Magnetic toner

Abstract: A magnetic toner having a specific surface area of not more than 3.0 m²/g computed by the Brunauer Emmett Teller equation and the number of molecules of CO₂ gas, being equal to 100/nm² to 1000/nm², adsorbed by the toner is provided. The triboelectrification of magnetic toner particles of the magnetic toner is uniformed by adjusting the magnetic toner using an impact force so that the specific surface area of the magnetic toner and the number of molecules of CO₂ gas adsorbed by the toner are presented in the range described above.

Description: The present invention relates to magnetic toners including magnetic powder for developing electrostatically charged images in electrophotographic methods, electrostatic-printing recording methods, and the like. In general, electrophotographic methods comprise the steps of: forming an electric latent image on a sensitizing material; developing the latent image with toners to form a toner image; optionally transferring the toner image to a decalcomania material such as paper; and fixing the toner image by means of heating, pressurization, and the like to obtain a copy. Classes of developers for use in such electrophotographic methods include two-component developers consisting of a toner and a carrier, and single-component developers consisting of only a toner which also functions as a carrier. As the single-component developer, so-called magnetic toners can be used. The magnetic toners include magnetic powder in an amount of approximately 10 % to 70 %. Generally, magnetic toners are roughly divided into conductive magnetic toners and insulating magnetic toners. The insulating magnetic toners have been used not only in single-component contact or non-contact developing systems, but also in two-component developing systems with appropriate carriers. In such a single-component developing system, it is extremely important that the magnetic toners retain triboelectrification (triboelectrification: the production of electrostatic charges by friction), since the single-component developer includes no carriers functioning to accelerate triboelectrification of the magnetic toners. Namely, a "triboelectrification property", which means that triboelectrification of magnetic toners speedily reaches a saturated value by causing the magnetic toner particles to come into light contact with one another or with a doctor blade or the like, largely affects durability of the magnetic toners and developing characteristics such as image density, smudging, image quality, and the like. In the two-component developing system mentioned above, a suitable triboelectrification is necessary in order to obtain stable developing characteristics at low toner-density as well as at a high toner-density, since almost all developing machines used in the two-component developing system are not sophisticated enough to control toner-density. In addition, since a magnetic toner particle is a mixture of magnetic powder, a binder resin, an electrostatic charge control agent, and the like and such materials tend to exist nonuniformly on the surface of the magnetic toner particles, each magnetic toner particle does not always have uniform triboelectrification properties. Therefore, in order to obtain magnetic toner particles having uniform triboelectrification, it has been proposed that developing characteristics can be improved by improving uniformity of the size of the magnetic toner particles by classificating such as to remove coarse particles and fine particles; or adhering or fixing various additives which participate in the triboelectrification on the surface of each magnetic toner particle. However, the conventional magnetic toners described above do not have sufficiently uniform triboelectrification properties which are desirable for magnetic toners. Document EP-A-0 238 130 relates to a toner for electrophotography. Document EP-A-0 357 042 relates to a composition and method for developing electrostatic latent images. In order to solve the problems described above, an object of the present invention is to provide a magnetic toner which exhibits good triboelectrification properties, i. e. characteristics of speedy rise time of triboelectrification in both single-component developing systems and two-component developing systems. The magnetic toners according to the present invention can contribute to obtaining multiple copies having a superior image quality and density without smudging in both copy machines using a single-component developing system and laser printers using a two-component developing system. Therefore, one aspect of the present invention is directed to providing a magnetic toner according to claim 1. Other features are recited in the subclaims. Another aspect of the present invention is directed to providing a method for producing a magnetic toner according to claims 6 and 7. The Brunauer Emmett Teller equation is hereafter abbreviated to "BET equation". The above objects, effects, features, and advantages of the present invention will become more apparent from the following description of preferred embodiments thereof. Fig. 1 is a graph showing characteristics of rise time of triboelectrification of magnetic toners according to Examples 1 to 3 of the present invention and the Comparative Example. When obtained by kneading raw materials described below by a melt-kneading machine such as a hot roll, a kneader, an extruder, or the like; pulverizing the kneaded mixture by a mill; and classificating the pulverized mixture to obtain a magnetic toner having an average particle size of 4 to 20 µm, a magnetic toner according to the present invention having a specific surface area of not more than 3.0 m 2 /g computed by BET equation and the number of molecules of CO 2 gas, being equal to 100/nm 2 to 1000/nm 2 , adsorbed by the magnetic toner can be obtained by a particular pulverization method in the pulverizing step or by an aftertreatment after the classificating step mentioned above. Namely, in order to obtain a magnetic toner having the above-mentioned specific surface area and the number of molecules of adsorbed CO 2 gas, an impact force is added to a magnetic toner to be manufactured. For example, such a desired magnetic toner can be formed by (a) subjecting crude magnetic toners to multiple physical impacts having a reduced force in the pulverizing step; or (b) pulverizing crude magnetic toners, classificating the pulverized magnetic toners, and treating the classificated magnetic toners by a fluid stirrer such as a high-speed mixer ("Henschell Mixer", produced by Mitsui Miike Engineering Co., Ltd.) for a fixed time or by a surface reformer such as "Nara Hybridization System, NHS-1 type", produced by Nara Machinery Co., Ltd. with a strong impact force. If a magnetic toner has a specific surface area of over 3.0 m 2 /g, each of the toner particles has a highly irregular surface, for which reason, the toner particles do not adequately contact one another and carrier particles. Such a magnetic toner has the disadvantages that the triboelectrification thereof is unstable and the magnetic toner splashes during copying. If the number of molecules of CO 2 gas adsorbed by the magnetic toner is below 100/nm 2 , image quality is poor or smudging occurs since not all of the magnetic toner particles participate in development of the sensitized material. On the other hand, when the number of molecules of CO 2 gas adsorbed by the magnetic toner is above 1000/nm 2 , the toner has disadvantages such that water absorption thereof is increased, the triboelectrification thereof is reduced, and smudging occurs at high temperatures and high humidity due to polar characteristics of CO 2 molecules. In the present invention, the number of molecules of CO 2 gas adsorbed by the magnetic toner is preferably in the range of 100/nm 2 to 500/nm 2 , in which case, the stable characteristics of rise time of triboelectrification and reduced humidity dependency are obtained. The specific surface area of the magnetic toner and the number of molecules of CO 2 gas adsorbed by the magnetic toner can be measured by using a commercially available full-automatic gas adsorption apparatus ("BELSORP 28", produced by Bell Japan, Inc.) and the like. In this case, the specific surface area is computed by BET equation. As the adsorption gas, an inert gas such as N 2 gas is used. Concretely, adsorption Vm (cc/g) needed to form a monomolecular layer on a surface of a magnetic toner is measured and a specific surface area S (m 2 /g) can be calculated by the following equation: S (m 2 /g) = 4.35 X Vm In general, the specific surface area of a magnetic toner is increased when the average particle size of magnetic toner is decreased. Accordingly, in the case where the specific surface area of the magnetic toner is not more than 3 m 2 /g, the average particle size thereof is in the range of 8 - 20 µm. The average particle sizes described above are measured using Coulter counter method. In addition, the specific surface area of the magnetic toner is adversely affected by increasing the amount of the magnetic powder included in the magnetic toner because the magnetic toner increases in weight when the amount of magnetic powder included in the magnetic toner is increased. In the present invention, the magnetic powder is contained in the magnetic toner in the amount of 10 to 70 %. The number of molecules of CO 2 gas adsorbed by a magnetic toner can be computed by the following equation: [the number of molecules of CO 2 gas adsorbed by a magnetic toner] (the number/nm 2 ) = [adsorbed CO 2 gas] X 6.02 X 10 23 22414 X [the specific surface area] X 10 18 Next, the materials which compose the magnetic toner according to the present invention will be described in detail. The magnetic toner of the present invention contains a magnetic material and a binder resin as main ingredients. As the magnetic material, magnetite, ferrite, or the like, which has crystallographically a spinel, perovskite, hexagonal, garnet, orthoferrite structure can be used in the present invention. More particularly, the magnetic material is a sintered compact of iron(III) oxide (ferric oxide) and an oxide of nickel, zinc, manganese, magnesium, copper, lithium, barium, vanadium, chromium, calcium, or the like. In addition, a suitable binder resin for the magnetic toner according to the present invention may include a thermoplastic resin such as a monomer of polystyrene, polyethylene, polypropylene, a vinyl resin, polyacrylate, polymethacrylate, polyvinylidene chloride, polyacrylonitrile, polyether, polycarbonate, thermoplastic polyester, or a cellulose resin, or a copolymer resin of the monomers listed above; and a thermosetting resin such as a modified acrylate resin, phenol resin, melamine resin, urea resin, or the like. In addition, various additives may be added to the magnetic toner of the present invention as necessary. Examples of the additives include charge control agents such as metal monoazo dyes, nigrosine dye, or the like; a coloring agent such as carbon black, or the like; and a fluidity modifier such as a colloidal silica, a metal salt of an aliphatic acid, or the like. According to the present invention, the triboelectrification of magnetic toner particles of the magnetic toner is made uniform by pulverizing the magnetic toner using an impact force so that the specific surface area of the magnetic toner and the number of molecules of CO 2 gas adsorbed by the toner produced thereby is in the range described above. In the case where the number of molecules of CO 2 gas adsorbed by the magnetic toner is increased, the surface of the magnetic toner is activated with respect to chemical adsorption. In this activated condition, it is believed that the surface of the magnetic toner can be easily triboelectrified. However, the triboelectrification is adversely affected by increasing the CO 2 gas adsorption because the water absorption is proportionally increased to the CO 2 gas adsorption. Therefore, both good characteristics of rise time of triboelectrification and uniformity of electrostatic charge can be obtained by adjusting the number of molecules of CO 2 gas adsorbed by the magnetic toner in an appropriate range. The present invention will be explained in detail hereinbelow with reference to examples. In the examples, all "parts" are by weight. Example 1 a) Styrene/acryl copolymer (Mn = 5,000, Mw = 140,000) 100 parts b) Magnetite ("EPT-500", produced by Toda Kogyo Corp.) 56 parts c) Azo-type chrome complex dye ("BONTRON S-34", produced by Orient Chemical Industrial Co., Ltd.) 1.6 parts d) Polypropylene ("VISCOL 550P", produced by Sanyo Chemical Industries, Ltd.) 3.2 parts The mixture of the above-described composition was heat-melted and kneaded by means of a biaxial kneading machine. The kneaded mixture was cooled and pulverized by a jet mill. The pulverized mixture was classificated by an air classifier to obtain fine particles (I). The condition of the pulverizing step by means of a jet mill is presented as follows: a) Jet mill ("IDS-2 type", produced by Nippon Pneumatic Mfg. Co., Ltd.) b) Angle of a collision plate 45° c) Pulverization pressure (Compressed air) 4 kg/cm 2 d) Throughput 1.6 kg/h To 100 parts of the fine particles (I) obtained above was added 0.3 parts of hydrophobic silica ("R-972", produced by Nippon Aerosil Co., Ltd.). In order to cause the silica to adhere to the surface of the particle, the mixture was mixed for approximately 1 or 2 minutes by means of a high-speed mixing machine ("Super Mixer", produced by Kawada Mfg. Co., Ltd.) at a peripheral speed at the blade tip equal to at most 20 m/s to obtain a magnetic toner according to the present invention, having an average particle diameter of 10 µm. The specific surface area of the magnetic toner and the number of molecules of CO 2 gas adsorbed by the magnetic toner according to the present invention were measured by means of a full-automatic gas adsorption apparatus ("BEL-SORP 28", produced by Bell, Japan Inc.). The results are as follows: Specific surface area of the magnetic toner 1.98 m 2 /g The number of molecules of CO 2 gas adsorbed by the magnetic toner 268.3/nm 2 Example 2 a) Styrene/acryl copolymer (Mn = 5,000, Mw = 140,000) 100 parts b) Magnetite ("EPT-500", produced by Toda Kogyo Corp.) 56 parts c) Azo-type chrome complex dye ("BONTRON S-34", produced by Orient Chemical Industrial Co., Ltd.) 1.6 parts d) Polypropylene ("VISCOL 550P", produced by Sanyo Chemical Industries, Ltd.) 3.2 parts The mixture of the above-described composition was heat-melted and kneaded by means of a biaxial kneading machine. The kneaded mixture was cooled and pulverized by a mill. The pulverized mixture was classificated by an air classifier to obtain fine particles (II). The condition of the pulverizing step by means of a jet mill is presented as follows: a) Jet mill ("IDS-2 type", produced by Nippon Pneumatic Mfg. Co., Ltd.) b) Angle of a collision plate 90° c) Pulverization pressure (Compressed Air) 6 kg/cm 2 d) Throughput 3.0 kg/h It is noted that the object to be pulverized is more pulverized when the angle of the collision plate is 90° as compared with 45°. Next, the fine particles (II) obtained above were aftertreated by stirring in "Henschell Mixer" (a moving blade of "CK/BO type") at a peripheral speed at the moving blade tip equal to 30 m/s for 10 minutes. To 100 parts of the aftertreated fine particles was added 0.3 parts of hydrophobic silica ("R-972", produced by Nippon Aerosil Co., Ltd.). The mixture was mixed for approximately 1 or 2 minutes by means of "Super Mixer" at a peripheral speed at the blade tip equal to at most 20 m/s to obtain a magnetic toner according to the present invention, having an average particle diameter of 10 µm. The specific surface area of the magnetic toner and the number of molecules of CO 2 gas adsorbed by the toner according to the present invention were measured by repeating the same procedure as described in Example 1. The results are as follows: Specific surface area of the magnetic toner 2.13 m 2 /g The number of molecules of CO 2 gas adsorbed by the magnetic toner 320.1/nm 2 Example 3 Fine particles (II) were prepared by repeating the same procedures as described in Example 2. The fine particles (II) were put in a surface reformer ("Nara Hybridization System, NHS-1 type", produced by Nara Machinery Co., Ltd.) and aftertreated at 5000 rpm for 3 minutes. To 100 parts of the treated fine particles was added 0.3 parts of hydrophobic silica ("R-972", produced by Nippon Aerosil Co., Ltd.). The mixture was mixed for approximately 1 or 2 minutes by means of "Super Mixer" at a peripheral speed at the blade tip equal to at most 20 m/s to obtain a magnetic toner according to the present invention, having an average particle diameter of 10 µm. The specific surface area of the magnetic toner and the number of molecules of CO 2 gas adsorbed by the magnetic toners according to the present invention were measured by repeating the same procedure as described in Example 1. The results are as follows: Specific surface area of the magnetic toner 1.76 m 2 /g The number of molecules of CO 2 gas adsorbed by the magnetic toner 458.5/nm 2 Comparative Example To 100 parts of the same fine particles (II) as described in Example 2 was added 0.3 parts of hydrophobic silica ("R-972", produced by Nippon Aerosil Co., Ltd.). The mixture was mixed for approximately 1 or 2 minutes by means of "Super Mixer" at a peripheral speed at the blade tip equal to at most 20 m/s to obtain a comparative magnetic toner, having an average particle diameter of 10 µm. The specific surface area of the comparative magnetic toner and the number of molecules of CO 2 gas adsorbed by the comparative magnetic toner were measured by repeating the same procedure as described in Example 1. The results are as follows: Specific surface area of the comparative magnetic toner 2.22 m 2 /g The number of molecules of CO 2 gas adsorbed by the comparative magnetic toner 63.4/nm 2 The magnetic toners according to Examples 1 to 3 and Comparative Example were evaluated in connection with characteristics of rise time of triboelectrification by the following procedures: 1) 100 parts of a carrier of non-coated iron powder and 10 parts of each of the magnetic toners according to Examples 1 to 3 and Comparative Example were put in a beaker; and 2) while the mixture of the carrier and the magnetic toner was stirred with a magnetic stirrer, the triboelectrification of the mixture was measured at fixed intervals. Here, the triboelectrification was measured by a magnet blow-off method, in which the magnetic toner is separated from the carrier by virtue of the difference of the magnetic forces thereof and the remaining electric charge of the carrier is measured. The results are shown in Table 1 and plotted in Figure 1. As will be apparent from the results shown in Table 1 and Figure 1, the magnetic toners according to the present invention exhibit a high triboelectrification and the triboelectrification of the magnetic toners reaches speedily the saturated value with a short time stirring. Results of characteristics of rise time of triboelectrification Stirring Time (s ) Example 1 Example 2 Example 3 Comparative Example 10 -5.2 -6.8 -8.2 -3.3 30 -12.2 -12.6 -14.6 -5.9 60 -14.5 -14.7 -17.7 -7.9 120 -18.2 -18.6 -20.2 -11.7 300 -20.3 -19.7 -21.8 -16.3 600 -20.5 -20.2 -22.7 -21.1 Furthermore, the magnetic toners according to Examples 1 to 3 and Comparative Example were evaluated in the case where each of the magnetic toners was set in both a copy machine using a single-component developing system and a laser printer using a two-component developing system, and 10,000 sheets were copied. The image density, smudging, and image quality of both the initial stage and the 10,000th copied sheet were evaluated. The results are shown in Table 2 and Table 3. In the case of evaluation tests using the laser printer, a developer obtained by mixing 15 parts of each of the magnetic toners and 100 parts of the carrier. The image density and smudging described in the tables were measured by process measurements Macbeth RD914 and brightness by Hunter, respectively and the image quality was evaluated by visual observation in accordance with the following: ○ Image quality good; ▵ Characters smudged; and X Characters smudged and blurred. Evaluation results in a copy machine using a single-component developing system Initial stage After 10,000 sheets Image density Smudging Image quality Image density Smudging Image quality Example 1 1.38 0.42 ○ 1.32 0.46 ○ Example 2 1.39 0.48 ○ 1.34 0.47 ○ Example 3 1.39 0.42 ○ 1.37 0.39 ○ Comparative Example 1.38 0.53 ▵ 1.26 0.73 X Evaluation results in a laser printer using two-component developing system Magnetic toner Initial stage After 10,000 sheets Image density Smudging Image quality Image density Smudging Image quality Example 1 1.42 0.65 ○ 1.44 0.67 ○ Example 2 1.43 0.55 ○ 1.42 0.55 ○ Example 3 1.43 0.54 ○ 1.44 0.64 ○ Comparative Example 1.40 0.66 ▵ 1.31 1.12 X As will be apparent from the results shown in Table 2 and Table 3, the magnetic toners of Examples 1 to 3 according to the present invention maintained both good image density and good image quality in the 10,000 copied sheet in both the copy machine with a single-component developing system and the laser printer with a two-component developing system. On the contrary, the comparative magnetic toner of Comparative Example exhibited poorer image quality in the 10,000 copied sheet than at the initial stage in both the copy machine using a single-component developing system and the laser printer using a two-component developing system. Furthermore, the 10,000 copied sheet with the comparative magnetic toner in both the copy machine using a single-component developing system and the laser printer using a two-component developing system had a poor image density. The 10,000 copied sheet with the comparative magnetic toner in the laser printer with a two-component developing system was much smudged. As explained above, the present invention provides a magnetic toner by means of which multiple copies having good image quality and good density without smudging can be obtained in both a copy machine using a single-component developing system and a laser printer using a two-component developing system. The present invention has been described in detail with respect to embodiments, and it will now be apparent from the foregoing to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and it is the intention, therefore, in the appended claims to cover all such changes and modifications.

Claims: A magnetic toner consisting essentially of a magnetic material and a binder resin as main ingredients in the form of a fine powder having a specific BET surface area S (m 2 /g) of not more than 3.0 m 2 /g calculated by the equation: S (m 2 /g) = 4.35 X Vm wherein Vm (cm 3 /g) is an adsorption needed to form a monomolecular layer on the surface of the magnetic toner with a number of adsorbed CO 2 molecules equal to 100/nm 2 to 1000/nm 2 , computed by the equation : [adsorbed CO 2 gas] X 6.02 X 10 23 22414 X [the specific surface area] X 10 18 A magnetic toner as recited in claim 1, wherein the magnetic material is a material selected from the group consisting of magnetite and ferrite, having crystallographically a spinel, perovskite, hexagonal, gamet, orthoferrite structure. A magnetic toner as recited in claim 3, wherein the magnetic material is a sintered compact of iron (III) oxide and an oxide of metal selected from the group consisting of nickel, zinc, manganese, magnesium, copper, lithium, barium, vanadium, chromium, and calcium. A magnetic toner as recited in claim 1, wherein the binder resin is a material selected from the group consisting of polystyrene, polyethylene, polypropylene, a vinyl resin, polyacrylate, polymethacrylate, polyvinylidene chloride, polyacrylonitrile, polyether, polycarbonate, thermoplastic polyester, a cellulose resin: copolymer of the monomers of the polymers listed above: a modified acrylate resin: phenol resin; melamine resin; and urea resin. A magnetic toner as recited in claim 1, further comprising at least one material selected from the group consisting of a charge control agent: a coloring agent: and a fluidity modifier. A method for producing a magnetic toner according to claims 1 to 5 consisting essentially of fine particles, comprising the steps of : (a) mixing raw materials including a magnetic material and a binder resin to form a mixture: (b) melt-kneading the mixture to form a melt-kneaded mixture: (c) giving an appropriate impact force to the melt-kneaded mixture by a jet mill to form a pulverized mixture: and (d) classifying the pulverized mixture to obtain fine particles, said steps being carried out under conditions selected to obtain a specific BET surface area of no more than 3.0 m 2 /g and a number of adsorbed CO 2 molecules equal to 100/nm 2 to 1000/nm 2 . A method for producing a magnetic toner according to claims 1 to 5 essentially of treated fine particles, comprising the steps of: (a) mixing raw materials including a magnetic material and a binder resin to form a mixture: (b) melt-kneading the mixture to form a melt-kneaded mixture; (c) pulverizing the melt-kneaded mixture to form a pulverized mixture; (d) classifying the pulverized mixture to obtain fine particles, and (e) treating the fine particles with an appropriate impact force to obtain treated fine particles, said steps being carried out under conditions selected to obtain a specific BET surface area of no more than 3.0 m 2 /g and a number of adsorbed CO 2 molecules equal to 100/nm 2 to 1000/nm 2 .

Inventors: MORIYA YUICHI, MORIYA, YUICHI, MORIYA, YUICHI, C/O TOMOEGAWA PAPER CO.,LTD.
Applicants: TOMOEGAWA PAPER CO LTD, TOMOEGAWA PAPER CO. LTD.
Application year: 1991
Main classification: G03G9
IPC codes: G03G9