Process for producing toner for developing electrostatic image

Abstract: A process for producing a toner for developing an electrostatic image, comprises; a first classification step for classifying a colored resin powder containing at least a resin and a coloring agent to remove fine powder to give a classified powder having a given particle size; a mixing step for mixing the classified powder thus obtained and a fine silica powder to give a mixed powder; and a second classification step for removing the fine powder from the mixed powder.

Description: The present invention relates to a process for preparing a toner for developing an electrostatic image, used in an image forming process such as electrophotography, electrostatic recording or electrostatic printing. A large number of methods are hitherto known as electrophotography, as disclosed in U.S. Patent No. 2,297,691, Japanese Patent Publications No. 42-23910 and No. 43-24748, etc. In general, copies are obtained by forming an electrostatic latent image on a photosensitive member, utilizing a photoconductive material as a photosensitive layer and according to various means, subsequently developing the latent image by the use of toner, and transferring the toner image to a transfer medium such as paper if necessary, followed by fixing of the toner image by the action of heat, pressure, heat-and-pressure, or solvent vapor. Toners are required to have a sharp particle size distribution. In the process of producing a toner, coarse particles that may adversely affect image quality or fine particles that may cause fog are removed by providing classification steps. Of the particles that should be removed through classification steps, however, fine particles with a particularly fine size of not more than 2 to 3 µm electrostatically firmly adhere to toner particles having the desired particle size. In the classification steps, it is difficult to sufficiently remove such particles. These fine particles firmly adhere to the surface of each part of a developing unit and are fixed there, tending to cause ghosts or a deterioration of images and a lowering of density when copies are taken in a large number. As a means for solving such problems, Japanese Patent Application Laid-Open No. 53-58244 proposes a method in which a fine silica powder is added to a colored resin powder that serves as a toner, which are mixed and then classified into powder with a specific particle diameter, or, after classification, further heated to carry out a treatment for making spherical the particles in the powder. The method disclosed in the above Japanese Patent Application Laid-Open No. 53-58244 employs a V-type mixer when powdery silica is mixed. The dispersion power of the V-type mixer is relatively weak, so that agglomerates tend to be present in a toner, white dots tend to appear at a black solid area of a toner image, and fog or the like tends to appear at its non-image area. This method also has a problem in the quality stability of a developer, because, even if a developer with the desired particle size has been obtained by classification, the product may be turned to have powdery silica in an amount different from the amount when it had been added, depending on the mixing conditions, types of classifier and classification conditions, and also these are not constant. In general, toners are prepared by melt-kneading at least a resin and a coloring agent and other additives, followed by pulverization and classification to control the resulting powder to have the desired particle size. In the course of the classification, powder is removed as coarse powder or fine powder in an amount of from 15 to 40 % by weight based on the feed, depending on the quality required for toners or the performance of a classifier used. These coarse powder and fine powder are blended with starting materials at the time of melt-kneading and thus subjected to recycling commonly for the economical reasons. In the above method proposed in Japanese Patent Application Laid-Open No. 53-58244, the powdery silica and additives which originally should not be included in toner particles are mixed into the coarse powder or fine powder at the time of the classification, and hence there is the problem that it becomes difficult to recycle the fine powder or coarse powder having been classified. Even if the fine powder included in a developer may have a better accuracy of classification than in the classification carried out before addition of powdery silica and the fine powder may become smaller in amount compared with the case when no silica is added, the fine powder removal is not satisfactory with the classification carried out once. When the powdery silica and other additives are added and mixed in a pulverized product in the presence of a large quantity of the fine powder, the mixing of these can not facilitate dispersion so much because of higher fluidity or agglomerating properties of the powdery silica than those of a toner. In addition, the mixing thereof may give a microscopically non-uniform state. Hence, the removal of the fine powder in the classification step can not be in a satisfactory extent, though in an improved state than ever. In respect of also the quality of an image, the above problems can not be eliminated. A conventional process for producing a toner will be further detailed with reference to the accompanying Figs. 2 and 3. Figs. 2 and 3 show flow charts of the respective steps in conventional processes for producing toners. The conventional process as shown in Fig. 2 can achieve a superior utilization efficiency of starting materials, but tends to result in an insufficient removal of fine powder (in particular, the one with a particle size of not larger than 2 to 3 µ as described above). This process has a limit in the removal of the fine powder even if the amount of powder discharged to the fine powder side is increased at the time of classification. Hence, not only the problems in quality as previously discussed are brought about, but also an increase in cost tends to be caused because of an increase in the amount of recycling to the step of kneading. The toner production steps as shown in Fig. 3 correspond to those of the production process disclosed in the Japanese Patent Application Laid-Open No. 53-58244. The process shown in Fig. 3 can achieve more effective removal of the fine particles of not larger than 2 to 3 µm or less as compared to the process shown in Fig. 2. However, as previously discussed, the removal of the fine particles of not larger than 2 to 3 µm is still unsatisfactory. In addition, the fine powder in which silica is included is difficult to be recycled which causes an increase in cost of toners. In addition, US-A-4 430 413 discloses a process for preparing a single-component toner or developer composition, wherein fine toner particles are removed from the composition prior to the addition of conductive carbon followed by a reclassification step to remove excess carbon particles. An object of the present invention is to provide a process for producing a toner for developing an electrostatic image, which has solved the above problems. Another object of the present invention is to provide a process for producing a toner for developing an electrostatic image, which can achieve a successful removal of the fine powder. Still another object of the present invention is to provide a process for producing a toner for developing an electrostatic image, the particle surfaces of which a fine silica powder has been imparted to in a good state. A further object of the present invention is to provide a process for producing a toner for developing an electrostatic image, which can achieve a good economical efficiency. According to the present invention, the above objects are achieved by a process for producing a toner for developing an electrostatic image, comprising a first classification step for classifying a colored resin powder containing at least a resin and a coloring agent by a first classifier to remove fine colored resin powder to give a classified colored resin powder having a given particle size, wherein the fine colored resin powder removed in the first classification step is recycled as a toner material, a mixing step for mixing the classified colored resin powder thus obtained and a fine silica powder to give a mixture of the classified colored resin powder and the fine silica powder, and a second classification step for removing still present fine colored resin powder from said mixture by a second classifier. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a flow chart to show the steps and material flow in the production process of the present invention. Figs. 2 and 3 are flow charts to show the steps and material flow in the conventional process. Figs. 4 and 5 each schematically illustrates an example of an apparatus in which a fine silica powder and a toner material powder are added, dispersed and mixed. DESCRIPTION OF THE PREFERRED EMBODIMENTS In the production process of the present invention, first classification and second classification are carried out. In the first classification, fine powder with a particle diameter smaller than a given size is removed from a powder material to be made into a toner in a classification step and coarse powder with a particle diameter larger than a given size is optionally removed so that the powder is controlled to have the desired particle size. As a result of this first classification, the greater part of the fine powder included in the material powder can be removed. After the first classification, the following steps are taken in order to remove the fine powder having been not completely removed. First, a fine silica powder is added to the material powder optionally together with other additives and the resulting material powder is dispersed and mixed using a mixer having a sufficient dispersion power. Thereafter, the second classification is carried out so that fine powder removed in the second classification as the fine powder may be approximately in an amount of from 0.5 to 15 % by weight. Fig. 1 shows a flow chart of the above process. The greater part of the fine powder is removed in the first classification, and also the material powder having been classified in the first classification is thoroughly dispersed in the presence of fine silica powder. As a result, the problem that the fine particles with a particle diameter of from 2 to 3 µm are firmly adhered to the toner particles with the desired particle size can be eliminated. Hence, as a result of further removal of the fine powder in the second classification, the particles with a particle diameter of from 2 to 3 µm not completely removed in the first classification and also fine silica powder not adhered to the toner particles can be removed in a very good efficiency. In the present invention, the process may preferably comprise the steps of cooling, crushing and pulverizing a melt-kneaded product containing at least a binder resin and a coloring agent, controlling in a first classification step the pulverized product to have the desired particle size, thereafter adding a fine silica powder to the classified powder optionally together with other additives to carry out dispersion and mixing, and then preferably carry out second classification at a finer cut size than that in the first classification step. The process of the present invention can be carried out also when the steps of melt-kneading and pulverizing in the process for producing a toner are replaced with spray drying or other means. In the present invention, classification conditions may preferably be set in such a manner that in the first classification the fine powder is removed in an amount of from 7 to 30 % by weight, and preferably from 10 to 25 % by weight, based on the feed of the material powder, and in the second classification the fine powder is removed in an amount of from 0.5 to 15 % by weight, preferably from 1 to 5 % by weight, and more preferably from 1 to 3 % by weight. In view of the production efficiency of toners and the cost of toners, it is more preferred that the amount of the fine powder removed in the second classification is controlled to be not more than 1/2 (in weight ratio) of the amount of the fine powder removed in the first classification. Even if the classification conditions are set in the manner that in the first classification the fine powder is removed in an amount of more than 30 % by weight, the content of the fine powder with a particle diameter of from 2 to 3 µm can not be so much effectively decreased. In addition, there is the possibility that the amount of its return to the melt-kneading step increases to bring about ill effects of not only a cost increase but also a broader particle size distribution. On the other hand, if the fine powder removed in the first classification is made to be in an amount less than 7 % by weight, the proportion of particles with a particle diameter of from 3 to 6 µm increases in the classified powder obtained in the first classification and this makes it necessary to increase the amount of the fine powder to be removed in the second classification, resulting in an increase in the fine powder to be discarded. This is hence undesirable from an economical viewpoint. In the first classification, a usual classifier may be used which is used in the preparation of toners. In the second classification, however, it is preferred in order to satisfy the above conditions to use a classifier having a very fine cut size, which is as fine as from about 1 to 4 µm in particle diameter. Such a classifier can be exemplified by T-Plex Ultrafine Separator (trade name), manufactured by Alpine Co.; Turboclassifier (trade name), manufactured by Nisshin Engineering Co.; Micron Separator (trade name), manufactured by Hosokawa Micron Co.; having a high-speed classifying blade. A classifier having no rotating blade can be exemplified by a cyclone type classifier manufactured by Ishikawajima-Harima Heavy Industries Co., Ltd.(IHI), a DS separator (a special type) manufactured by Nippon Pneumatic Industries Co., and Elbow Jet Classifier manufactured by Nittetsu Kogyo K.K. The classifiers of the type having a rotating classifying blade must be operated at a very high rotational speed (from twice to ten times the rotational speed of that in the case when usual toner particles are classified). Hence, from the viewpoints of the inclusion of toner agglomerates produced at bearings or the like because of generation of heat, the durability of bearings and the long-run stability of the apparatus, it is preferred to use the classifiers of the latter group, having no rotating blade, as the classifier used in the second classification. In this instance, in order to make stable the amount of the fine silica powder (optionally with other additives) present in a toner product, it is required for the material powder to be sufficiently dispersed and for the fine silica powder to be adhered to the toner particles so that substantially no coarse particles due to agglomeration of these may be present. If the fine silica powder is insufficiently dispersed, the coarse particles formed of agglomerates of the fine silica powder may cause fog or white dots on a black solid area. Moreover, in the step of removing coarse powder by the use of a sieve, the agglomerates of the fine silica powder are removed together with the coarse powder, so that the amount of fine silica powder to be added may decrease to make unstable the amount of the fine silica powder present in a toner. If the fine silica powder is insufficiently dispersed and the fine silica powder is not well firmly adhered to the toner particles, the amount of the presence of the fine silica powder may decrease at the time of classification and also can not be made stable. In order for the fine silica powder to be sufficiently dispersed taking account of the dispersion power and the requirement that the toner particles are not ground, it is preferred to carry out the dispersion and mixing by means of a mixer of from 20 m/sec to 70 m/sec, and more preferably from 25 m/sec to 60 m/sec, in peripheral speed at the tip of its stirring blade (rotating blade). A mixing time of from 0.1 to 60 minutes, and preferably from 1 to 30 minutes, is advantageous in view of efficiency. Figs. 4 and 5 each illustrate an example of a mixer having a stirring blade. The mixer shown in Fig. 4 comprises a jacket 1, a stirring blade 2, a motor 3, a cover 4, a base 5, a control board 6, a cylinder 7, a rock 8 for the cover, a cylinder 9, a direction control unit 10, and an outlet 11. A specific example of the mixer shown in Fig. 4 includes a Henschel mixer. The mixer shown in Fig. 5 comprises a rotating shaft 12, a rotor 13, a dispersion blade 14, a rotating member (blade) 15, a partition disc plate 16, a casing 17, a liner 18, an impact zone 19, an inlet chamber 20, an outlet chamber 21, a return path 22, a product take-off valve 23, a material feed valve 24, a blower 25, and a jacket 26. In the production process of the present invention, good results can be obtained when the fine silica powder is added preferably in an amount of from 0.1 to 3 % by weight, and more preferably from 0.2 to 2 % by weight, based on the weight of the first classified powder or the toner. Addition of the fine silica powder in an excessive amount may result in not only a lowering of toner image density or humidity characteristics with regard to image quality but also a difficulty in mixing and dispersion with regard to the process for producing a toner. It may also cause the fine silica powder to move in a large quantity into the fine powder to be removed at the time of classification. The process of the present invention, however, can enjoy a greater latitude than the conventional process when the fine silica powder is added in an excessive amount, showing the tendency that its ill effect is decreased. In the present invention, the particle size distribution is measured in the following way: Coulter Counter TA-II Type (manufactured by Coulter Electronics Inc.) or Elzone Particle Counter 80XH-2 (Particle Data Co., U.S.A.) is used as a measuring apparatus, and the number average distribution and volume average distribution are outputted. As an electrolytic solution, an aqueous 1 to 4 % NaCl solution is used. As a measuring method, 0.1 to 5 mℓ of a surface active agent (preferably an alkylbenzene sulfonate) is added as a dispersant to 100 to 150 ml of the aqueous electrolytic solution, and 0.5 to 50 mg of the sample to be measured is further added. The electrolytic solution in which a sample has been suspended is put in an ultrasonic dispersing machine, and dispersion treatment is carried out for about 1 to 3 minutes. Particle size distribution of the particles of 1 to 40 µm is measured with the above Coulter Counter TA-II Type, using a 12 to 120 µm aperture as an aperture, to determine the volume average distribution and number average distribution. As a method of measuring particle diameter of not more than 3 µm, the Coulter counter may often result in a poor reproducibility because of the influence by noise. Hence, particles are photographed using a microscope with changes of the depth of focus on the same plane, and the data obtained are analyzed to determine number distribution and make a check. In this instance, particles with a particle diameter of from 0.6 to 20 µm are analysed and those of less than 0.6 µm are deleted from analysis on account of the influence of the fine silica powder. When the microscope is used, particle diameters of about 3,000 particles are measured to determine the distribution. In the present invention, the binder resin in the toner includes, for example, homopolymers of styrene and derivatives thereof, such as polystyrene, poly-p-chlorostyrene, and polyvinyltoluene; styrene copolymers such as a styrene/p-chlorostyrene copolymer, a styrene/propylene copolymer, a styrene/vinyltoluene copolymer, a styrene/vinylnaphthalene copolymer, a styrene/methyl acrylate copolymer, a styrene/ethyl acrylate copolymer, a styrene/butyl acrylate copolymer, a styrene/octyl acrylate copolymer, a styrene/methyl methacrylate copolymer, a styrene/ethyl methacrylate copolymer, a styrene/butyl methacrylate copolymer, a styrene/methyl α-chloro methacrylate copolymer, a styrene/acrylonitrile copolymer, a styrene/vinyl methyl ether copolymer, a styrene/ethyl vinyl ether copolymer, a styrene/methyl vinyl ketone copolymer, a styrene/butadiene copolymer, a styrene/isoprene copolymer, and a styrene/acrylonitrile/indene copolymer; polyvinyl chloride, polyvinyl acetate, polyethylene, polypropylene, silicone resins, polyesters, epoxy resins, polyvinyl butyral, rosins, modified rosins, terpene resins, phenol resins, xylene resins, aliphatic or alicyclic hydrocarbon resins, aromatic petroleum resins, chlorinated paraffins, and paraffin wax. These may be used alone or in the form of a mixture. Of these resins, styrene/acrylate copolymers can be preferably used in the present invention. Particularly preferably used are a styrene/n-butyl acrylate (St-nBA) copolymer, a styrene/n-butyl methacrylate (St-nBMA) copolymer and a styrene/n-butyl acrylate/2-ethylhexyl methacrylate (St-nBA-2EHMA) copolymer. As the coloring agent that can be added to the toner according to the present invention, carbon black, copper phthalocyanine, and black iron oxide can be used which are conventionally known in the art. In the case when the toner is a magnetic toner, materials capable of being magnetized when placed in a magnetic field are used as magnetic fine particles contained in the magnetic toner. They include powders of ferromagnetic metals such as iron, cobalt and nickel, or alloys or compounds such as magnetite, γ-Fe 2 O 3 and ferrite. These magnetic fine particles may preferably have a BET specific surface area, as measured by nitrogen adsorption, of from 2 to 20 m 2 /g, and particularly from 2.5 to 12 m 2 /g. Magnetic powder with a Mohs hardness of from 5 to 7 is more preferred. This magnetic powder should be contained in an amount of from 10 to 70 % by weight based on the amount of toner. The toner of the present invention may optionally contain a charge controlling agent. Usable are negative charge controlling agents such as metal complex salts of monoazo dyes, and metal complex salts of salicylic acid, an alkyl salicylic acid, a dialkyl salicylic acid or naphthoic acid. The toner according to the present invention may preferably be an insulating toner having a volume specific resistivity of not less than 10 10 Ω·cm, and particularly not less than 10 12 Ω·cm. The fine silica powder used in the present invention may preferably have a particle diameter of from 0.005 to 0.2 µm. The fine silica powder used in the present invention includes a fine silica powder produced by vapor phase oxidation of a silicon halide, and a fine silica powder prepared by the wet process. It may further include powders obtained by subjecting any of these fine silica powders to a treatment such as a silicone oil treatment, an amino-modified silicone oil treatment, or a treatment with a silane coupling agent. The fine silica powder produced by vapor phase oxidation of a silicon halide refers to those called the dry process silica or the fumed silica. For example, it is a process that utilizes heat decomposition oxidation reaction in the oxyhydrogen flame of silicon tetrachloride gas. The reaction basically proceeds as follows. SiCl 4 + 2H 2 + O 2 → SiO 2 + 4HCl In this preparation step, it is also possible to use a metal halide such as aluminum halide or titanium chloride together with the silicon halide to give a composite fine powder of silica and other metal oxide. The fine silica powder of the present invention includes these, too. Commercially available fine silica powders used in the present invention, produced by the vapor phase oxidation of the silicon halide, include, for example, those which are on the market under the following trade names. Aerosil 130, 200, 300, 380, OX50, TT600, MOX80, MOX170, COK84 (Aerosil Japan, Ltd.); Ca-O-SiL M-5, MS-7, MS-75, HS-5, EH-5 (CABOT CO.); Wacker HDK N 20, V15, N20E, T30, T40 (WACKER-CHEMIE GMBH); D-C Fine Silica (Dow-Corning Corp.); and Fransol (Franzil Co.). As the wet process preparation method for the fine silica powder used in the present invention, various conventionally known methods can be applied. For example, they include a method of forming it by the decomposition of sodium silicate in the presence of an acid, a reaction scheme of which is shown below. Na 2 O·XSiO 2 + HCl + H2O → SiO 2 ·nH 2 O + NaCl Besides, they include the decomposition of sodium silicate in the presence of ammonium salts or alkali salts, a method in which an alkaline earth metal silicate is produced from sodium silicate, followed by decomposition in the presence of an acid to form silicic acid, a method in which a sodium silicate solution is formed into silicic acid through an ion-exchange resin, and a method in which naturally occurring silicic acid or silicate is utilized. In the fine silica powder herein mentioned, it is possible to apply anhydrous silicon dioxide (silica), as well as silicates such as aluminum silicate, sodium silicate, potassium silicate, magnesium silicate, and zinc silicate. A silica powder obtained by heat treatment of any of these silica powders at a temperature of not lower than 400°C is the fine silica powder used in the present invention. The heat treatment may be carried out, for example, by putting in an electric furnace the fine silica powder synthesized by the wet process and allowing it to stand at a temperature not lower than 400°C for a suitable period of time (for example, for 10 minutes to 10 hours). There are no particular limitations on the heat treatment so long as the properties of toners are not seriously lowered. In the present invention, a developer containing the fine silica powder synthesized by the wet process, having been subjected to heat treatment at a temperature of not lower than 400°C, gives a stable and uniform amount of triboelectricity between toner particles, between a toner and a carrier, or between a toner and a toner support such as a sleeve in the case of a one-component developer. It is also free from fog, toner black spots around line images and toner agglomeration, and is a toner durable to the copying on a large number of sheet. It is also a toner capable of reproducing a stable image without influence of changes in temperature and humidity, in particular, a toner that can achieve a great transfer efficiency even under conditions of extremely high temperature and high humidity. In addition, it is a developer that may cause only a very small decrease in the amount of triboelectricity and also little cause a lowering of the quality of reproductions even if it is stored under conditions of high temperature and high humidity for a long period of time. The wet process silica include, for example, the following ommercially available products. Nipsil Nippon Silica Industrial Co., Ltd. Tokusil, Finesil Tokuyama Soda Co., Ltd. Vitasil Taki Seihi Co. Silton, Silnex Mizusawa Industrial Chemicals, Ltd. Starsil Kamishima Kagaku Co. Himezil Ehime Yakuhin Co. Sairoid Fuji-Davison Chemical Ltd. Hi-Sil Pittsburgh Plate Glass Co. Durosil Fiillstoff-Gesellschaft Marquart Ultrasil " Manosil Hardman and Holden Hoesch Chemische Fabrik Hoesch K-G Sil-Stone Stone Rubber Co. Nalco Nalco Chemical Co. Quso Philadelphia Quaetz Co. Imsil Illinis Minerals Co. Calcium Silikat Chemische Fabrik Hoesh K-G Calsil Füllstoff-Gesellschaft Marquart Fortafil Imperial Chemical Industries, Ltd. Microcal Joseph Crosfield & Sons, Ltd. Manosil Hardman and Holden Vulkasil Farbenfabiken Bryer, A.-G. Tufknit Durham Chemicals, Ltd. Silmos Shiraishi kogyo, Ltd. Starlex Kamishima Kagaku Co. Fricosil Taki Seihi Co. In the present invention, it is preferred to use a hydrophobic silica treated with a silane coupling agent or a silicone oil. As a hydrophobicity required in the fine silica powder, preferred is a fine silica powder having a hydrophobicity in the range of from 30 to 80 as measured by ethanol titration. A method for the hydrophobic treatment includes a conventionally known method for making a fine silica powder hydrophobic. It can be made hydrophobic by chemical treatment with an organic silicon compound capable of reacting with, or physical adsorption on, the silica fine powder. A preferred method includes a method in which the fine silica powder produced by vapor phase oxidation of a silicon halide is treated with an organic silicon compound after it has been treated with a silane coupling agent or at the same time when it is treated with a silane coupling agent. The silane coupling agent or the organic silicon compound includes hexamethyldisilazane, trimethylsilane, timethylchlorosilane, timethylethoxysilane, dimethyldichlorosilane, methyltrichlorosilane, allyldimethylchlorosilane, allylphenyldichlorosilane, benzyldimethylchlorosilane, bromomethyldimethylchlorosilane, α-chloroethyltrichlorosilane, p-chloroethyltrichlorosilane, chloromethyldimethylchlorosilane, triorganosilyl mercaptan, trimethylsilyl mercaptan, triorganosilyl acrylate, vinyldimethylacetoxysilane, dimethylethoxysilane, dimethyldimethoxysilane, diphenyldiethoxysilane, hexamethyldisiloxane, 1,3-divinyltetramethyldisiloxane, 1,3-diphenyltetramethyldisiloxane, and a dimethylpolysiloxane having 2 to 12 siloxane units per molecule and containing a hydroxyl group bonded to each Si in the units positioned at the terminals. These may be used alone or in the form of a mixture of two or more kinds. The silicone oil used when the fine silica powder is treated with a silicone oil commonly refers to a silicone oil represented by the following formula: A silicone oil with a viscosity of from about 5 to 5,000 cSt. at 25°C is used as a preferred silicone oil. For example, preferred are methylsilicone oil, dimethylsilicone oil, phenylmethylsilicone oil, chlorophenylmethylsilicone oil, an alkyl-modified silicone oil, a fatty acid-modified silicone oil, and a polyoxyalkylene-modified silicone oil. These may be used alone or in the form of a mixture of two or more kinds. As a preferred method for the silicone oil treatment, the fine silica powder produced by vapor phase oxidation of a silicon halide is treated with the silicone oil after it has been treated with the silane coupling agent previously described or at the same time when it is treated with the silane coupling agent. For example, the fine silica powder and the silicone oil may be directly mixed using a mixer such as a Henschel mixer, or may be treated by spraying the silicone oil to the fine silica powder. After the silicone oil has been dissolved or dispersed in a suitable solvent, the fine silica powder may be mixed therein, followed by removal of the solvent to obtain the desired product. The fine silica powder used in the present invention is treated with the both treating agents, i.e., the silane coupling agent and silicone oil previously described. Hence, when it is incorporated in a developer, the developer can have a stable and large amount of triboelectricity and also a sharp and uniform distribution of the amount of triboelectricity. The silane coupling agent and silicone oil used for the treatment of the fine silica powder may preferably be used in a weight ratio of 15:85 to 85:15. This ratio may be varied, whereby the value of the amount of triboelectricity of the developer containing the fine silica powder can be controlled to the desired value. This ratio can be arbitrarily selected. The total of the silane coupling agent and silicone oil may preferably be in an amount of from 0.1 to 30 % by weight, and more preferably from 0.2 to 20 % by weight, based on the fine silica powder. In the present invention, a silicone oil having an amine on its side chain can be used as a treatment for the fine silica powder so that a positively chargeable hydrophilic fine silica powder can be obtained. Such an amino-modified silicone oil includes, for example, the following: Trade name Viscosity at 25°C Amine equivalent (cps) SF8417 1,200 3,500 (Toray Silicone Co., Ltd.) KF393 60 360 (Shin-Etsu Chemical Co., Ltd.) KF857 ( " ) 70 830 KF859 ( " ) 60 22,500 KF860 ( " ) 250 7,600 KF861 ( " ) 3,500 2,000 KF862 ( " ) 750 1,900 KF864 ( " ) 1,700 3,800 KF865 ( " ) 90 4,400 KF869 ( " ) 20 320 KF383 ( " ) 20 320 X-22-3680 ( " ) 90 8,800 X-22-380D ( " ) 2,300 3,800 X-22-3801C ( " ) 3,500 3,800 X-22-3810B ( " ) 1,300 1,700 The fine silica powder, preferably a hydrophobic colloidal fine silica powder, may preferably have a BET specific surface area of from 40 to 400, and preferably from 70 to 300, in view of its dispersion and mixing with classified powder and also in view of its adhesion to toner particles. In the present invention, a different material may be added for the purpose of improving the properties of a toner together with the fine silica powder. Examples of such a material are particles having an abrasive action, lubricating fine powder, and so forth. The particles having an abrasive action refer to an inorganic metal oxide, nitride, carbide, or metallic sulfate or carbonate having a Mohs hardness of not less than 3, which can be used alone or in combination. Examples thereof are shown below, but without limitation to these. They include metal oxides such as SrTiO 3 , CeO 2 , CrO, Al 2 O 3 and MgO, nitrides such as Si 3 N 4 , carbides such as SiC, and metallic sulfates or carbonates such as CaSO 4 , BaSO 4 , CaCO 3 . They preferably include SiTiO 3 , CeO 2 (as exemplified by powders comprising CeO 2 and a rare earth element such as Milek, Milek T and ROX M-1), Si 3 N 4 and SiC having a Mohs hardness of not less than 5. These materials may be those having been subjected to surface treatment with a silane coupling agent, a titanium coupling agent, a zircoaluminate coupling agent, a silicone oil or other organic compound. The lubricating fine powder that can be preferably used includes particles of fluorinated polymers as exemplified by a tetrafluoroethylene resin (such as Teflon), polyvinylidene fluoride and carbon fluoride; and particles of fatty acid metal salts such as stearic acid zinc particles. These lubricating fine powders may preferably have an average particle diameter of not more than 6 µ, and more preferably not more than 5 µm. Addition of the particles having an abrasive action, the lubricating powder or the like makes it possible to prevent a phenomenon of film formation due to paper powder or toner fine powder on a photosensitive member and to obtain a better image which is stable with time. The present invention will be described below in greater detail by giving Examples. In the following, "part(s)" refers to "part(s) by weight". Example 1 Following the flow chart as shown in Fig. 1, a toner was prepared as follows: Chromium complex of di-t-butylsalicylic acid (a negative charge controlling agent) 4 parts Styrene/2-ethylhexyl acrylate/divinylbenzene copolymer (copolymerization ratio: 80:20:1; a binder resin; weight average molecular weight: about 300,000) 90 parts Polyethylene wax (Hi-wax 200p, a product of Mitsui Petrochemical Company Limited) 4 parts Magnetic material (specific surface area: 8 m 2 /g; a coloring agent) 60 parts The above materials were heat-kneaded using a roll mill (150°C) for about 30 minutes. The resulting kneaded product was cooled and thereafter granulated. The granulated product was subsequently pulverized using a pulverizer to have a volume average particle diameter of about 10 µm. A pulverized product was thus prepared. The pulverized product thus prepared was put in a zig-zag classifier manufactured by Alpine Co., in which the cut size was so set that particles with a particle diameter of not more than 5 µm were decreased, and then fine powder was removed so that the classified powder had a volume average particle diameter of about 10.8 µm. The fine powder removed at this stage was in an amount of 18 % by weight. The classified powder had negatively chargeable properties. To 100 parts by weight of the classified powder (toner particles) obtained after the above first classification, 0.5 part by weight of a negatively chargeable hydrophobic colloidal fine silica powder (R972, a product of Nippon Aerosil Co., Ltd.) was added, and then the classified powder and the fine silica powder were mixed and dispersed for 5 minutes using the mixer as shown in Fig. 4 (a Henschel mixer with a capacity of 75 lit.), at a peripheral speed of 40 m/sec at the tip of its stirring blade. The classified powder mixed with the negatively chargeable hydrophobic colloidal fine silica powder was put in Elbow Jet Classifier (manufactured by Nittetsu Kogyo K.K.) in which the cut size was so set that particles with a particle diameter of not more than 3 µm were decreased, and thus fine powder was removed in an amount of 2 % by weight to obtain a second classified powder having a volume average particle diameter of about 11.4 µm. The second classified powder was passed through a sieve of 100 meshes, and the powder having passed through the sieve of 100 meshes was used as a negatively chargeable magnetic toner for developing an electrostatic image. On the sieve of 100 meshes, about 0.1 % by weight of coarse powder remained. Particle surfaces of the toner was observed with an electron microscope to confirm that the fine silica powder was adhered to the toner particle surfaces in a good state. In the toner having been passed through the second classification step, the fine silica powder was contained in an amount of 0.49 % by weight based on 100 parts by weight of the toner. The above negatively chargeable magnetic toner was introduced in NP7050, manufactured by Canon Inc., to carry out development. As a result, a good image with an image density of 1.42 was obtained, and no fog and also no black spots around line images of letters or characters were seen. A 100,000 sheet durability test was also carried out. As a result, no substantial deterioration of images was seen, and also no lowering of the density at black solid areas in a copy because of the influence of white solid areas of the previous copy was seen. An image reproduction test was carried out after the toner was left standing for 2 weeks under conditions of high temperature and high humidity of a temperature of 35°C and a humidity of 90 %. As a result, no increase in fog was seen. Example 2 A negatively chargeable magnetic toner was obtained in the same manner as in Example 1, except that in the first classification the fine powder was removed in an amount of 12 % by weight to obtain a classified powder with a volume average particle diameter of 10.4 µm and in the second classification the fine powder was removed in an amount of 13 % by weight to prepare a second classified powder with a volume average particle diameter of 11.5 µm. The resulting negatively chargeable magnetic toner showed good development performance like that in Example 1. In the toner of the present Example 2, however, the rate of utilization of the toner was inferior to that in Example 1. Comparative Example 1 Following the flow chart as shown in Fig. 2, a toner was prepared as follows: Chromium complex of di-t-butylsalicylic acid (a negative charge controlling agent) 4 parts Styrene/2-ethylhexyl acrylate/divinylbenzene copolymer (copolymerization ratio: 80:20:1; a binder resin; weight average molecular weight: about 300,000) 90 parts Polyethylene wax (Hi-wax 200p, a product of Mitsui Petrochemical Company Limited) 4 parts Magnetic material (specific surface area: 8 m 2 /g; a coloring agent) 60 parts The above materials were heat-kneaded using a roll mill (150°C) for about 30 minutes. The resulting kneaded product was cooled and thereafter granulated. The granulated product was subsequently pulverized using a pulverizer to have a volume average particle diameter of about 10 µm. A pulverized product was thus prepared. The pulverized product thus prepared was put in a zig-zag classifier manufactured by Alpine Co., in which the cut size was so set that particles with a particle diameter of not more than 5 µ were decreased, and then fine powder was removed in an amount of 32 % by weight so that the classified powder with a volume average particle diameter of about 11.7 µm was prepared. To 100 parts by weight of the resulting classified powder, 0.5 part by weight of a negatively chargeable hydrophobic colloidal fine silica powder (R972, a product of Nippon Aerosil Co., Ltd.) was added, and then the classified powder and the fine silica powder were mixed and dispersed for 5 minutes using the mixer as shown in Fig. 4 (a Henschel mixer with a capacity of 75 lit.), at a peripheral speed of 40 m/sec at the tip of its stirring blade. The mixed powder thus obtained was passed through a sieve of 100 meshes, and the powder having passed through the sieve of 100 meshes was used as a negatively chargeable magnetic toner for developing an electrostatic image. On the sieve of 100 meshes, about 2 % by weight of coarse powder remained. The negatively chargeable magnetic toner obtained in Comparative Example 1 was evaluated in the same manner as in Example 1. At the initial stage, a good image with an image density of 1.38 was obtained and the fog and the black spots around line images of letters or characters were in good states. A 100,000 sheet durability test was also carried out. As a result, the image density was lowered to 1.28. A lowering of image density was also seen occurring at black solid areas in a copy because of the influence of white solid areas of the previous copy. Here, the image density of 1.38 was lowered to 1.18. An image reproduction test was carried out after the toner was left standing for 2 weeks under conditions of high temperature and high humidity of a temperature of 35°C and a humidity of 90 %. As a result, a little increase in fog was seen. The surface of the developing sleeve was observed to find that fine toner particles of 3 µm or less in particle diameter were adhered in a larger quantity than in Example 1 on the developing sleeve corresponding to the part at which the lowering of image density occurred. Comparative Example 2 Following the flow chart as shown in Fig. 3, a toner was prepared as follows: Chromium complex of di-t-butylsalicylic acid (a negative charge controlling agent) 4 parts Styrene/2-ethylhexyl acrylate/divinylbenzene copolymer (copolymerization ratio: 80:20:1; a binder resin; weight average molecular weight: about 300,000) 90 parts Polyethylene wax (Hi-wax 200p, a product of Mitsui Petrochemical Company Limited) 4 parts Magnetic material (specific surface area: 8 m 2 /g; a coloring agent) 60 parts The above materials were heat-kneaded using a roll mill (150°C) for about 30 minutes. The resulting kneaded product was cooled and thereafter granulated. The granulated product was subsequently pulverized using a pulverizer to have a volume average particle diameter of about 10 µm. A pulverized product was thus prepared. To the resulting pulverized product with a volume average particle diameter of about 10 µm, 0.5 part by weight of a negatively chargeable hydrophobic colloidal fine silica powder (R972, a product of Nippon Aerosil Co., Ltd.) was added, and these powders were mixed and dispersed for 5 minutes using the mixer as shown in Fig. 4, at a peripheral speed (40 m/sec) of its stirring blade. The resulting mixed powder was put in a zig-zag classifier manufactured by Alpine Co., in which the cut size was so set that particles with a particle diameter of not more than 5 µm were decreased, and thus fine powder was removed in an amount of 31 % by weight to obtain a classified powder having a volume average particle diameter of 11.4 µm. The classified mixed powder thus obtained was passed through a sieve of 100 meshes, and the powder having passed through the sieve of 100 meshes was used as a negatively chargeable magnetic toner for developing an electrostatic image. On the sieve of 100 meshes, about 0.1 % by weight of coarse powder remained. Since the hydrophobic fine silica powder was included in the 31 % by weight of classified fine powder, it was difficult to recycle the fine powder, and this caused a great increase in cost in the production of the toner. The negatively chargeable magnetic toner obtained in Comparative Example 2 was evaluated in the same manner as in Example 1. At the initial stage, a good image with an image density of 1.40 was obtained and the fog and the black spots around line images of letters or characters were seen only a little. As a result of a 100,000 sheet durability test, the image density of 1.40 was lowered to 1.33. In a 100,000 sheet durability test under conditions of a normal environment, a lowering of image density was also seen occurring at black solid areas in a copy because of the influence of white solid areas of the previous copy. Here, the image density of 1.40 at the initial stage was a little lowered to 1.34 after 100,000 sheet copying, showing that the toner of Example 1 was on a better level in its performance. An image reproduction test was carried out after the toner was left standing for 2 weeks under conditions of high temperature and high humidity of a temperature of 35°C and a humidity of 90 %. As a result, a little increase in fog was seen. In a durability test carried out after the toner was left standing for 2 weeks under conditions of high temperature and high humidity, the image density of 1.40 at the black solid areas was lowered to 1.25 because of the influence of white solid areas of the previous copy. Fine toner particles of 3 µm or less in particle diameter were adhered in a larger quantity than in Example 1 and a smaller quantity than Comparative Example 1 on the developing sleeve corresponding to the part at which the lowering of image density occurred. Data concerning the processes for producing toners according to Examples 1 and 2 and Comparative Examples 1 and 2 are shown in the following table. Amount of fine powder (Microscopic method) Volume average particle diameter Particle diameter: 3µm to 0.6µm Particle diameter: 1.8µm to 0.6µm Material utilization rate (number %) (number %) Example: 1 11.4 µm 6.5 0.9 98 % 2 11.5 µm 6.1 0.8 87 % Comparative Example: 1 11.7 µm 9.4 2.0 98 % 2 11.4 µm 8.8 1.6 69 % Example 3 Using a V-type mixer with a capacity of 100 lit. having no stirring blade, 100 parts by weight of the first classified powder with a volume average particle diameter of 10.8 µm as prepared in Example 1 and 0.5 part by weight of a hydrophobic colloidal fine silica powder (R972) were mixed for 10 hours. A mixed powder obtained after mixing for 10 hours was classified using Elbow Jet Classifier in the same manner as in Example 1 to give a second classified powder with a volume average particle diameter of 11.3 µm. The second classified powder was passed through a sieve of 100 meshes, and the powder having passed through the sieve of 100 meshes was used as a negatively chargeable magnetic toner for developing an electrostatic image. On the sieve of 100 meshes, about 0.1 % by weight of coarse powder and agglomerates of the fine silica powder remained. In the resulting toner, the amount of fine silica powder was decreased to 0.4 % by weight. The toner of Example 3 was evaluated in the same manner as in Example 1. As a result, a good image with an image density of 1.35 was obtained at the initial stage, but the image density changed to 1.22 as a result of a 100,000 sheet durability test. Comparative Example 3 Using a V-type mixer with a capacity of 100 lit. having no stirring blade, 100 parts by weight of the first classified powder with a volume average particle diameter of 11.7 µm as prepared in Example 1 and 0.5 part by weight of a hydrophobic colloidal fine silica powder (R972) were mixed for 10 hours. The resulting mixed powder was passed through a sieve of 100 meshes, and the powder having passed through the sieve of 100 meshes was used as a negatively chargeable magnetic toner for developing an electrostatic image. On the sieve of 100 meshes, about 0.2 % by weight of coarse powder and agglomerates of the fine silica powder remained. The toner of Comparative Example 3 was evaluated in the same manner as in Example 1. As a result, a good image with an image density of 1.25 was obtained at the initial stage, but the image density changed to 1.0 as a result of a 100,000 sheet durability test and more fog appeared than the case of Example 3. Example 4 Following the flow chart as shown in Fig. 1, a toner was prepared as follows: Nigrosine (a positive charge controlling agent) 2 parts Styrene/2-ethylhexyl acrylate/divinylbenzene copolymer (copolymerization ratio: 80:20:1; a binder resin; weight average molecular weight: about 300,000) 90 parts Polyethylene wax (Hi-wax 200p, a product of Mitsui Petrochemical Company Limited) 4 parts Magnetic material (specific surface area: 8 m 2 /g; a coloring agent) 60 parts The above materials were heat-kneaded using a roll mill (150°C) for about 30 minutes. The resulting kneaded product was cooled and thereafter pulverized using a pulverizer to have a volume average particle diameter of about 10 µm. A pulverized product was thus prepared. The pulverized product was put in a zig-zag classifier manufactured by Alpine Co., and fine powder was cut off so that the classified powder had a volume average particle diameter of about 10.8 µm. The fine powder removed at this stage was in an amount of 15 % by weight. To 100 parts by weight of the resulting classified powder, 0.4 part by weight of a positively chargeable hydrophobic colloidal fine silica powder treated with an amino-modified silicone oil was added, and then these powders were mixed and dispersed for 5 minutes using the mixer as shown in Fig. 4, at a peripheral speed of 40 m/sec at the tip of its stirring blade. Thereafter, second classification was carried out using Elbow Jet Classifier and fine powder was removed in an amount of 2 % by weight to obtain a powder having a volume average particle diameter of about 11.4 µm. The resulting powder was passed through a sieve of 100 meshes, to give a toner product. The above toner was introduced in NP7050, manufactured by Canon Inc., to carry out development. As a result, a good image with an image density of 1.35 was obtained without fog and with less black spots around line images of letters or characters. An image reproduction test was carried out after the toner was left standing for 2 weeks under conditions of high temperature and high humidity of a temperature of 35°C and a humidity of 90 %. As a result, no increase in fog was seen. In a 50,000 sheet durability test, substantially no lowering was seen in the image density. Comparative Example 4 Following the flow chart as shown in Fig. 2, a toner was prepared as follows: In Example 4, classification of the first one only was carried out, and the fine powder was removed in an amount of 32 % by weight to give a powder with a volume average particle diameter of 11.4 µm. In the same manner as in Example 4, the positively chargeable hydrophobic colloidal fine silica powder was added, followed by dispersion and mixing, and the resulting mixed powder was sieved to give a toner product. The toner was evaluated in the same manner as in Example 4. As a result, the image density was lowered to 1.25 when copies were continuously taken on 50,000 sheets, and a little increase was seen in fog and black spots around line images of letters or characters. Example 5 Following the flow chart as shown in Fig. 1, a toner was prepared as follows: Chromium complex of di-t-butylsalicylic acid (a negative charge controlling agent) 4 parts Styrene/2-ethylhexyl acrylate/divinylbenzene copolymer (copolymerization ratio: 80:20:1; a binder resin; weight average molecular weight: about 300,000) 90 parts Polyethylene wax (Hi-wax 200p, a product of Mitsui Petrochemical Company Limited) 4 parts Carbon black 10 parts The above materials were heat-kneaded using a roll mill (150°C) for about 30 minutes. The resulting kneaded product was cooled and thereafter pulverized using a pulverizer to have a volume average particle diameter of about 10 µm. A pulverized product was thus prepared. The pulverized product was put in a zig-zag classifier manufactured by Alpine Co., and fine powder was cut off so that the classified powder had a volume average particle diameter of about 11.0 µm. The fine powder removed at this stage was in an amount of 17 % by weight. To 100 parts by weight of the resulting classified powder, 0.3 part by weight of a negatively chargeable hydrophobic colloidal fine silica powder (R972, a product of Nippon Aerosil Co., Ltd.) was added, and then these powders were mixed and dispersed for 5 minutes using the mixer as shown in Fig. 4, at a peripheral speed of 50 m/sec at the tip of its stirring blade. Thereafter, second classification was carried out using Elbow Jet Classifier and fine powder was removed in an amount of 2 % by weight to obtain a powder having a volume average particle diameter of about 11.5 µm. The resulting powder was passed through a sieve of 100 meshes to remove agglomerates. A toner product was thus obtained. The surfaces of 100 parts by weight of ferrite particles having a particle diameter between 250 meshes and 300 meshes were coated with 0.8 part by weight of silicone resin to give magnetic particles. The above toner (10 parts by weight) and 100 parts by weight of the magnetic particles were mixed, and the mixed powder was introduced in a developing apparatus NP3525, manufactured by Canon Inc., to carry out development. As a result, a good toner image with an image density of 1.44 was obtained, a good fixability was achieved, and also a good offset resistance was obtained. Moreover, no fog was seen with less black spots around line images of letters or characters to give a good image. When copies were continuously taken on 50,000 sheets, substantially no lowering was seen in the image density. The phenomenon that a fine toner is released from a carrier under conditions of a high humidity to contaminate the inside of a copying machine was remarkably decreased compared with conventional cases. Comparative Example 5 In Example 5, classification of the first one only was carried out, and the fine powder was removed in an amount of 32 % by weight to give a powder controlled to have a volume average particle diameter of 11.6 µ. To 100 parts by weight of the resulting toner particles, 0.5 part by weight of a hydrophobic colloidal fine silica powder (R972, a product of Nippon Aerosil Co., Ltd.) was added, and then these powders were mixed and dispersed. The resulting powder was passed through a sieve of 100 meshes to give a toner product. The toner was evaluated in the same manner as in Example 5. As a result, a good image with an image density of 1.38 was obtained, but a little increase in fog was seen under conditions of a low humidity. As a result of 50,000 sheet durability test, the image density was lowered to 1.25. In addition, the phenomenon that a fine toner is released from a carrier to contaminate the inside of a copying machine was a little seen under conditions of a high humidity. As having been described above, the process for producing a toner of the present invention can efficiently and economically give a toner that can provide a high-quality image for a long period of time, and thus is very useful.

Claims: A process for producing a toner for developing an electrostatic image, comprising: a first classification step for classifying a colored resin powder containing at least a resin and a coloring agent by a first classifier to remove fine colored resin powder to give a classified colored resin powder having a given particle size, wherein the fine colored resin powder removed in the first classification step is recycled as a toner material; a mixing step for mixing the classified colored resin powder thus obtained and a fine silica powder to give a mixture of the classified colored resin powder and the fine silica powder; and a second classification step for removing still present fine colored resin powder from said mixture by a second classifier. The process according to Claim 1, wherein said classified powder and said fine silica powder are mixed using a mixing means having a stirring blade. The process according to Claim 2, wherein said classified powder and said fine silica powder are mixed under conditions of a peripheral speed of from 20 to 70 m/s at the tip of the stirring blade. The process according to Claim 2, wherein said classified powder and said fine silica powder are mixed under conditions of a peripheral speed of from 25 to 60 m/s at the tip of the stirring blade. The process according to Claim 1, wherein from 7 to 30 % by weight of the fine powder is removed in the first classification step and from 0.5 to 15 % by weight of the fine powder is removed in the second classification step. The process according to Claim 1, wherein from 10 to 25 % by weight of the fine powder is removed in the first classification step and from 1 to 5 % by weight of the fine powder is removed in the second classification step. The process according to Claim 6, wherein from 1 to 3 % by weight of the fine powder is removed in the second classification step. The process according to Claim 1, wherein the amount of the fine powder removed in the second classification step is not more than 10 % by weight of the amount of the colored resin powder classified in the first classification step. The process according to Claim 1, wherein the first classified powder is mixed with the fine silica powder added in an amount of from 0.1 to 3 % by weight based on the first classified powder. The process according to Claim 1, wherein the first classified powder is mixed with the fine silica powder added in an amount of from 0.2 to 2 % by weight based on the first classified powder. The process according to Claim 1, wherein the first classified powder and the fine silica powder are mixed for a period of time of from 0.1 to 60 minutes, using a mixing means having a stirring blade. The process according to Claim 11, wherein said mixing means is a Henschel mixer. The process according to Claim 1, wherein the first classified powder and the fine silica powder are mixed for a period of time of from 1 to 30 minutes, using a mixing means having a stirring blade. The process according to Claim 1, wherein said mixing means is a Henschel mixer, and its stirring blade is rotated at a peripheral speed of from 20 to 70 m/s. The process according to Claim 1, wherein the second classification step is carried out at a smaller cut size than the cut size in the first classification step. The process according to Claim 1, wherein said fine silica powder comprises a hydrophobic colloidal fine silica powder. The process according to any one of the preceding claims, wherein the toner is an insulating toner having a triboelectric chargeability, the toner having a volume specific resistivity of not less than 10 10 Ω·cm. The process according to any one of the preceding claims, wherein the toner contains a charge controlling agent. The process according to any one of the preceding claims, wherein the fine silica powder is a hydrophobic fine silica powder.

Inventors: HIKAKE NORIO, HIKAKE, NORIO
Applicants: CANON KK, CANON KABUSHIKI KAISHA
Application year: 1990
Main classification: G03G9
IPC codes: G03G9