Process for preparation of a gelled polyester for toner

Abstract: Disclosed is a crosslinked polyester for a toner, and a process for its manufacture wherein the polyester has an acid value of 5 to 20 mgKOH/g, a flow index of 0.1 x 10⁻⁴ to 300 x 10⁻⁴ ml/sec and softening point lower than 145°C, the polyester being formed by mixing a dicarboxylic acid component, a diol component and at least one crosslinking component selected from a polyfunctional carboxylic acid component having a trivalency or a higher valency and a polyhydric alcohol component having a trivalency or a higher valency at a mixing ratio represented by the following formula (1), reacting the mixture at a reaction ratio represented by the following formula (2) and subjecting the esterification product to polycondensation and crosslinking. 0.8 ≦ R ≦ 1 + 5 a (1) 0.7 ≦ P ≦ [R/(1 + a )] 1/2 (2) wherein R is the ratio of the mole number of the total alcohol components to the mole number of the total acid components, a is the ratio of the sum of the mole number of the polyvalent carboxylic acid component and the mole number of the polyhydric alcohol component to the mole number of the total acid components, and P is the conversion of the carboxylic acid components. A toner comprising this crosslinked polyester as the binder has an excellent offset-preventing property, low-temperature fixing property and blocking resistance and good charging characteristics with a high moisture resistance, and gives a copied image having good sharpness and image density.

Description: BACKGROUND OF THE INVENTION (1) Field of the Invention The present invention relates to process for preparation of a gelled polyester for a toner to be used for the development of an electronic latent image such as a statically charged image in the electrostatic printing process. (2) Description of the Related Art An image-forming process, such as an electrophotographic copying process or an electrostatic printing process, which comprises forming an electronic latent image such as a statically charged image or an electroconductive image corresponding to an image to be recorded on the surface of an electrostatic recording material, developing and visualizing the electronic latent image with a charged toner, transferring the formed toner image on the surface of the electrostatic recording material to a paper or a recording film, and fixing the transferred image, is advantageous in that prints can be obtained at a high speed, the fixing stability of the image on the surface of the recording material is good, and the image-forming apparatus used in this process is easily operated. Accordingly, this image-forming process is widely used in the field of copying machines. For example, when an image is formed by a photographic copying machine, the surface of a roller composed of a photoconductive and photosensitive material is charged, an electrostatic latent image is formed by the exposure to light reflected from the surface of an original to be copied, the latent image is developed with a toner, the formed visible image is transferred to a paper or the like, and the transferred image is fixed on the paper by compression under heating, and thus a copy print is obtained. Toners comprising a crosslinked polyester as the binder have been developed for the above-mentioned image-forming process, and toners of this type are disclosed, for example, in U.S. Patent No. 3,938,972, British Patent No. 2,082,788A, Japanese Examined Patent Publication No. 61-59333, and Japanese Unexamined Patent Publication No. 62-127752. To increase the operational efficiency of copying machines or printers, the image-forming treatment should be carried out at a higher speed, and accordingly, various attempts have been made to increase the treatment speed. A serious problem when carrying out an image-forming treatment at a high speed in the above-mentioned image-forming process is how to increase the speed of fixing a toner image, formed by visualizing an electrostatic latent image, to the surface of a recording material. To solve this problem, the toner must have an excellent low-temperature fixing property and an excellent electric characteristic such that the electrostatic latent image formed on the surface of the photoconductive and photosensitive material is clearly visualized, but none of the conventional toners comprising a polyester as the binder satisfies these requirements. The low-temperature fixing property of the toner can be improved by using a polyester binder having a low softening point, but a toner comprising a polyester having a low softening point as the binder is unsatisfactory in that, since the transferability of the toner at the fixing treatment is poor, the toner remains on the surface of a transferring hot roller or the like, and an offset phenomenon, i.e., contamination of a following transfer paper of the like, occurs. As a toner having an improved offset-preventing property, Japanese Examined Patent Publication No. 61-59333 proposed a toner comprising, as the binder, a crosslinked polyester formed by reacting etherified bisphenol A with a dicarboxylic acid to obtain a linear polyester, and reacting this linear polyester with a polyfunctional carboxylic acid having a trivalency or higher valency, such as trimellitic anhydride. This toner has an excellent offset-preventing property, but since the softening point of the crosslinked polyester constituting the binder of this toner is high, the high-speed fixing property is not satisfactory. For example, if the copying operation is carried out at a fixing speed of about 50 sheets per minute when using this toner in the electrostatic photographic copying process, the fixing property of the toner is poor and a copy having a satisfactory toner fixing strength cannot be obtained. A polyester having a reduced softening point, which can be used as a toner having a good offset-preventing property and a good low-temperature fixing property, is disclosed in Japanese Unexamined Patent Publication No. 62-127752. This polyester is a crosslinked polyester in which long-chain aliphatic hydrocarbon units are introduced, but since the glass transition point (Tg) of the crosslinked polyester is too low, in a toner comprising this polyester as the binder, an agglomeration of toner particles occurs during storage, resulting in blocking. Namely, the toner has a poor storage stability. The image density and contrast of a toner image formed by visualizing a charged latent image formed on the photoconductive and photosensitive material with a toner are greatly influenced by the toner charge quantity. Accordingly, the toner charge quantity is generally adjusted to an appropriate level by the addition of a charge-control agent. This charge-control agent is expensive, and therefore, the development of a binder resin having an excellent self-chargeability and able to provide an excellent charge-control effect although using a reduced amount of the charge-control agent, is strongly desired, but such a polyester resin has not been developed as yet. Furthermore, the moisture resistance of the toner is important when ensuring the stability of the image formed by visualizing the electrostatic latent image on the photoconductive and photosensitive material, but a polyester resin capable of imparting a required moisture resistance to the toner has not been developed. EP-A-0250139 describes a toner composition which comprises a polyester having an acid value of 5 KOHmg/g or less and a hydroxyl value of 60 KOHmg/g or less. EP-A-0259642 describes a toner comprising a polyester component which is obtained by co-condensation of a diol component, a dicarboxylic acid or anhydride or lower alkyl ester thereof and a polycarboxylic acid. However, neither of these references disclose polyesters having all of the properties of the present invention, or preparing of such polyesters which are cross-linked. EP-A-0,291,059, which has a priority date of 13 May 1987 but which was not published until after the priority date of the present claims, describes a process for the preparation of a gelled polyester for a toner which is similar to the process claimed herein with the exception that the conversion ratio P of the carboxylic acid components in the first step is approximately 1. JP-A-62-45622 describes a process for preparation of cross-linked polyesters in which the degree of crosslinking is controlled by the addition of a non-volatile monofunctional carboxylic acid component at or after the start of polymerisation. SUMMARY OF THE INVENTION Under the above background, the inventors carried out research into the provision of a toner having an excellent offset-preventing property, low-temperature fixing property, and self-chargeability and able to be manufactured at a low cost, and as a result, completed the present invention. More specifically, in accordance with the present invention, there is provided a process for making a gelled polyester for a toner as defined in claim 1. Furthermore, the gelled polyester for a toner made by the present invention preferably has a hydroxyl group value of 5 to 50 mgKOH/g. The polyester resin for a toner made by the present invention is a gelled polyester resin having a network structure, and therefore, a toner comprising this polyester resin as the binder has an excellent offset-preventing property. Furthermore, the polyester resin made by the present invention has a softening point lower than 145°C, and a good flowability when molten, and a toner comprising this polyester as the binder has an excellent low-temperature fixing property, thus allowing the development to be performed at a high speed. Since the toner comprising the polyester made by the present invention as the binder has the above-mentioned excellent characteristics, even if the toner-fixing temperature is considerably higher than the softening point of the polyester, the fixing property to a paper, a film or the like is excellent, and the offset to a fixing roller or the like is effectively prevented. Moreover, since the polyester made by the present invention has a specific acid value, it exhibits a good and negative self-chargeability. Accordingly, if the polyester made by the present invention is used, a toner having a good self-chargeability can be obtained even if a charge-control agent is not used. If a charge-control agent is incorporated, however, the chargeability characteristics are further improved. If a mixture of the starting materials in which R is smaller than 0.8 is used for obtaining an esterification product, it is impossible to obtain an esterification product that can be converted to a polyester at the subsequent polycondensation step, and if a mixture of the starting materials in which R is larger than 1 + 5 a is used, the acid value of the polyester obtained by the polycondensation of the esterification product under the condition represented by the formula (2) is smaller than 5 mgKOH/g, and the self-chargeability is poor. Even if as esterification product obtained by esterifying the above-mentioned mixture of the starting materials under conditions where P is smaller than 0.7, is subjected to a subsequent polycondensation, a polyester having the characteristics required for the present invention can not be easily obtained. In an esterification, if P is larger than [R/(1 + a)] 1/2 , gelation occurs at the esterification step, and a reaction cannot be controlled. An embodiment of the process of the invention for the preparation of a polyester resin will now be described. The above-mentioned polycarboxylic acid and polyol components are charged in an autoclave at a ratio satisfying the requirement of formula (1), and esterification is carried out within a conversion represented by formula (2). If the esterification is advanced beyond the upper limit of the conversion P represented by formula (2), i.e., [R/1 + a)] 1/2 , a rapid and uncontrollable gelation occurs during the.reaction. In contrast, if the reaction is conducted under conditions where the conversion P does not reach the lower limit represented by formula (2), i.e., 0.7, gelation hardly occurs at the subsequent step of a polycondensation and crosslinking of the esterification product, and the intended crosslinked polyester cannot be obtained. The reaction for forming the esterification product from the mixture of the starting materials can be carried out under a pressure of 40 kPa (300 mmHg) to 7 kg/cm 2 , but preferably the reaction is carried out under atmospheric pressure or an elevated pressure of up to 5 kg/cm 2 while removing water or a monoalcohol formed by the reaction from the reaction system by distillation. As specific examples of the dicarboxylic acid used for the preparation of the polyester of the present invention, there can be mentioned alkylene-dicarboxylic acids such as 1,2-propane-dicarboxylic acid, 1,3-butane-dicarboxylic acid, 2,3-butane-dicarboxylic acid, 3-methyl-glutaric acid, 2,2-dimethyl-1,3-propane-dicarboxylic acid, 1,2-dimethyl-1,3-propane-dicarboxylic acid, 1,3-dimethyl-1,3-propane-dicarboxylic acid, 1,2,3-trimethyl-1,3-propane-dicarboxylic acid, 2,3-dimethyl-1,4-butane-dicarboxylic acid, 3,3-diethyl-1,5-pentane-dicarboxylic acid, malonic acid, maletic acid, glutaric acid, adipic acid and sebacic acid, alicyclic dicarboxylic acids such as cyclohexane-dicarboxylic acid, aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, orthophthalic acid, 3,5-toluene-dicarboxylic acid, 2,4-toluene-dicarboxylic acid, 2,5-toluene-dicarboxylic acid and napthalene-dicarboxylic acid, anhydrides of the foregoing dicarboxylic acids, and alkyl esters of the foregoing dicarboxylic acids. These compounds can be used singly or as a mixture of two or more thereof. Where an alkyl ester of a dicarboxylic acid is used, preferably the alkyl ester of a dicarboxylic acid has up to 6 carbon atoms in the alkyl group, as this will increase the speed of the ester exchange with the other starting material, and from this viewpoint, an alkyl ester of a dicarboxylic acid having up to 3 carbon atoms in the alkyl group is especially preferred. Among the foregoing starting dicarboxylic acid components, isophthalic acid, dimethyl isophthalate, terephthalic acid, and dimethyl terephthalate are especially effective for lowering the softening point of the obtained crosslinked polyester resin. Where the aromatic dicarboxylic acid and a derivative thereof are used, in view of the Tg of the obtained polyester, preferably the amount of terephthalic acid and a dimethyl ester thereof is at least 40 mole%, and the amount of isophthalic acid and a dimethyl ester thereof is up to 60 mole%. Where the amount of terephthalic acid structural units in a polyester is too small, and the amount of the isophthalic acid structural units is too large, the Tg is usually lowered, and the storage stability of a toner comprising this polyester as the binder, are unsatisfactory. As specific examples of the diol used for the preparation of the crosslinked polyester resin, there can be mentioned alkylene glycols such as ethylene glycol, 1,2-propylene glycol, trimethylene glycol, tetramethylene glycol, hexamethylene glycol and neopentyl glycol, alkylene ether glycols such as diethylene glycol, triethylene glycol, polyethylene glycol, polytetramethylene ether glycol and polypropylene tetramethylene ether glycol, alicyclic diols such as cyclohexane dimethanol and hydrogenated bisphenol A, and aromatic diols such as polyoxypropylene(2.3)-2,2-bis(4-hydroxyphenyl)propane, polyoxyethylene(2.0)-2,2-bis(4 -hydroxyphenyl)propane and polyoxypropylene-p-hydroxybenzene. These diols can be used singly or as a mixture of two or more thereof. Ethylene glycol has a property such that the speed of the reaction with the dicarboxylic acid is increased, and an aromatic diol has a property such that is the obtained polyester is used as a binder, the chargeability is improved. Furthermore, a toner comprising a polyester prepared by using neopentyl glycol as the binder has an improved adhesiveness to a paper and a film. Accordingly, preferably these diols are used singly or in combination according to the characteristics required for the toner. Preferably, an aromatic diol, and neopentyl glycol are used in amounts of up to 80 mole%, and up to 80 mole%, respectively, based on the total carboxylic acid components. As an alcohol having a trivalency, to be used for the preparation of the crosslinked polyester of the present invention, these can be mentioned, for example, 1,4-sorbitane, pentaerythritol, 1,2,4-butane-triol, 1,2,5-pentane-triol, 2-methylpropane-triol, 2-methyl-1,2,4-butane-triol, trimethylolethane, trimethylolpropane, 1,3,5-trihydroxybenzene and glycerol. These alcohols can be used singly or as a mixture of two or more thereof. Preferably, pentaerythritol, 1,1,1-trimethylolpropane and glycerol are used as the polyhydric alcohol, because the reactivity thereof with carboxylic acids is high. As pentaerythritol or a trivalent alcohol, as exemplified above, is used for the preparation of the polyester, it is easy to control the Tg of the obtained polyester to a desired level, and thus in the present invention, this component is used in an amount of 1 to 30 mole% based on the total carboxylic acid components. In the present invention, additives can be used according to need in the production of the polyester. As the additive, an antioxidant and an inorganic filler can be used. Where an esterification product is prepared by using an alkyl ester of a dicarboxylic acid as the starting material, preferably a compound of titanium, manganese, magnesium, tin, calcium, zinc, lead, germanium or antimony is used as the ester exchange catalyst. The reaction is preferably carried out at a temperature higher than 150°C. The conversion P (the ratio of conversion of the total carboxylic acid components to an esterification product) at the reaction for obtaining the esterification product can be determined by measuring the amount of water or the mono-alcohol formed during the reaction. The amount of water or the mono-alcohol distilled from the reaction system is measured, for example, by separating water or the mono-alcohol, distilled together with the diol from the reaction vessel, from the diol by a distillation column, removing the separated water or mono-alcohol from the reaction system, and measuring the obtained amount of water or mono-alcohol. The gelled polyester made by the present invention is prepared by subjecting the obtained esterification product to polycondensation in the presence of a polycondensation catalyst at a temperature of about 200 to about 280°C and under a reduced pressure lower then 20.0 kPa (150 mmHg), preferably lower than 2.7 kPa (20 mmHg), more preferably lower than 0.7 kPa (5 mmHg). Any catalysts customarily used for the polycondensation for the synthesis of polyesters can be used as the polycondensation catalyst in the present invention. For example, there can be mentioned compounds of tin, antimony, titanium, calcium, lead, iron, and nickel. When the polycondensation of the esterification product is started, the diol is mainly formed with the advance of the reaction, and by removing the formed diol from the reaction system, the polycondensation is further advanced, whereby the intended crosslinked polyester of the present invention is obtained. The reaction speed of the polycondensation can be controlled by adjusting the speed at which the diol is removed from the reaction system by distillation. The ratio of the carboxylic acids to polyols in the reaction mixture is controlled to a level necessary for advancing the crosslinking reaction by adjusting the distillation of the diol from the reaction system; the crosslinking reaction is thus advanced and the formed polyester is crosslinked. Finally, the reaction mixture reaches the gelling point, and just after the reaction mixture reaches the gelling point, the crosslinking reaction is drastically advanced. The arrival at the gelling point can be confirmed by an abrupt rise of the viscosity of the reaction liquid, observed just after the gelling point is reached. The speed of the crosslinking reaction after the gelling point is reached by the polyester condensation reaction can be controlled by adjusting the speed of distillation of the diol from the reaction system. After reaching the gelling point, the viscosity of the reaction liquid is drastically increased with a distillation of the diol from the reaction system. At this point, the vacuum degree in the reaction vessel is reduced, i.e., the pressure in the reaction vessel is elevated, and thus a too rapid advance of the gelling reaction of the polyester is controlled by controlling the distillation speed of the diol, and the reaction is stopped at the point at which the desired gelling degree is attained, whereby a gelled polyester having the required characteristics is obtained. At an appropriate stage after reaching the gelling point, the condensation reaction is stopped by restoring the pressure in the reaction vessel to atmospheric pressure or stopping the distillation of the diol from the reaction system, whereby a polyester having a required gelling degree is obtained. If the reaction is stopped at a point at which the reaction mixture has a required viscosity, a gelled polyester resin having a required melt viscosity can be obtained. This viscosity is such that the flow index is 0.1 x 10 -4 to 300 x 10 -4 ml/sec. As pointed out hereinbefore, the polyester made by the present invention has an acid value of 5 to 20 mgKOH/g, preferably 5 to 15 mgKOH/g. Accordingly, in a toner prepared by using this polyester as the binder, the charge quantity is adjusted to about -10 to about -30 µC/g, and a copied image having a good image density and a good contrast can be obtained when this toner is used. A conventional polyester used in this field has carboxyl groups at the terminals and a high acid value, and the polyester has a negative chargeability. Moreover, since the terminal carboxyl group concentration is relatively high, the self-chargeability is high, and therefore, a toner prepared by using this polyester as the binder has an unsatisfactory sharpness of the formed image. In contrast, since the polyester made by the present invention has an appropriate acid value, a toner prepared by using the polyester made by the present invention as the binder has good chargeability characteristics and provides a sharp image. The acid value of the polyester can be controlled by (a) adjusting the ratio of the carboxylic acids to diols in the starting material mixture, and (b) adjusting the conversion P at the step of forming the esterification product. In the adjusting method (a), the acid value of the polyester can be increased by increasing the amount of the carboxylic acid component or reducing the amount of the lower alkyl ester of the carboxylic acid. In the adjusting method (b), the acid value of the obtained polyester is increased by reducing the conversion P. Namely, by adjusting the ratio of the carboxylic acids to diols and the conversion at the step of forming the esterification product within the ranges represented by the formulae (1) and (2), a polyester having an acid value within the range specified in the present invention can be obtained. If it is necessary to change the acid value of the polyester within the range specified in the present invention, preferably a rough adjustment is carried out by the method (a) and a fine adjustment is carried out mainly by the method (b), because the influence of the obtained polyester on the acid value in the method (a) is larger than that in the method (b). A polyester having a hydroxyl group value smaller than 5 mgKOH/g does not have a satisfactory reactivity, and a toner obtaining by using a polyester having a hydroxyl group value larger than 50 mgKOH/g as the binder has a poor moisture resistance. Preferably, the hydroxyl group value of the polyester is 7 to 40 mgKOH/g, more preferably 10 to 35 mgKOH/g. The acid value and hydroxyl group value of the polyester can be determined by the method of JIS K-0070. The gelled polyester made by the present invention has a flow index of 0.1 x 10 -4 to 300 x 10 -4 ml/sec, and in the softened or molten state, the polyester has a flowability suitable for adhesion and fixing to a paper or the like. A toner prepared by using a polyester having a flow index included within the above-mentioned range as the binder will easily intrude into voids of the containing surface layer of a paper or the like at the fixing step, and can be firmly adhered to the surface layer. In contrast, a toner prepared by using a polyester having a flow index smaller than 0.1 x 10 -4 ml/sec as the binder does not have a good flow ability under heating, and therefore, the toner is not properly fixed to the surface of the paper or film and remains on the fixing hot roll to contaminate a following paper or film. A toner prepared by using a polyester having a flow index larger than 300 x 10 -4 ml/g as the binder causes an offset phenomenon at the fixing step, and good results cannot be obtained. In the polyester made by the present invention, the flow index is controlled to 0.1 x 10 -4 to 300 x 10 -4 ml/sec, as pointed out above, but preferably the flow index of the polyester is 0.5 x 10 -4 to 50 x 10 -4 ml/sec, more preferably 1 x 10 -4 to 20 x 10 -4 ml/sec. Since the gelled polyester resin made by the present invention has a softening point lower than 145°C, it is possible to fix a toner image at a low temperature, and accordingly, a toner having a practically satisfactory heat efficiency for the fixation and high fixation speed can be provided by using the polyester made by the present invention as the binder. Note, if the toner is prepared by using a polyester having a softening point higher than 145°C as the binder, the low-temperature fixing property is poor and the copying operation cannot be carried out at a high speed. Preferably, the Tg of the polyester made by the present invention is set at 30 to 68°C. In a toner prepared by using a polyester having a Tg lower than 30°C as the binder, adhesion or agglomeration (blocking) of toner particles occurs during storage, and the storage stability is poor. In a toner prepared by using a polyester having a Tg higher than 68°C as the binder, the low-temperature fixing property is poor and good results cannot be obtained. In the present invention, the acid value of a polyester was determined by titrating a solution of the polyester in benzyl alcohol with KOH. The Tg was determined by the DSC method (temperature-elevating rate 5°C/min). The softening point was determined by a method in which a flow tester provided with a nozzle having a diameter of 1.0 mm and a length of 1.0 mm (Model CFT-500 supplied by Shimadzu Corporation) was used, and the temperature at which 1/2 of 1 g of the sample heated under a load of 30 kg at a temperature-elevating rate of 3°C/min flowed from the top end of the nozzle was measured. The flow index was determined by a method in which a flow tester provided with a nozzle having a diameter of 1.0 mm and a length of 10.0 mm was used, the polyester was extruded from the nozzle under a load of 10 kg at a temperature of 150°C, and the flow speed of the extruded softened polyester was measured. The charge quantity of a toner comprising a polyester as the binder was determined by the following procedures. In a Henschel mixer, 95 parts by weight of a polyester were thoroughly blended with 5 parts by weight of carbon black, and the mixture was kneaded at 180°C in a screw extruder. The kneaded mixture was cooled and pulverized to a particle size of 5 to 20 µm by a jet mill, to obtain a toner, and 1 g of the obtained toner and 19 g of an iron powder as the carrier were charged in a sample bottle and shaken for about 15 minutes in an atmosphere maintained at a temperature of 25°C and a relative humidity of 50%. Then, 0.2 g of the mixture was samples and the charge quantity was measured by a blow-off powder charge quantity measuring device (supplied by Toshiba Chemical) (blow-off method). The present invention will now be described in detail with reference to the following examples and comparative examples. Note, all of "part" in the examples and comparative examples are molar parts, unless otherwise indicated. In the tables given hereinafter, BPPO represents polyoxypropylene-(2.3)-2,2-bis(4-hydroxyphenyl)propane, and BPEO represents polyethylene-(2,2)-bis(4-hydroxyphenyl)propane. Examples 1 to 5 and Comparative Example 1 Starting materials (total amount - 800 g) comprising components in the ratios shown in Table 1 were charged in an autoclave having a capacity of 2 ℓ and equipped with a distillation column and esterification was carried out until a conversion shown in Table 1 was attained. In examples 1-5 400 ppm (based on the total carboxylic acid components) of zinc acetate as an ester exchange catalyst was also used. Then, a polycondensation catalyst was charged in the autoclave in examples 1 to 5 the polycondensation catalyst was 500 ppm based on the charged carboxylic acids and polycondensation was carried out while maintaining the pressure in the autoclave at 0.4 kPa (3 mmHg) and removing glycol from the reaction mixture, whereby a gelled polyester was obtained. Note, at the point when the stirring torque was elevated to 1.5 kg-cm (200 rpm) during the polycondensation, the vacuum degree in the autoclave was adjusted to 4 kPa (30 mmHg) and the stirring rotation number was adjusted to 100 rpm, and the reaction was further conducted. In examples 1 to 5, when the stirring torque was elevated to 7 kg-cm (100 rpm), the pressure in the autoclave was restored to atmospheric pressure and the reaction was terminated. In comparative example 1 the reaction was terminated when the stirrer stopped. The acid value, softening point, and flow index of the obtained polyester were measured. The results are shown in Table 1. Then, 95 parts by weight of the obtained polyester were mixed and kneaded with 5 parts by weight of carbon black, and the mixture was cooled, pulverized and classified to obtain a toner composed of particles having an average particle size of 10 to 13 µm. The charge quantity, lowest fixing temperature, offset-generating temperature and blocking resistance of the toner were examined. The results are shown in Table 1. The lowest fixing temperature was determined by the following method. A hot roller fixing device comprising a pair of a hot rollers composed of a fluorine resin and a rubber roller, in which the heating temperature of the hot roller could be freely set, was used. The peripheral speed of the roller composed of a fluorine resin was adjusted to 20 cm/sec, and the roller compression load was adjusted to 14 kg-f. A toner image-transferred paper was passed between the two rotating rollers, and the toner fixing ratio of the fixed image was determined by the method described below. The temperature at which the fixing ratio rose to 95% was designated as the lowest fixing temperature. The toner fixing ratio was determined by the following method. An adhesive cellophane tape was applied to the surface of a fixed toner image (solid black portion) and then peeled off. The toner density was measured before and after this treatment by a reflection densitometer (supplied by Macbeth Co.), and the ratio between the values obtained before and after the treatment was determined as the fixing ratio. The offset-generating temperature was determined by the following method. In the same manner as for the measurement of the lowest fixing temperature, the toner image was fixed on a copying paper by the hot roller fixing device while changing the heating temperature of the hot roller, and then a white copying paper was fed under the same conditions to the fixing device and it was determined whether or not the copying paper was contaminated with the toner. The temperature of the hot roller at which contamination with the toner began on the white copying paper was designated as the offset-generating. temperature. The blocking resistance of the toner was determined by the following method. The toner was packed in a vessel and allowed to stand under a temperature of about 25°C and a relative humidity of 60% for 48 hours. The agglomeration of particles and the degree of the agglomeration were examined and the blocking resistance was evaluated according to the following rating. o ○: very good (no agglomeration observed) ○: good (if the vessel was turned upside down and lightly tappet, the particles were dispersed again) Δ: relatively bad (if the vessel was turned upside down and strongly tapped, the particles were dispersed again) X: bad (even if the vessel was tapped, the particles were not dispersed again) The results are shown in Table 1. From the results shown in Table 1, it is understood that the gelled polyester resins obtained in the examples 1 to 5 were excellent as the binder for a toner. As apparent from the results shown in Table 1, the toner obtained in the present comparative example did not have completely satisfactory toner characteristics. When copying was carried out by using the toner of comparative example 1 by the electrostatic copying process, a copy having a high image density and a high contrast could not be obtained. Comparative Example 2 An autoclave equipped with a distillation column was charged with carboxylic acids, alcohols and a catalyst, as shown in Table 2, and the temperature was elevated under atmospheric pressure. When the inner temperature reached at 170°C, distillation of water from the distillation column began. Esterification was carried out while maintaining the temperature of the top of the column at 100°C. When the conversion was elevated to 65%, the esterification reaction was terminated, the distillation column dismounted, the pressure in the autoclave reduced to 0.27 kPa (2 Torr), and polycondensation was carried out while removing distilled water and ethylene glycol from the reaction system. When the stirring torque began to rise, the pressure in the autoclave was adjusted to 6.75 kPa (50 Torr) and when the crosslinking degree reached a desired level, the pressure in the autoclave was restored to atmospheric pressure. The content was extruded into water through a valve arranged at the bottom of the autoclave, and then removed therefrom. The acid value of the obtained crosslinked polyester was 25 mgKOH/g, and the hydroxyl group value was 53 mgKOH/g. Then, 100 parts by weight of the crosslinked polyester were heated and kneaded with 5 parts by weight of carbon black (Regal 400R supplied by Cabot), and the kneaded mixture was cooled, pulverized and classified to obtain toner particles having a particle size of 5 to 20 µ. A developer was prepared by mixing 5 parts by weight of the toner with 95 parts by weight of an iron powder carrier (TEFV 200/300 supplied by Nippon Teppun). The relative charge quantity Q/M of the toner is the developer was measured at a temperature of 25°C and a relative humidity of 50% (normal humidity), by the blow-off method, and it was found that the relative charge quantity was - 31 µC/g. The mixing of the developer comprising the above-mentioned toner and iron powder carrier was carried out at a temperature of 30°C and a relative humidity of 90% (high humidity). The relative charge quantity Q/M of the toner in the developer was - 21 µC/g. Molar Parts Terephthalic acid 80 Isophthalic acid 20 Ethylene glycol 160 Polyoxypropylene-(2,2)-2,2-bishydroxyphenylpropane 20 Glycerol 20 Dibutyl tin oxide 0.04 From the foregoing results, it was confirmed that the charge quantity of the polyester obtained in the present comparative example was too large and the charge characteristics were strongly influenced by the humidity, and that the polyester was not suitable as the binder for a toner. As apparent from the foregoing description, the polyester resin made by the present invention is a gelled polyester having an appropriately low softening point and a good flowability when softened and molten. Accordingly, a toner prepared by using this polyester has an excellent offset-preventing property and low-temperature fixing property and is very suitable for a high-speed fixing operation. Furthermore, the gelled polyester of the present invention has an acid value necessary for imparting a good charge quantity to a toner, and by using this polyester, a toner having a good charge quantity can be obtained without using a charge-control agent. Since the acid value of the gelled polyester can be optionally controlled according to the process of the present invention, the charge quantity of the toner can be optionally controlled by adjusting the acid value of the gelled polyester. The gelled polyester has a satisfactorily high glass transition temperature (Tg), although the softening point is low, and accordingly, a toner comprising this gelling polyester as the binder has a good offset-preventing property and a good low-temperature fixing property, and at the same time, the toner has a good storage stability. Therefore, if a toner comprising the gelled polyester made by the present invention as the binder is used, a toner image can be obtained by high-speed development, and a high operation speed can be attained in a copying machine or a laser beam printer (LBP).

Claims: A process for making a gelled polyester for a toner, which has an acid value of 5 to 20 mgKOH/g and a softening point lower than 145°C, said process comprising mixing components consisting of a dicarboxylic acid component, a diol component comprising ethylene glycol in an amount of at least 20 mole% based on the total carboxylic acid component and at least one crosslinking component selected from the group consisting of trivalent alcohols and pentaerythritol in an amount in the range 1 to 30 mol% based on the total carboxylic acid component at a mixing ratio represented by the following formula (1), in a first, esterification step reacting the mixture under conditions such that the conversion ratio P of the carboxylic acid components at the end of the said first step is represented by the following formula (2) with the proviso that P<0.95 and subjecting the esterification product to a second, polycondensation step during which formed diol comprising ethylene glycol is removed from the reaction system at a temperature in the range 200 to 280°C and under a reduced pressure of less than 20.0 kPa (150 mmHg), including a first phase in which the pressure is reduced to a value less than 2.7 kPa (20 mmHg) and a second phase after reaching the gelling point in which the pressure is raised to a higher value than the value in the first phase whilst diol continues to be removed whereby crosslinking and gelation takes place, the extent of said crosslinking being monitored by monitoring the viscosity of the molten reaction medium and being controlled so as to obtain a product having a flow index determined by a method in which a flow tester provided with a nozzle having a diameter of 1.0 mm and a length of 10 mm was used, the polyester being extruded from the nozzle under a load of 10 kg at a temperature of 150°C in the range (0.1-300) x 10 -4 ml/s: 0.8 ≤ R ≤ 1 + 5 a 0.7 ≤ P ≤ [R/(1 + a )] ½ wherein R stand for the ratio of the number of moles of the total alcohol components to the number of moles of the total acid components and a stands for the ratio of the sum of the number of moles of the polyhydric alcohol component selected from the group consisting of trivalent alcohols and pentaerythritol to the number of moles of the total acid components. A process according to any preceding claim in which the pressure in the polycondensation step is initially reduced to a value below 0.7 kPa (5 mmHg). A process according to any preceding claim wherein the dicarboxylic acid component comprises at least 40 mole%, based on the total carboxylic acid components, of terephthalic acid or dimethyl terephthalate, and up to 60 mole%, based on the total carboxylic acid components, of isophthalic acid or dimethyl isophthalate. A process according to any preceding claim wherein the diol component comprises, based on the total carboxylic acid components, up to 80 mole% of neopentyl glycol. A process according to any preceding claim wherein the polyhydric alcohol is selected from trimethylol propane, pentaerythritol and glycerol. A process according to any preceding claim wherein the acid value is 5 to 15 mgKOH/g. A process according to any preceding claim wherein the flow index is 0.5 x 10 -4 to 100 x 10 -4 ml/sec and most preferably 1.0 x 10 -4 to 50 x 10 -4 ml/sec.

Inventors: FUNATO RYO, ITO HIROKAZU, KUBO SHINJI, TAJIRI NORIYUKI, TAKYU MASAYUKI, FUNATO, RYO, ITO, HIROKAZU, KUBO, SHINJI, TAJIRI, NORIYUKI, TAKYU, MASAYUKI
Applicants: MITSUBISHI RAYON CO, MITSUBISHI RAYON CO., LTD.
Application year: 1989
Main classification: C08G63
IPC codes: G03G9, C08G63