Colored toner compositions

Abstract: A colored magnetic encapsulated toner composition comprised of a core comprised of a polymer binder, a colorless or light colored magnetic material, a color pigment, dye or mixture thereof excluding black, and a whitening agent; and which core is encapsulated in a polymeric shell containing a metal oxide.

Description: The present invention is generally directed to electrophotographic colored encapsulated toner compositions. Encapsulated and cold pressure fixable toner compositions are known. Cold pressure fixable toners have a number of advantages in comparison to toners that are fused by heat, primarily relating to the utilization of less energy since, for example, these toner compositions can be fused at room temperature. Cold pressure fixability also enables the instant-on copy machine feature. Nevertheless, many of the prior art cold pressure fixable toner compositions suffer from a number of deficiencies. For example, the prior art colored toners, particularly magnetic colored toners, usually do not possess sufficiently low volume resistivity of, for example, 10 4 to 10 6 ohm-cm to be effectively useful for inductive single component development; the prior art magnetic colored toners also do not usually offer the desirable color quality or a wide color variety; and they are usually fixed under high pressure of, for example, in excess of 3,500 psi, which has a tendency to severely affect the image quality of the toner selected. Specifically, the high fixing pressure can lead to images of low resolution and severe image offset. Also, with some of the prior art cold pressure toner compositions inclusive of black toners, substantial image smearing can result from the high pressures selected. The high fixing pressure also generates in some instances objectionable paper calendering problems. In addition, a number of the prior art encapsulated toners, inclusive of black toners, often suffer from the known image ghosting problem when used in the transfix ionographic printers such as the Delphax printers. Additionally, the preparative processes of the prior art pressure fixable encapsulated toner compositions usually employ flammable organic solvents as the diluting vehicles and reaction media, and this could drastically increase the toner's manufacturing cost because of expensive solvent separation and recovery procedure, and the need for explosion-proof equipment, and the necessary precautions that have to be undertaken to prevent the solvent associated hazards. Moreover, the involvement of a solvent in the prior art processes also may decrease the product yield per unit volume of reactor size. Furthermore, with many of the prior art processes narrow size dispersity toner particles cannot be easily obtained by conventional bulk homogenization techniques. The following United States patents have been noted: 4,803,144 which discloses an encapsulated toner with a core containing as a magnetizable substance, a magnetite, see Example 1, which is black in color, wherein on the outer surface of the shell there is provided a white electroconductive powder, preferably a metal oxide powder, such as zinc oxide, titanium oxide, tin oxide, silicon oxide, barium oxide and others, see column 3, line 59 to column 4; in column 8 it is indicated that the colorant can be carbon black, blue, yellow, and red; in column 14 it is indicated that the electroconductive toner was employed in a one component developing process with magnetic brush development, thus it is believed that the toner of this patent is substantially insulating; 4,937,167 which relates to controlling the electrical characteristics of encapsulated toners, see for example columns 7 and 8, wherein there is mentioned that the outer surface of the shell may contain optional surface additives 7, examples of which include fumed silicas, or fumed metal oxides onto the surfaces of which have been deposited charge additives, see column 17 for example; 4,734,350 which discloses an improved positively charged toner with modified charge additives comprised of flow aid compositions having chemically bonded thereto, or chemiadsorbed on the surface certain amino alcohol derivatives, see the Abstract for example; and also 2,986,521; 4,051,077; 4,108,653; 4,301,228; 4,301,228 and 4,626,487. The following United States Patents have also been noted: 4,514,484 directed to a powder suitable for developing latent images comprising of magnetic particles coated with a mixture of a thermoplastic resin and a silane, see for example the Abstract of the Disclosure; note column 3, beginning at line 15, wherein it is indicated that into the organic thermoplastic resin is incorporated a silane selected from those illustrated; also incorporated into the thermoplastic resin are magnetic materials, see column 3, beginning at line 35; 4,565,773 directed to dry toners surface coated with nonionic siloxane polyoxy alkalene copolymers with a polarend, see the Abstract of the Disclosure; and also 4,640,881; 4,740,443; 4,803,144 and 4,097,404. The following prior art, all United States patents, is also noted: 4,770,968 directed to polysiloxane butadiene terpolymer toner resins, reference for example column 4, and note the formulas of Figures 1 to 6, including Figure 2B, which toners can be selected wherein silicone release oils are avoided, with no apparent teaching in this patent directed to encapsulated toners; 4,814,253 directed to encapsulated toners comprised of domains containing a polymer component having dispersed therein a release composition and thereover a host resin component comprised of toner resin particles and pigment particles, see for example the Abstract of the Disclosure and column 4, and note column 4 wherein there is illustrated as one of the components of the encapsulated toner domains comprised of styrene butadiene block polymers such as Kraton, styrene copolymers, or styrene siloxanes, which components have entrapped or dissolved therein mineral oils or silicon oils; 4,430,408 relating to developer compositions containing a fluorene modified alkyl siloxane and a surface treatment carbon black, reference the Abstract of the Disclosure for example; 4,758,491 relating to dry toner and developer compositions with a multiphase polyorgano siloxane block or graft condensation copolymer, which provides polyorgano siloxane domains of a particular size and concentration at the toner particle surfaces; and 4,820,604 directed to toner compositions comprised of resin particles, pigment particles, and a sulfur containing organo polysiloxane wax such as those of the formulas illustrated in the Abstract of the Disclosure. There are disclosed in U.S. Patent 4,307,169 microcapsular electrostatic marking particles containing a pressure fixable core, and an encapsulating substance comprised of a pressure rupturable shell, wherein the shell is formed by an interfacial polymerization. One shell prepared in accordance with the teachings of this patent is a polyamide obtained by interfacial polymerization. Furthermore, there are disclosed in U.S. Patent 4,407,922 pressure sensitive toner compositions comprised of a blend of two immiscible polymers selected from the group consisting of certain polymers as a hard component, and polyoctyldecylvinylether-co-maleic anhydride as a soft component. Interfacial polymerization processes are also selected for the preparation of the toners of this patent. Also, there are disclosed in the prior art encapsulated toner compositions containing in some instances costly pigments and dyes, reference for example the color photocapsule toners of U.S. Patents 4,399,209; 4,482,624; 4,483,912 and 4,397,483. Moreover, illustrated in U.S. Patent 4,758,506 are single component cold pressure fixable toner compositions, wherein the shell selected can be prepared by an interfacial polymerization process. Illustrated in European patent application No. 0,413,604 is an encapsulated, toner composition comprised of a core comprised of pigments or dyes, and a polysiloxane-incorporated core binder, which core is encapsulated in a shell. EP-A-463,412 falling within the teen of Art. 54(3)EPC discloses an encapsulated toner composition comprised of a core comprised of a polymer resin, color pigment, dye or mixtures thereof, a substantially colorless magnetic material, and a whitening agent; which core is encapsulated in a polymeric shell comprising conductive metal oxides. It is an object of the present invention to provide a toner composition which enables some, at least, of the above-described defficiencies of prior art toners to be overcome. The present invention provides an electrophotographic colored magnetic encapsulated toner composition as claimed in claim 1. A toner in accordance with the invention may comprise from about 3 to about 30 weight percent of shell polymer, from about 20 to about 75 weight percent of core binder, from about 1 to 20 weight percent of pigment, from about 20 to about 60 weight percent of a substantially colorless or light colored magnetic material, from about 1 to about 20 weight percent of a whitening agent, and from about 0.1 to about 20 weight percent of conductive metal oxide powder. Alternatively, in a toner in accordance with the invention, the polymer binder is present in an amount of from about 20 to about 78 weight percent of the toner, the magnetic material is present in an amount of from about 20 to about 60 weight percent, the color pigment, dye or mixtures thereof are present in an amount of from about 1 to about 20 weight percent, the whitening agent is present in an amount of from about 1 to about 20 weight percent, and the metal oxide is present in an amount of from about 0.1 to about 20 weight percent of toner. The encapsulated toners of the present invention can be prepared by a number of different methods including the known chemical microencapsulation processes involving a shell forming interfacial polycondensation and a core binder forming free radical polymerization. The aforementioned preparative process is comprised of (1) mixing or blending of a core monomer or monomers, up to 10, and preferably 5 in some embodiments, a free radical initiator or initiators, pigments, dyes or a mixture thereof, a colorless or lightly colored magnetic material, a whitener, and an oil-soluble shell precursor or precursors; (2) dispersing the resulting mixture by high shear blending into stabilized microdroplets in an aqueous medium containing suitabledispersants or suspension agents; (3) thereafter subjecting the aforementioned stabilized microdroplets to a shell forming interfacial polycondensation by adding a water-soluble shell monomer or monomers; (4) subsequently forming the core binder by heat induced free radical polymerization within the newly formed microcapsules; and (5) washing and drying the resulting encapsulated particles, and surface treating them with conductive metal oxide powder to afford the colored magnetic encapsulated toner of the present invention. The shell forming interfacial polycondensation is generally accomplished at ambient temperature, about 25°C, but elevated temperatures may also be employed depending on the nature and functionality of the shell precursors selected. The core binder forming free radical polymerization is generally effected at a temperature of from ambient temperature to about 100°C, and preferably from ambient or room temperature, about 25°C to about 90°C. In addition, more than one known initiator may be utilized to enhance the polymerization conversion, and to generate the desired molecular weight and molecular weight distribution. The surface conductivity characteristics of the toners of the present invention are primarily achieved by powder coating the toners with conductive fine powdered metal oxides or mixed oxides. Toners with conductive additives such as carbon black, graphite, and mixture thereof may not be suitable for magnetic colored toner compositions as they usually render the toners black in color, a disadvantage avoided or minimized with the toners of the present invention in embodiments thereof. The aforementioned metal oxide surface additives of the present invention may also serve to impart the desired powder flow and surface release properties to the resultant toners. Thus, in one embodiment the present invention is directed to a simple and economical process for pressure fixable colored magnetic encapsulated toner compositions by a chemical microencapsulation method involving a shell forming interfacial polycondensation and a core binder forming free radical polymerization, and wherein there are selected as the core binder precursors an addition-type monomer or monomers, and as shell polymer precursors polycondensation reagents with at least one of them being oil soluble, and at least one of them water soluble, and which precursors are capable of undergoing condensation polymerization at the microdroplet/water interface leading to shell formation. The resultant encapsulated particles are subsequently rendered conductive by application to their surfaces of a conductive metal oxide or mixed oxide powder, which application can be accomplished by known conventional dry blending and mixing techniques. Specifically, the volume resistivity of the encapsulated toners can be reduced to a level of, for example, from about 10 3 ohm-cm to about 10 8 ohm-cm by blending the toner with an effective amount of, for example, from about 1 to about 15 weight percent of conductive fine metal oxide powder, which metal oxide powder has a low specific resistivity of generally less than about 1,000 ohm-cm, and more specifically less than 100 ohm-cm. Furthermore, the metal oxide powder possesses a primary particle size of less than 0.1 µm (1,000 Angstroms), for example less than 0.015 µm (150 Angstroms). The encapsulated toners of the present invention generally have an average particle diameter of from about 5 to about 50 µm, a saturation magnetic moment of from about 25 to about 60 emu per gram, and a volume resistivity of from about 10 3 to about 10 8 ohm-cm, and preferably from about 10 4 to 10 6 ohm-cm, with the latter range of volume resistivity being particularly ideal for a number of commercial inductive single component development systems such as the Delphax printers S3000 TM , S4500 TM , and S6000 TM and the Xerox Corporation printer 4075 TM . The aforementioned conductive metal oxide powders are available, or can in one embodiment be prepared by (1) high temperature flame hydrolysis of volatile metal compounds, such as titanium tetrahalide, especially the chloride, or tin tetrahalide, especially the chloride, in a hydrogen-oxygen flame, optionally in the presence of another metal dopant such as bismuth halide, especially the chloride in effective amounts of from about 0.1 to about 50 weight percent, and more specifically from about 5 to 15 weight percent, to yield highly dispersed metal oxide or mixed oxide powder; and (2) subsequently heating the resultant metal oxide powder at a temperature of, for example, from about 400°C up to 600°C under a hydrogen atmosphere to remove the residual halides. Illustrative examples of powdered metal oxides suitable for the toners of the present invention include oxides or mixed oxides of aluminum, antimony, barium, bismuth, cadmium, chromium, indium, lithium, magnesium, molybdenum, nickel, niobium, ruthenium, tantalum, titanium, tin, vanadium, zinc, zirconium, and the like. The conductive metal oxide powders can be surface treated by the addition thereto with mixing of certain silane agents to, for example, improve their powder flow properties and to reduce their sensitivity to moisture. The silane component may be hexamethyl disilazane, bis(trimethylsilyl)acetamide, alkyltrialkoxysilane, dialkyldialkoxysilane, alkoxytrialkylsilane, or siloxysilanes. In a toner composition in accordance with the invention, the metal oxide may be tin oxide doped with bismuth/antimony, or titanium oxide doped with tantalum/antimony/indium. The dopant in the metal oxide may be present in an amount of from about 0.1 to about 20 mole percent. The present invention also provides a toner composition comprised of a core comprised of a polymer binder, colored pigment particles, a substantially colorless, or lightly colored magnetic material, and a whitening agent, which core is encapsulated in a polymeric shell containing colorless conductive components comprised of mixed oxides of tin and bismuth; mixed oxides of tin and antimony; mixed oxides of tin and tantalum; mixed oxides of tin and niobium; mixed oxides of titanium and bismuth; mixed oxides of titanium and antimony; mixed oxides of titanium and tantalum; mixed oxides of titanium and niobium. Embodiments of the present invention include a colored magnetic encapsulated toner composition comprised of a core comprised of a polymer binder, a colorless or light colored magnetic material, a color pigment, dye or mixture thereof excluding black, and a whitening agent, and which core is encapsulated in a polymeric shell containing therein or thereon a conductive metal oxide powder; a colored conductive magnetic encapsulated toner composition comprised of a core comprised of a polymer binder, a substantially colorless magnetic material, a color pigment, excluding black, and a whitening agent, and which core is encapsulated in a polymeric shell containing thereon a conductive metal oxide powder, and wherein the toner has a volume of from about 10 3 ohm-cm to about 10 8 ohm-cm; a colored magnetic encapsulated toner composition comprised of a core comprised of a polymer binder, a grayish color magnetic material, a pigment, and a whitening agent, and wherein the core is encapsulated in a polymeric shell containing a conductive metal oxide powder, and wherein the toner has a volume of from about 10 4 ohm-cm to about 10 6 ohm-cm., which metal oxide can be comprised of the oxides of aluminum, antimony, barium, bismuth, cadmium, chromium, indium, lithium, magnesium, molybdenum, nickel, niobium, ruthenium, tantalum, titanium, tin, vanadium, zinc, zirconium, mixtures thereof, and the like. Examples of core binders present in effective amounts, for example, of from about 20 to about 90 weight percent, that can be selected include, but are not limited to, known polymers such as addition polymers, such as acrylate, methacrylate, styrene polymers or copolymers thereof and the like, which binders can be obtained by in situ polymerization of addition monomers within the microcapsules after shell formation, and wherein the monomers can be selected from the group consisting preferably of methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, butyl acrylate, butyl methacrylate, pentyl acrylate, pentyl methacrylate, hexyl acrylate, hexyl methacrylate, heptyl acrylate, heptyl methacrylate, octyl acrylate, octyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, lauryl acrylate, lauryl methacrylate, stearyl acrylate, stearyl methacrylate, benzyl acrylate, benzyl methacrylate, ethoxypropyl acrylate, ethoxypropyl methacrylate, methyl butyl acrylate, methylbutyl methacrylate, ethylhexyl acrylate, ethylhexyl methacrylate, methoxybutyl acrylate, methoxybutyl methacrylate, cyanobutyl acrylate, cyanobutyl methacrylate, tolyl acrylate, tolyl methacrylate, styrene, substituted styrenes, other substantially equivalent addition monomers, and other known addition monomers, reference for example U.S. Patent 4,298,672, and mixtures thereof. In a toner composition in accordance with the invention, the pigment may be selected from the group consisting of Heliogen Blue, Pylam Oil Blue, Pylam Oil Yellow, Pigment Blue, Pigment Violet, Pigment Red, Lemon Chrome Yellow, Bon Red, NOVAperm Yellow FGL, Hostaperm Pink, 2,9-dimethyl-substituted quinacridone, Dispersed Red, Solvent Red, copper tetra(octadecyl sulfonamido) phthalocyanine, copper phthalocyanine, diarylide yellow 3,3-dichlorobenzidene acetoacetanilides, a nitrophenyl amine sulfonamide, DispersedYellow 2,5-dimethoxy-4-sulfonanilide phenylazo-4'-chloro-2,5-dimethoxy acetoacetanilide, and Permanent Yellow FGL. Various known colorants or pigments present in the core in an effective amount of, for example, from about 1 to about 20 percent by weight of toner, and preferably in an amount of from about 3 to about 10 weight percent, that can be selected include Heliogen Blue L6900, D6840, D7080, D7020, Pylam Oil Blue (already mentioned) and Pylam Oil Yellow (already mentioned), Pigment Blue 1 available from Paul Uhlich & Company Inc., Pigment Violet 1, Pigment Red 48, Lemon Chrome Yellow DCC 1026, E.D. Toluidine Red and Bon Red C available from Dominion Color Corporation Ltd., Toronto, Ontario, NOVAperm Yellow FGL (already mentioned), Hostaperm Pink E from Hoechst, Cinquasia Magenta available from E.I. DuPont de Nemours & Company, Lithol Scarlet, Hostaperm Blue, Hostaperm Red, Hostaperm Green, PV Fast Green, Cinquasia Yellow, PV Fast Blue, and the like. Generally, colored pigments or dyes that can be selected are red, blue, green, brown, cyan, magenta, or yellow pigments or dyes, and mixtures thereof. Examples of magenta materials that may be selected as pigments include, for example, 2,9-dimethyl-substituted quinacridone (already mentioned) and anthraquinone dye identified in the Color Index as CI 60710, CI Dispersed Red 15, diazo dye identified inthe Color Index as CI 26050, Cl Solvent Red 19, and the like. Illustrative examples of cyan materials that may be used as pigments include copper tetra-(octadecyl sulfonamido) phthalocyanine (already mentioned), x-copper phthalocyanine pigment listed in the Color Index as Cl 74160, Cl Pigment Blue, and Anthrathrene Blue identified in the Color Index as Cl 69810, Special Blue X-2137, and the like; while illustrative examples of yellow pigments that may be selected are diarylide yellow 3,3-dichlorobenzidene acetoacetanilides (already mentioned), a monoazo pigment identified in the Color Index as Cl 12700, Cl Solvent Yellow 16, a nitrophenyl amine sulfonamide identified in the Color Index as Foron Yellow SE/GLN, Cl Dispersed Yellow 33 2,5-dimethoxy-4-sulfonanilide phenylazo-4'-chloro-2,5-dimethoxy acetoacetanilide, and Permanent Yellow FGL(already mentioned). Examples of typical known shell polymers include polyureas, polyamides, polyesters, polyurethanes, mixtures thereof, and other similar polycondensation products, which shell polymers may have optionally incorporated within their polymer structures certain soft and flexible segments such as polyether or polymethylene moiety. The shells are generally comprised of from about 5 to about 30 weight percent of the toner, and have a thickness generally, for example, of less than about 5 microns. Other shell polymers (for example, poly carbonates), shell amounts, and thicknesses may be selected. When the shell polymer is a polyurea, the polyurea may be derived from the polycondensation of a mixture of polyisocyanate and polyether polyisocyanate with a diamine. The polyisocyanate and polyether polyisocyanate may be selected from the group consisting of benzene diisocyanate, toluene diisocyanate, diphenylmethane diisocyanate, cyclohexane diisocyanate, hexane diisocyanate, and polyether polyisocyanates. Preferably, liquid polyether polyisocyanates are selected. The oil soluble shell forming precursors present in the microdroplet phase during the microencapsulation process are preferably comprised of diisocyanates, diacyl chloride, and bischloroformate having soft and flexible moieties such as polymethylene or polyether segments within their molecular structures. Optionally, appropriate polyfunctional crosslinking agents, in effective amounts, such as, for example, from about 1 to about 25 weight percent, such as triisocyanate, triacyl chloride, and the like, can also be added to generate crosslinked shell polymers to improve their mechanical strength. Illustrative examples of the shell precursors include the polyether-based polyisocyanate such as Uniroyal Chemical's diphenylmethane diisocyanate based liquid polyether Vibrathanes, B-635, B-843, and the like, and toluene diisocyanate based liquid polyether Vibrathanes, B-604, B-614, and the like, and Mobay Chemical Corporation's liquid polyether isocyanate prepolymers, E-21 or E-21A, 743, 744, and the like, adipoyl chloride, fumaryl chloride, suberoyl chloride, succinyl chloride, phthaloyl chloride, isophthaloyl chloride, terephthaloyl chloride, ethylene glycol bischloroformate, diethylene glycol bischloroformate, triethylene glycol bischloroformate, and the like. In addition, other polyfunctional reagents can also be added as coreactants to improve shell properties such as mechanical strength and pressure sensitivity. In one embodiment of the present invention, the aforementioned co-reactants can be selected from the group consisting of benzene diisocyanate, toluene diisocyanate, diphenylmethane diisocyanate, 1,6-hexamethylene diisocyanate, bis(4-isocyanatocyclohexyl)methane, MONDUR CB-60, MONDUR CB-75, MONDUR MR, MONDUR MRS 10, PAPI 27, PAPI 135, Isonate 143L, Isonate 181, Isonate 125M, Isonate 191, and Isonate 240. The water soluble shell forming monomer component,s which can be added to the aqueous phase, include polyamine or polyol including bisphenol. Illustrative examples of the water soluble shell monomers include ethylenediamine, tetramethylenediamine, pentamethylenediamine, 2-methylpentamethylene diamine, hexamethylenediamine, p-phenylenediamine, m-phenylenediamine, 2-hydroxy trimethylenediamine, diethylenetriamine, triethylenetetraamine, tetraethylenepentaamine, 1,8-diaminooctane, xylylene diamine, bis(hexamethylene)triamine, tris(2-aminoethyl)amine, 4,4'-methylene bis(cyclohexylamine), bis(3-aminopropyl)ethylene diamine, 1,3-bis(aminomethyl)cyclohexane, 1,5-diamino-2-methylpentane, piperazine, 2-methylpiperazine, 2,5-dimethylpiperazine, 1,4-bis(3-aminopropyl)-piperazine, and 2,5-dimethylpentamethylene diamine, bisphenol A, bisphenol Z, and the like. When desired, a water soluble crosslinking component, such as triamine or triol, can also be added in effective amounts sufficient to introduce crosslinking into the shell polymer structure to improve its mechanical strength. Examples of magnetic materials which can be selected for the toner compositions of the present invention, and which are present in an effective amount of, for example, from about 20 to about 60 weight percent, include iron powder, such as those derived from the reduction of iron tetracarbonyl, and commercially available from BASF as Sicopur 4068 FF™; cobalt powder, commercially available from Noah Chemical Company; Metglas™, Metglas™ ultrafine, commercially available from Allied Company; treated iron oxides such as Bayferrox AC5106M™ commercially available from Mobay; treated iron oxide TMB-50, commercially available from Magnox; carbonyl iron Sf™, commercially available from GAF Company; Mapico Tan™, commercially available from Columbia Company; treated iron oxide MO-2230™, commercially available from Pfizer Company; nickel powder ONF 2460™, commercially available from Sherritt Gordon Canada Company; nickel powder; chromium powder; manganese ferrites; and the like; and a combination or two or more of the metal powders. The preferred average diameter particle size of the magnetic material is from about 0.1 µm to about 6 µm, although other particle sizes may also be utilized. Examples of conductive components present on the shell, and/or contained therein include powdered metal oxides and mixed oxides such as tin oxide, zinc oxide, yttrium oxide, vanadium oxide, tungsten oxide, titanium oxide, thalium oxide, tantalum oxide, silicon oxide, ruthenium oxide, rhodium oxide, platinum oxide, palladium oxide, niobium oxide, nickel oxide, molybdenum oxide, manganese oxide, magnesium oxide, lithium oxide, iridium oxide, cobalt oxide, chromium oxide, cesium oxide, calcium oxide, cadmium oxide, bismuth oxide, berylium oxide, barium oxide, antimony oxide, aluminum oxide, mixtures thereof, and the like. The conductive powders are present in various effective amounts, such as, for example, from 0.1 to about to about 20 weight percent and preferably from about 1 to about 15 weightpercent. In one specific embodiment of the present invention, the conductive powdered metal oxide is a mixed oxide comprising from about 90 to about 95 weight percent of tin oxide andfrom about 5 to about 10 weight percent of bismuth oxide or antimony oxide. These oxides assist in enabling the formation of a relatively conductive colored magnetic encapsulated toner wherein high quality images can be obtained. Additionally, the aforementioned conductive metal oxide powders can be surface treated with a silane agent, such as, for example, hexamethyl disilazene or bis(trimethylsilyl)acetamide, and the like by exposing the oxide powders to the silane vapor at elevated temperature of, for example, 200°C to 300°C to improve their powder flow characteristics. The effective amount of silane agent is, for example, from about 0.1 to about 10 weight percent, and preferably from about 0.5 to 5 weight percent. Various known whitening agents can be selected, such as an inorganic white powder selected from the group consisting of powdered aluminum oxide, barium oxide, calcium carbonate, calcium oxide, magnesium oxide, magnesium stearate, titanium oxide, tin oxide, zinc oxide, zinc stearate, and the like. The whitening agent is present in various effective amounts, for example from about 1 to about 20 weight percent. In one specific embodiment of the present invention, there is provided an improved process for the preparation of colored magnetic encapsulated toner compositions, which process comprises mixing and dispersing a core monomer or monomers, a free radical initiator, colored pigment particles, dyes, or mixtures thereof, a magnetic material, a whitener, and a shell precursor or precursors into microdroplets of a specific droplet size in an aqueous medium containing a dispersant or suspension stabilizer wherein the volume average diameter of the microdroplet can be readily adjusted to be from about 5 µm to about 30 µm, with its volume average droplet size dispersity being less than 1.4 as determined from Coulter Counter measurements of the microcapsule particles after encapsulation; forming a microcapsule shell around the microdroplet via interfacial polymerization by adding a water soluble shell monomer component; and subsequently affecting a free radical polymerization to form the core binder within the newly formed microcapsules by, for example, heating the reaction mixture from room temperature to about 90°C for a period of from about 1 to about 10 hours. Examples of known suspension stabilizers, present in effective amounts of, for example, from about 0.1 to about 15 weight percent in some embodiments selected for the process of the present invention include water soluble polymers such as poly(vinyl alcohols), methyl cellulose, hydroxypropyl cellulose, hydroxyethylmethyl cellulose and the like. Illustrative examples of known free radical initiators selected for the preparation of the toners of the present invention include azo compounds such as 2-2'-azodimethylvaleronitrile, 2-2'-azoisobutyronitrile, azobiscyclohexanenitrile, 2-methylbutyronitrile, Vazo 52, Vazo 64, commercially available, or mixtures thereof with the quantity of initiator(s) being, for example, from about 0.5 percent to about 10 percent by weight of that of the core monomer(s). Interfacial polymerization processes selected for the toner shell formation and shells thereof are as illustrated, for example, in U.S. Patents 4,000,087 and 4,307,169. After the formation of encapsulated particles, the surface additive components, such as zinc stearate and conductive metal oxide powders, can be incorporated therein, or thereon by, for example, mixing or blending using conventional known processes. Thus in embodiments of the present invention there can be added to the toner product surface by mixing, for example, additional known surface release and/or flow aid additives, such as Aerosils, such as Aerosil R972 TM , metal salts, metal salts of fatty acids, such as zinc stearate, or colloidal silicas, and the like, in effective amounts of, for example, from about 0.05 to about 3, and preferably about 1 weight percent, reference for example the United States patents mentioned herein. Examples of the aforementioned additives are illustrated in United States Patents 3,590,000; 3,720,617; 3,900,588 and 3,983,045. A toner composition in accordance with the invention may be used in an imaging method which comprises the formation of an image on an imaging member; subsequently developing the image with the toner composition, transferring the image to a suitable substrate and affixing the image thereto. The following examples are being submitted to illustrate various aspects of the present invention. EXAMPLE I The following procedure illustrates the preparation of a conductive tin oxide powder that was utilized to assist in rendering a toner composition in accordance with the present invention to a specific level of conductivity. Nitrogen gas (2.0 liters per minute) was bubbled through tin tetrachloride (100 grams) at room temperature, about 25°C, and the resulting vapor was mixed with oxygen and hydrogen both flowing at about 0.7 liter per minute with the feed oxygen and hydrogen flow rates maintained at 0.85 liter per minute. The resulting mixture with approximate molar ratios of tin tetrachloride 1, nitrogen 59, hydrogen 15, and oxygen 15, was then burned into a flame. The combustion products were allowed to agglomerate in flight for about 10 seconds in a glass tube heated to about 200°C, and then collected in a Teflon TM fabric filter by suction. The collected tin oxide product (55.0 grams) was heated in a 500-milliter rotating flask at 400°C. A stream of air and water vapor was passed into the flask for 30 minutes, followed by a stream of hydrogen gas, argon gas and water vapor for another 30 minutes. The gas flow rate was adjusted to provide more than 10 flask volume exchanges in each of these treatments. The resulting off-white tin (IV) oxide product (54.0 grams) has an average particle diameter size of about 0.009 µm (90 Angstroms) as measured by transmission electron microscopy, and a specific resistivity determined by known methods, and more specifically as indicated herein, see Example IV, of 18 ohm-cm was obtained on a pressed pellet sample. EXAMPLE II The following procedure illustrates the preparation of a conductive doped tin oxide powder: Nitrogen gas (2.0 liters per minute) was bubbled through tin tetrachloride at room temperature, and was then passed over a bed of bismuth trichloride crystals maintained at a temperature of about 160°C by electric heaters. The resulting vapor was mixed with oxygen and hydrogen both flowing at about 0.7 liter per minute. The resulting gas mixture was maintained at 160°C and burned in a flame. The molar ratios of the gas mixture were about the same as in Example I except for added traces of bismuth trichloride at about 0.3 percent molar versus tin tetrachloride. The combustion products were allowed to agglomerate in flight for about 10 seconds in a glass tube heated to about 200°C, and then collected in a Teflon TM fabric filter by suction. The collected doped tin oxide product (60.0 grams) was subsequently heated in a 500 milliter rotating flask at 400°C. A stream of air and water vapor was passed into the flask for 30 minutes, followed by a stream of hydrogen gas, argon gas and water vapor for another 30 minutes. The gas flow rate was adjusted to give more than 10 flask volume exchanges in each of these treatments. The resulting off-white doped tin (IV) oxide powder (59.0 grams) has an average primary particle size of about 0.01 µm (100 Angstroms) as measured by transmission electron microscopy, and a specific resistivity of 11 ohm-cm was obtained on a pressed pellet sample as indicated herein. EXAMPLE III The following procedure illustrates the preparation of a conductive silane-treated tin oxide powder: Tin (IV) oxide powder (50.0 grams) as prepared in Example I was placed into a rotating 500 milliliter flask heated at 300°C. Hexamethyl disilazene vapor generated by passing a stream of argon into liquid hexamethyl disilazene (16.0 grams) in another flask was passed into the flask containing tin oxide powder. The resulting off-white silane-treated tin (IV) oxide powder had an average primary particle size of about 100 Angstroms as measured by transmission electron microscopy, and a specific resistivity of 210 ohm-cm was obtained as indicated in Example I on a pressed pellet sample. EXAMPLE IV The following example illustrates the preparation of a 17.2 µm red magnetic encapsulated toner comprised of a polyether-urea shell, a core of poly(lauryl methacrylate), Lithol Scarlet pigment, iron powder, and titanium dioxide, and the conductive tin oxide powder of Example I as a shell surface additive. A mixture of lauryl methacrylate (113.0 grams, available as Rocryl 320 fromRohm and Haas), Isonate 143L (42.0 grams), Desmodur E-21 (5.7 grams), free radical initiators Vazo 52 (1.6 grams), and Vazo 64 (1.6 grams), was thoroughly mixed at 4,000 rpm using an IKA T-50 polytron with a G45/M probe for 30 seconds. To this mixture were added titanium dioxide powder (rutile form, 90.0 grams), Sicopur 4068 TM iron powder (245.0 grams) and Lithol Scarlet pigment (29.0 grams), followed by blending at 8,000 rpm for 3 to 5 minutes. Tothe resulting slurry was then added one liter of a 0.10 percent aqueous poly(vinyl alcohol) solution, and the mixture resulting was then homogenized at 9,000 rpm for 2 minutes. The resulting dispersion was transferred to a two liter kettle equipped with a mechanical stirrer. Bis(3-aminopropyl)piperazine (33.0 grams) was then added to the flask, and the resulting mixture was stirred for one hour at room temperature. Subsequently, the reaction mixture was heated in an oil bath,with the temperature of the bath being raised from ambient temperature to 90°C over a period of 45 minutes, and then held at this temperature for another 6 hours. After cooling to room temperature, the mixture was permitted to remain at room temperature to allow the encapsulated particle product to settle to the bottom of the reaction kettle. The particles were washed repeatedly with water until the aqueous phase was clear. The wet encapsulated particles were sieved through a 180 µm screen, and freeze dried to provide 350.0 grams of red encapsulated particles. A mixture of 120.0 grams of the red encapsulated particles as obtained above and 9.0 grams of the conductive tin oxide powder of Example I was dry blended in a Lightnin CBM dry blender at 3,000 rpm for 20 minutes, followed by sieving through a 63 µm screen. The resulting red encapsulated toner had a volume average particle diameter of 17.2 µm and a particle size distribution of 1.33 as determined by the Coulter Counter measurement using Coulter Counter Model ZM, available from Coulter Electronics, Inc. The volume resistivity of the toner was measured by gently filling a 1 cm 3 cell sitting on a horseshoe magnet with the above powdered toner sample. Two opposite walls of the cell are comprised of 1 centimeter x 1 centimeter conductive metal plates. The other two walls and the bottom of the cell are also 1 centimeter x 1 centimeter in dimension, butare comprised of insulating material. A voltage of 10 volts is applied across the plates, and the current flowing through the plates is measured using an electrometer. The device is standardized using a nickel standard whose saturation magnetic moment is known (55 emu/gram). The nickel sample is magnetized between two magnetic pole faces with a saturating magnetic field of 2,000 Gauss such that the induced magnetic field is perpendicular to one of the faces of the cell. The integrated current that is induced when the nickel sample is removed from the saturating magnetic field is measured. Next, the integrated current induced by a toner sample under identical conditions is also measured. The encapsulated toner saturation magnetic moment is then obtained by referencing its induced current per gram of sample to that of the nickel sample. For the toner of this example, the saturation magnetic moment was measured to be 49 emu per gram, and its volume resistivity was measured to be 8.5 x 10 6 ohm-cm. The specific resistivity of the metal oxide powders can be determined in a similar manner, or by other known methods. The above prepared toner was evaluated in a Xerox 4060 TM printer. The toned images were transfixed onto paper with a transfix pressure of 2,000 psi. Print quality was evaluated from a checkerboard print pattern. The image optical density was measured with a standard integrating densitometer. Image fix was measured by the standardized scotch tape pull method, and is expressed as a percentage of the retained image optical density after the tape test relative to the original image optical density. Image smearing was evaluated qualitatively by hand rubbing the fused checkerboard print using a blank paper under an applied force for a specific cycle time, and viewing the surface cleanliness of nonprinted and printed areas of the page. Image ghosting on paper was evaluated visually. For the above prepared toner, the image fix level was 84 percent, and no image smear and no image ghosting were observed in this machine testing for at least 2,000 prints. The toner displayed a resistance to agglomeration even when heated at 55°C for 48 hours. EXAMPLE V The following example describes the preparation of an 18.8 micron blue magnetic encapsulated toner comprised of a polyether-urea shell and a core of poly(lauryl methacrylate), Hostaperm Blue pigment, iron powder, and titanium dioxide together with the conductive tin oxide powder of Example I as a surface additive. The blue toner was prepared in accordance with the procedure of Example IV except that Hostaperm Blue pigment (Hoechst) was employed in place of Lithol Scarlet pigment. Three hundred and twenty (320.0) grams of blue encapsulated particles were obtained after freeze drying, and these particles were then dry blended in accordance with the procedure of Example IV yielding a blue encapsulated toner with a volume average particle diameter of 18.8 microns and a particle size distribution of 1.35. The toner's saturation magnetic moment was measured to be 50 emu per gram, and the toner volume resistivity was found to be 9.5 x 10 6 ohm-cm. The above prepared toner was evaluated according to the procedure of Example IV. For this toner, the image fix level was 82 percent, and no image ghosting and no image smear were observed. This toner displayed a resistance to agglomeration even when heated at 55°C for 48 hours. EXAMPLE VI A 13.2 micron blue encapsulated toner comprised of a polyether-urea shell and a core of polysiloxane-containing poly(lauryl methacrylate), iron powder, Heliogen Blue pigment, and titanium dioxide together with the conductive doped tin oxide powder of Example II as a surface additive was prepared as follows: The toner was prepared in accordance with the procedure of Example IV with the exception that a mixture of 103.0 grams of lauryl methacrylate and 10.0 grams of methacryloxypropyl terminated polydimethylsiloxane (viscosity of 1,500 to 2,500 centistokes) was employed in place of 113.0 grams of lauryl methacrylate. In addition, 25.0 grams of Heliogen blue pigment (BASF) was utilized instead of 29.0 grams of Lithol Scarlet pigment. The encapsulated particles obtained after freeze drying were dry blended with 4.2 percent by weight of the conductive doped tin oxide powder of Example II affording a blue encapsulated toner with a volume average particle diameter of 13.2 microns and a particle size distribution of 1.37. The toner's saturation magnetic moment was measured to be about 42 emu per gram, and the toner volume resistivity was found to be 8.6 x 10 5 ohm-cm. For this toner, the image fix level was 81 percent, and no image smear and no image ghosting were observed after 2,000 prints. This toner did not show any signs of agglomeration with storage for seven months. EXAMPLE VII A 14.0 micron green encapsulated toner with a polyether-urea shell, a poly(lauryl methacrylate) core binder and Sicopur 4068 TM iron powder material was prepared in accordance with the procedure of Example IV except that Hostaperm Green pigment (Hoechst) was utilized in place of Lithol Scarlet pigment. The encapsulated particles obtained after freeze drying were dry blended with 4.5 percent by weight of conductive doped tin oxide powder of Example II. The green encapsulated toner as obtained in this manner has a volume average diameter of 14.0 microns and a particle size distribution of 1.36. The toner's volume resistivity was 1.3 x 10 6 ohm-cm, and its saturation magnetic moment was measured to be 48 emu per gram. The toner was evaluated in accordance with the procedure of Example IV, and substantially similar results were obtained. EXAMPLE VIII A 15.3 micron brown encapsulated toner with a polyether-urea shell and a core of poly(lauryl methacrylate), Magnox iron oxide TMB-50 TM , Microlith brown pigment, and titanium dioxide was prepared in accordance with the procedure of Example IV except that 300 grams of Magnox iron oxide TMB-50 TM and 5.0 grams of Microlith Brown pigment was used instead of Sicopur 4068 TM iron powder and Lithol Scarlet pigment (BASF), respectively. The encapsulated particles obtained after freeze drying were dry blended with 5.5 percent by weight of the conductive silane-treated doped tin oxide powder of Example III. The toner had a volume average particle diameter of 15.3 microns and a particle size distribution of 1.34. The toner displayed a volume resistivity of 6 x 10 7 ohm-cm and a saturation magnetic moment of 45 emu per gram. For this toner, the image fix was 79 percent with no signs of image smear, image ghosting, or toner agglomeration. EXAMPLE IX A 13.8 micron blue encapsulated toner with a polyurea shell and a (lauryl methacrylate-stearyl methacrylate) copolymeric core resin was prepared as follows: A mixture of lauryl methacrylate (93.0 grams), stearyl methacrylate (20.0 grams) Isonate 143L (42.0 grams), Desmodur E-21 (5.7 grams), Vazo 52 (1.6 grams), and Vazo 64 (1.6 grams) was thoroughly mixed at 4,000 rpm using an IKA T-50 polytron with a G45/M probe for 30 seconds. To this mixture were added titanium dioxide powder (rutile form, 90 grams), Sicopur 4068 TM iron powder (245.0 grams) and Heliogen Blue pigment (25.0 grams, BASF), followed by blending at 8,000 rpm for 3 to 5 minutes. To the resulting slurry was then added one liter of a 0.10 percent aqueous poly(vinyl alcohol) solution, and the mixture was then homogenized at 9,000 rpm for 2 minutes. The dispersion was transferred to a two liter reactionkettle, and into this mixture was added bis(3-aminopropyl)piperazine (33.0 grams). The resulting mixture was stirred at room temperature for 1 hour. Subsequently, the reaction mixture was heated in an oil bath with the temperature of the bath being raised from ambient temperature to 90°C over a period of 45 minutes, and then held at this temperature for another 6 hours. After cooling to room temperature, the mixture was permitted to remain at room temperature to allow the encapsulated particle product to settle to the bottom of the reaction kettle. The particles were washed repeatedly with water until the aqueous phase was clear. The wet encapsulated particles were sieved through a 180 micron screen, and freeze dried to provide 365.0 grams of blue encapsulated toner particles. The aforementioned blue encapsulated particles were dry blended with 5.5 percent by weight of the conductive silane-treated doped tin oxide powder of Example III. The resulting toner displayed a volume average particle diameter of 13.8 microns and a particle size distribution of 1.33. This toner exhibited a saturation magnetic moment of 43 emu per gram, and a volume resistivity of 2.0 x 10 7 ohm-cm. The toner was machine tested in a Delphax S6000 TM printer, and substantially similar results were obtained as reported in Example IV. EXAMPLE X A 14.6 micron red encapsulated toner comprised of a polyether-urea shell, a core of poly(lauryl methacrylate), Lithol Scarlet pigment, iron powder, and titanium dioxide was prepared in accordance with the procedure of Example IV. The encapsulated particles obtained after freeze drying were dry blended with 5.5 percent by weight of the conductive silane-treated doped tin oxide of Example III. The red encapsulated toner product has a volumeaverage particle diameter of 14.6 microns and a particle size distribution of 1.34. Its volume resistivity was found to be 8.8 x 10 6 ohm-cm and its saturation magnetic moment was 44 emu per gram. The toner was evaluated in a Delphax S6000™ printer, and substantially similar results were obtained as reported in Example IV. Toner compositions in accordance with the present invention and as described above can, for example, be selected for single component development, and more specifically for a number of inductive single component development processes. The toner compositions generally possess a volume resistivity of from about 10 3 to about 10 8 ohm-cm, and preferably a volume resistivity of about 10 4 to about 10 6 ohm-cm. This level of toner conductivity is particularly suited for use in a number of inductive single component development systems. The presence in the shell polymer of a flexible structural moiety such as a polyether or polymethylene segment can improve its packing, and thus enhance resistance to core component diffusion or leaching through the toner shell structure. Examples of advantages associated with toner compositions in accordance withthe present invention and as described above include brilliant image color, and widecolor variety; relatively high surface conductivity and thus suitability for use in many inductive single component development systems; cold pressure fixability; high image fix; nonagglomerating and excellent shelf-life stability of, for example, up to 2 years in some instances; and suitability for use in highlight color reprographic processes, especially xerographic and ionographic imaging and printing processes. Additionally, the use of the aforementioned conductive powders can also enhance the toner powder flow characteristics, thus eliminating, if desired, the utilization of other additives such as Aersoils, and zinc stearate for surface release and flow properties. Another advantage of the conductive oxide powder is related to its ability to reduce the toner's sensitivity to humidity. Toner compositions in accordance with the present invention can be selected for a variety of known reprographic imaging processes including electrophotographic and ionographic processes. In one example, the encapsulated toner compositions can be selected for pressure fixing processes wherein the image is fixed with pressure. Pressure fixing is common in ionographic processes in which latent images are generated on a dielectric receiver such as silicon carbide, reference United States Patent 4,885,220. The latent images can then be toned with a conductive encapsulated toner of the present invention by inductive single component development, and transferred and fixed simultaneously (transfix) in one single step onto paper with pressure. Specifically, the toner compositions of the present invention can be selected for the commercial Delphax printers, such as the Delphax S9000™, S6000™, S4500™, S3000™, and Xerox Corporation printers such as the 4060™ and 4075™ wherein, for example, transfixing is utilized. In another example, the toner compositions can be utilized in xerographic imaging apparatuses wherein image toning and transfer are accomplished electrostatically, and transferred images are fixed in a separate step by means of a pressure roll with or without the assistance of thermal or photochemical energy fusing. In toner compositions in accordance with the present invention, narrow size dispersity toner particles can be more easily and economically obtained than in many prior art compositions. With encapsulated toners in accordance with the present invention, control of the toner surface conductivity, and toners with excellent color quality can be achieved. Also, with the encapsulated toners in accordance with the present invention, undesirable leaching or loss of core components can be minimized or avoided, and image ghosting can be eliminated, in many instances, primarily because of the utilization of an impermeable polymeric shell in some embodiments. Image ghosting, which is one of the known common phenomena in transfix ionographic printing processes, refers to, for example, the contamination of dielectric receiver by residual toner materials which cannot be readily removed in the cleaning process. The result is the retention of latent images on the dielectric receiver surface after cleaning, and the subsequent unwarranted development of these images. One of the common causes of image ghosting is related to the leaching of the sticky core binder out to the toner's surface leading to their adherence to the dielectric receiver during the image development process. Toner compositions in accordance with the invention provide high quality images with acceptable fixing levels of, for example, over 80 percent at low fixing pressure of, for example, 2,000 psi. Through the use of the invention, there can be provided colored magnetic encapsulated toners with excellent powder flow and surface release properties enabling their selection for use in imaging systems without the use of surface release fluids such as silicone oils to prevent image offsetting to the fixing or fuser roll. There can also be provided, for the toners, conductive surface additives which are capable of imparting desirable levels of surface conductivity to colored toners without adversely affecting their image color quality. There is also provided, for the toners, conductive powdered metal oxides and mixed oxides, such as, for example, tin oxides, which have primary particle sizes of less than 0.1 µm (1,000 Angstroms), and specific resistivities of less than 1,000 ohm-cm, and which powders are useful as surface conductivity control and release agents for colored magnetic toner compositions which are suitable for inductive single component development. The toners can be formed by simple and economic processes, for example a chemical microencapsulation process which involves a shell forming interfacial polycondensation and a core binder forming free radical polymerization, and wherein flammable organic solvents are not employed in their preparation in some embodiments. Moreover, there is provision for enhanced flexibility in the design and selection of the shell and core materials for pressure fixable colored magnetic encapsulated toners and/or for flexibility in controlling the toner physical properties such as the bulk density, particle size, and size dispersity.

Claims: An electrophotographic colored magnetic encapsulated toner composition comprised of a core comprised of a polymer binder, a colorless or light colored magnetic material, a color pigment, dye or mixture thereof excluding black, and a whitening agent; and which core is encapsulated in a polymeric shell containing a conductive powder comprising an oxide selected from the group consisting of metal oxides, silicon oxide, germanium oxide and any mixtures thereof, said powder having an average diameter primary particle size of less than 0.1 micrometers (1000 Angstrom). A toner composition in accordance with claim 1, wherein the encapsulated toner composition is conductive; and wherein the toner volume resistivity is, more particularly, 10 4 ohm-cm to 10 6 ohm-cm. A toner composition in accordance with claim 1 or claim 2, wherein the metal oxide is comprised of an oxide of aluminum, antimony, barium, bismuth, cadmium, chromium, indium, lithium, magnesium, molybdenum, nickel, niobium, ruthenium, tantalum, titanium, tin, vanadium, zinc, or zirconium, and mixtures thereof. A toner composition in accordance with claim 1 or claim 2, wherein the metal oxide is comprised of a mixture of metal oxides wherein the metal is selected from the group consisting of aluminum, antimony, barium, bismuth, cadmium, chromium, indium, lithium, magnesium, molybdenum, nickel, niobium, ruthenium, tantalum, titanium, tin, vanadium, zinc, or zirconium; and wherein one of the metals is present in an amount of from about about 0.01 to about 50 mole percent. A toner composition in accordance with any one of the preceding claims, wherein the metal oxide is present in an amount of from about 0.1 weight percent to about 20 weight percent. A toner composition in accordance with claim 1 or claim 2, wherein the metal oxide is tin oxide, tin oxide doped with bismuth, tin oxide doped with antimony, titanium oxide, titanium oxide doped with tantalum, titanium oxide doped with antimony, or titanium oxide doped with indium. A toner composition in accordance with any one of the preceding claims, wherein the metal oxide particles have been surface treated with a silane component. A toner composition in accordance with claim 1 or claim 2, wherein the metal oxide is comprised of from about 80 to about 95 weight percent of tin oxide or titanium oxide and from about 5 to about 20 weight percent of bismuth or antimony.

Inventors: LEVY MICHAEL J, LEWIS RICHARD B, ONG BENG S, SACRIPANTE GUERINO, LEVY, MICHAEL J., LEWIS, RICHARD B., ONG, BENG S., SACRIPANTE, GUERINO
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1991
Main classification: G03G9
IPC codes: G03G9