0.5 to 5 times, the amount of the initially added polymerization initiator based on the weight. Furthermore, the additional polymerization initiator may be dissolved in the additional monomer and the solution may be added to the polymerization mixture. Since the polymerization product is obtained in the form of particles having a particle size within the above-mentioned range, the formed particles are filtered, washed with the above-mentioned solvent if necessary and dried to obtain colored particles for a toner. If necessary, the colored particles for a toner are sprinkled with carbon black, hydrophobic silica or the like to obtain a final toner. As the dispersion stabilizer, there are used polymers soluble in the reaction medium, such as polyvinyl alcohol, methylcellulose, ethylcellulose, polyacrylic acid, polyacrylamide, polyethylene oxide and poly(hydroxystearic acid-g-methyl methacrylate-comethacrylic acid) copolymer, and non-ionic and ionic surface active agents. In the polymerization process according to the present invention, there may be preferably adopted a method in which the radical-polymerizable monomer (A) is polymerized to the midway, a radical-polymerizable monomer (B) having a charge-controlling functional group (hereinafter referred to as "polar group") is added to the reaction mixture, and the polymerization is conducted. In the case where the monomer (B) having a charge-controlling functional group is made present from the start of the polymerization, fine polymer particles formed at the initial stage are stably dispersed in the polymerization mixture by the electrostatic repulsive force owing to the charge of the functional group, and appropriate aggregation or coalescence of fine particles is hardly caused and coalescence with the colorant is not caused even to the terminal stage of the polymerization, and fine particles of the polymer having a charge-controlling functional group are present in the state mixed in the toner polymer particles free of the functional group or containing the functional group at a very low concentration. When the product is used for a toner, such uncolored resin fine particles should be removed and the content of the polar group is very low as compared with the amount incorporated of the monomer (B), and it often happens that the intended chargeability-imparting effect cannot be obtained. Furthermore, in some cases, the chargeability-imparting effect differs among the particles. Moreover, since the monomer (B) having a polar group is relatively expensive, the process is economically disadvantageous. In contrast, according to the preferred embodiment, the monomer (A) convertible to an insulating binder resin is first polymerized to form a colorant-containing copolymer particles and the monomer (B) having a polar group is added to continue the polymerization, whereby the monomer (B) having a polar group is efficiently included in the toner particles and in this state, the polymerization and formation of spherical particles are advanced. Accordingly, the residual amount of uncolored polymer fine particles can be controlled to a very low level, and the polar group-containing monomer can be made present efficiently at a uniform concentration in colored particles valuable as a toner. Furthermore, the step of separating and removing uncolored fine particles can be omitted and the amount of the expensive polar group-containing monomer can be reduced, and the process is economically advantageous. Even the method in which a part of the polar group-containing monomer (B) is added at the initial stage of the polymerization is included in the scope of the present invention, so far as the above-mentioned polymerization state is maintained. In the toner obtained according to this preferred embodiment, the binder resin is characterized in that the binder resin contains a resin component I composed of the monomer (A) convertible to an insulating binding resin and a copolymer resin component II composed of the monomer (A) and the monomer (B) having a charge-controlling functional group in the form of a mixture. Parts of the resin components I and II may be connected in the form of a block or graft copolymer. Namely, the resin component I consists of a polymer chain of the formula -A-A-A-A-A-A-A-A-A-, and the resin component II consists of a random copolymer chain of the formula -A-A-B-A-A-A-B-B-A-. A part of the resin component I and a part of the copolymer component II are present in the form of a block or graft copolymer. Since the copolymer resin component II has the above-mentioned chain structure and is rich in the compatibility with the resin component I, the spherical toner particles obtained according to this preferred embodiment are characterized in that the resin composition is uniform among the respective particles. Furthermore, a sufficient charge-controlling effect can be attaiend with a relatively small amount of the monomer (B), and the fixing property is good, there is no moisture sensitivity, the particle size is uniform and the flowability is excellent. If the monomer (B) having a charge-controlling functional group is used in such a small amount as 0.1 to 10 mole%, especially 0.5 to 5 mole%, based on the monomer (A), a satisfactory charge-controlling effect can be attained. If the amount of the monomer (B) is too small and is below the above-mentioned range, the charge-controlling effect is reduced, and if the amount of the monomer exceeds the above-mentioned range, the toner becomes moisture-sensitive and degradation of charging characteristics and flowability is readily caused under high humidity conditions. In the toner of this preferred embodiment, it is important that 30 to 99 mole%, especially 50 to 95 mole%, of the monomer (A) should be included in the resin component I while 1 to 70 mole%, especially 5 to 50 mole%, of the monomer (A) should be included in the copolymer resin component II. If this requirement is not satisfied, the efficiency of inclusion of the monomer (B) in the spherical particles is reduced. The obtained colored particles need not be subjected to the classifying operation and the loss of the starting materials can be reduced, and the productivity is very high. The toner particles are excellent in the flowability and anti-blocking property as the powder and also excellent in the fixing property and charge-controlling effect. Furthermore, by controlling the amount used of the dispersant or activating agent, factors inhibiting the electrophotographic characteristics can be substantially eliminated. As the charge-controlling functional group-containing monomer (B), there may be used radical-polymerizable monomers having an electrolyzable group, for example, a sulfonic acid, phosphoric acid or carboxylic acid type anionic group or a cationic group such as a primary, secondary or tertiary amino group or a quaternary ammonium group. As preferred examples, there can be mentioned styrene-sulfonic acid, sodium styrene-sulfonate, 2-acrylamido-2-methylpropane-sulfonic acid, 2-acid-phosphoxypropyl methacrylate, 2-acid-phosphoxyethyl methacrylate, 3-chloro-2-acid-phosphoxypropyl methacrylate, acryic acid, methacrylic acid, fumaric acid, crotonic acid, tetrahydroterephthalic acid, itaconic acid, aminostyrene, aminoethyl methacrylate, aminopropyl acrylate, diethylaminopropyl acrylate, γ-N-(N',N'-diethylaminoethyl)aminopropyl methacrylate and trimethyl ammonium propyl methacrylate. According to this preferred embodiment, the monomer (B) is added to the polymerization mixture in the midway of the polymerization, that is, when the polymerization ratio of the monomer (A) is 30 to 99%, especially 50 to 95%. The monomer (B) may be added in one stage or a plurality of stages, or cointinuously. The monomer (B) may be added singly or in the form of a mixture with the monomer (A). When the monomer (B) is added in the midway of the polymerization of the monomer (B), the monomer (B) can be efficiently absorbed in growing polymer particles of the monomer (A). The present invention will now be described in detail with reference to the following examples that by no means limit the scope of the invention. Example 1 In 800 mℓ of ethanol was dissolved 8 g of polyacrylic acid, and 80 g of styrene, 20 g of n-butyl methacrylate, 5 g of carbon black (Printex L supplied by Degussa) and 1 g of azobisisobutyronitrile were added to the solution and reaction was carried out with stirring at 150 rpm in a nitrogen current at 80°C for 15 hours in a separable flask having a capacity of 1 ℓ to complete polymerization. When the obtained polymer was observed by an optical microscope, it was found that the polymer was composed of spherical black particles having a particle size of about 10 µm. The polymer was separated by sedimentation, washed with ethanol 3 times and dried to obtain 95 g of a toner. At the separation by sedimentation, small quantities of polymer particles were still left in the supernatant. It is considered that since these polymer particles were removed at the washing step, the yield was somewhat reduced. The particle size distribution of the toner was determined by a coal tar counter. The obtained results are shown in Table 1. It was found that the particle size distribution was sharp and the average particle size was 10.4 µm. When the copying operation was carried out in a copying machine (Mita DC-211) charged with this toner, a clear image was obtained. Particle Size Example 1 Commercial Product (for DC-211) average particle size (µm) 10.4 12.0 smaller than 8.0 µm 6 % 6 % 8.0 to 12.7 µm 74 % 51 % larger than 12.7 µm 20 % 43 % Comparative Example 1 The procedures of Example 1 were repeated in the same manner except that 800 mℓ of distilled water was used instead of 800 mℓ of ethanol and the mixture was sufficiently dispersed by stirring at 3000 rpm for 5 minutes by using a homogenizing mixer (supplied by Tokushu Kika Kogyo) before the polymerization. The obtained polymer was slightly grayish. When the polymer was observed by an optical microscope, it was found that black indeterminate aggregates of carbon black and transparent polymer particles having a broad particle size distribution were present. Black particles that could be used as an electrophotographic toner were not obtained. The polymer was separated by sedimentation, washed with distilled water 3 times and dried to obtain 83 g of a comparative toner. The toner was only a mixture of polymer particles and carbon black. When the copying operation was carried out in a copying machine (Mita DC-211) charged with this toner, no clear image was obtained. Example 2 In 760 mℓ of methyl cellosolve and 40 mℓ of distilled water were dissolved 8 g of ethyl cellulose and 1 g of sodium dodecylbenzene-sulfonate, and 70 g of styrene, 29 g of 2-ethylhexyl methacrylate, 1 g of divinylbenzene, 5 g of cadmium red and 1 g of benzoyl peroxide were added to the solution. Reaction was carried out in a nitrogen current with stirring at 150 rpm at 80°C for 8 hours in a separable flask having a capacity of 1 ℓ to complete polymerization. When the obtained polymer was observed by an optical microscope, it was found that the polymer was composed of spherical red particles having a uniform particle size of about 10 µm. The polymer was separated by sedimentation, washed with methyl cellosolve 3 times and dried to obtain 98 g of a toner. When the copying operation was carried out in a copying machine (Mita DC-211) charged with this toner, a clear image was obtained. Comparative Example 2 The procedures of Example 2 were repeated in the same manner except that methyl cellosolve was not used but only 800 mℓ of distilled water was used as the medium, whereby polymerization was completed. Incidentally, the mixture was sufficiently dispersed by stirring at 3000 rpm for 5 minutes by using a homogenizing mixer (supplied by Tokushu Kika Kogyo) before the polymerization. The obtained polymer was opaque and when the polymer was observed by an optical microscope, it was found that red indeterminate aggregates of cadmium red and very fine transparent polymer particles were present. The polymer was separated by sedimentation, washed with distilled water 3 times and dried to obtain 45 g of a comparative toner. The toner was only a mixture of polymer particles and cadmium red. When the copying operation was carried out in a copying machine (Mita DC-211) charged with this toner, no clear image was obtained. Example 3 In 800 mℓ of ethanol was dissolved 8 g of polyacrylic acid, and 20 g of styrene, 5 g of n-butyl methacrylate, 5 g of carbon black (Printex L supplied by Degussa) and 1 g of azobisisobutyronitrile were added to the solution. In a separable flask having a capacity of 1 ℓ, the temperature was elevated to 80°C in a nitrogen current with stirring at 150 rpm, and after passage of 2 hours, 4 hours and 6 hours, 20 g of styrene and 5 g of n-butyl methacrylate were additionally incorporated and reaction was conducted for 15 hours to complete polymerization. When the obtained polymer was observed by an optical microscope, it was found that the polymer was composed of spherical black particles having a particle size of about 10 µm. The polymer was separated by sedimentation, washed with ethanol 3 times and dried to obtain 105 g of a toner. The yield was 100%. The particle size distribution of the toner was measured by a coal tar counter. The obtained results are shown in Table 2. It was found that the particle size distribution was sharp. When the copying operation was carried out in a copying machine (Mita DC-211) charged with this toner, a clear image was obtained. Comparative Example 3 Polymerization was carried out in the same manner as described in Example 3 except that 80 g of styrene and 20 g of n-butyl methacrylate were first charged and the additional charging was not performed. When the obtained polymer was observed by an optical microscope, it was found that not only spherical particles having a particle size of about 10 µm but also small quantities of transparent particles composed solely of the polymer and having a particle size of about 2 µm were present. The polymer was separated by sedimentation, washed with ethanol 3 times to completely remove the particles composed solely of the polymer and dried to obtain 95 g of a toner. The yield was 90%. The particle size distribution of the obtained toner was measured by a coal tar counter. The obtained results are shown in Table 2. It was found that the particle size distribution was broader than that of the toner obtained in Example 3. When the copying operation was carried out in a copying machine (Mita DC-211) charged with the obtained toner, a clear image was obtained, but the resolving power was somewhat lower than in Example 3. Particle Size Example 3 Comparative Example 3 average particle size (µm) 10.0 10.4 smaller than 8.0 µm 3 % 6 % 8.0 to 12.7 µm 82 % 74 % larger than 12.7 µm 15 % 20 % Comparative Example 4 Three toners having an average particle size of 10 µm were prepared by melt-kneading, pulverizing and classifying compositions shown in Table 3. The polarity of each toner was negative as shown in Table 5 illustrating the results of the measurement of the charge quantity according to the blow-off method. When the copying operation was carried out in a copying machine (Mita DC-211) by using these toners, a clear image having no fog was obtained in case of the toner of run No. 9, but slight fogging was observed in images formed by using the toners of runs Nos. 7 and 8. Run No. 7 Run No. 8 Run No. 9 styrene/n-butyl methacrylate copolymer resin (g) 100 100 100 carbon black (g) 7 7 7 polyolefin wax (g) 0.1 0.1 0.1 styrene/sodium styrene sulfonate copolymer (5/1) (g) 0.6 6 30 Comparative Example 5 Three toners (runs Nos. 10 through 12) having an average particle size of 10 µm were prepared by melt-kneading, pulverizing and classifying compositions shown in Table 4. The polarity of each toner was positive as shown in Table 5 illustrating the results of the measurement of the charge quantity according to the blow-off method. When the copying operation was carried out in a copying machine (Mita DC-15) by using these toners, a clear image having no fog was obtained in case of the toner of runs Nos. 10 and 11. Run No. 10 Run No. 11 Run No. 12 styrene/n-butyl methacrylate copolymer resin (g) 100 100 100 carbon black (g) 7 7 7 polyolefin wax (g) 0.1 0.1 0.1 styrene/dimethylaminoethyl methacrylate quaternary compound copolymer resin (5/1) (g) 0.6 6 30 Comparative Example 6 A sufficiently stirred mixture comprising 96 parts by weight of styrene, 4 parts by weight of divinylbenzene, 1 part by weight of acid-phosphoxyethyl methacrylate, 5 parts by weight of carbon black and 1 part by weight of azobisisobutyronitrile was added to 500 parts by volume of distilled water containing, dissolved therein, 20 parts by weight of partially saponified Poval (having a saponification degree of 88%) and 1 part by weight of sodium dodecylsulfate, and the mixture was stirred at 3000 rpm for 10 minutes by using a homogenizing mixer (supplied by Tokushu Kika Kogyo) and charged in a separable flask. Reaction was carried out at 70°C in a nitrogen current with stirring at 150 rpm for 8 hours to complete polymerization. The polymer was separated by filtration, sufficiently washed, dried under reduced pressure and classified to obtain a toner having an average particle size of 10 µm. The polarity of the toner was negative as shown in Table 5 illustrating the results of the measurement of the charge quantity according to the blow-off method. When the copying operation was carried out in a copying machine (Mita DC-211) charged with this toner, slight fogging was observed in the obtained image. Comparative Example 7 A sufficiently stirred mixture comprising 96 parts by weight of styrene, 4 parts by weight of divinylbenzene, 2 parts by weight of diethylaminoethyl methacrylate quaternary compound, 5 parts by weight of carbon black and 1 part by weight of azobisisobutyronitrile was added to 500 parts by volume of distilled water containing, dissolved therein, 20 parts by weight of partially saponfied Poval (having a saponification degree of 88%) and 1 part by weight of sodium dodecylsulfate, and the mixture was stirred at 3000 rpm for 10 minutes by using a homogenizing mixer (supplied by Tokushu Kika Kogyo) and charged in a separable flask. Reaction was carried out at 70°C in a nitrogen current with stirring at 150 rpm for 8 hours to complete polymerization. The polymer was separated by filtration, sufficiently washed, dried under reduced pressure and classified to obtain a toner having an average particle size of 10 µm. The polarity of the toner was positive as shown in Table 5 illustrating the results of the measurement of the charge quantity according to the blow-off method. When the copying operation was carried out in a copying machine (Mita DC-15) charged with the toner, slight fogging was observed in the obtained image.

Claims: A process for the preparation of an electrophotographic toner comprising a binder resin and a colorant dispersed in the binder resin, which comprises dissolving at least one radical-polymerizable monomer (A) selected from aromatic hydrocarbons of formula (1) wherein R₁ is hydrogen, lower alkyl or halogen and R₂ is hydrogen, lower alkyl, halogen, alkoxy, amino, nitro, vinyl or carboxyl, and acrylic monomers of formula (2) wherein R₃ is hydrogen or lower alkyl and R₄ is hydrogen, a hydrocarbon group having up to 12 carbon atoms, a hydroxyalkyl group, a vinyl ester group or an aminoalkyl group; and a dispersion stabilizer; and dispersing 1 to 30% by weight, based on the charged weight of monomers, of a colorant in a reaction medium comprising an organic solvent selected from alcohols and cellosolves; the reaction medium being selected so that the monomer (A) is soluble in the reaction medium but the resultant polymer is insoluble in the reaction medium; polymerizing the monomer (A) in the presence of a radical polymerization initiator precipitating substantially spherical particles composed of the resultant resin and the colorant and having an average particle size of 1 to 30µm; and recovering the particles from the reaction medium. A process according to claim 1, wherein a part of the monomer (A) is dissolved in the reaction medium, polymerization is initiated, and the remainder of the monomer (A) is added in a plurality of stages or continuously during the polymerization. A process according to claim 2, wherein the polymerization initiator is added in a plurality of stages or continuously during the polymerization. A process according to any preceding claim wherein the resultant polymer of the radical-polymerizable monomer (A) is readily soluble in the monomer (A) per se. A process according to any preceding claim wherein the radical-polymerizable monomer (A) is a styrene type monomer and the reaction medium comprises an alcohol or a cellosolve. A process according to any preceding claim wherein the radical-polymerizable monomer (A) is polymerized so that 30 to 90 mole% of the monomer (A) is converted to polymer, and a radical-polymerizable monomer (B) having a charge-controlling functional group is added to the polymerization mixture continuously or in one stage or in a plurality of stages and the polymerization is continued.

Inventors: MATSUMOTO, TSUNETAKA, OKUBO, MASAYOSHI, TOKUNO, TOSHIRO
Applicants: MITA INDUSTRIAL CO. LTD.
Application year: 1986
Main classification: G03G9
IPC codes: G03G9