Toner compositions, developer comprising the same and process for preparation

Abstract: A toner comprised of binder, colorant, and a silica containing a coating of an alkylsilane.

Description: The present invention is generally directed to toner and developer compositions, and more specifically, the present invention is directed to positively, or negatively charged toner compositions, or toner particles containing certain silica surface additives, and more specifically, silicas coated with an alkylsilane inclusive of polyalkylsilanes such as decylsilane, and which coated silicas are available from Cabot Corporation. With the toners of the present invention, in embodiments thereof a number of advantages are achievable, such as excellent triboelectric charging characteristics, substantial insensitivity to humidity, especially humidities of from 20 to 80 percent, superior toner flow through, stable triboelectric charging values, such as from 10 to 55 microcoulombs per gram as determined for example, by the known Faraday cage, and wherein the toners enable the generation of developed images with superior resolution, and excellent color intensity. The aforementioned toner compositions can contain colorants, such as dyes, pigments comprised of, for example, carbon black, magnetites, or mixtures thereof, cyan, magenta, yellow, blue, green, red, or brown components, or mixtures thereof, thereby providing for the development and generation of black and/or colored images, and enabling two component development and single component development wherein carrier or carrier particles are avoided. The toner and developer compositions of the present invention can be selected for electrophotographic, especially xerographic, imaging and printing processes, including color and digital processes. Toner compositions with certain surface additives, including certain silicas, are known. Also known are toners containing a mixture of hexamethyldisilazane (HMDZ) and aminopropyltriethoxysilane (APTES). Disadvantages associated with these toners may include in certain instances a low, relatively unstable triboelectic charge, and high relative humidity sensitivity, and disadvantages of toners containing as surface additives HMDZ include, for example, unstable tribo, relative humidity sensitivity, and low charge/wrong sign toner as measured by a charge spectrograph. EP-A-0 592 018 discloses a developer for developing an electrostatic image, said developer containing a toner and a hydrophobic inorganic fine powder such as silica treated with a silicone oil or a silicone varnish. This publication discloses that the surface of the silica may be treated with a silane coupling agent in advance. Examples of suitable silane coupling agents comprise hexamethyldisilazane and alkylsilanes. The examples of EP-A-0 592 018 disclose silica particles treated with hexamethyldisilazane or hexamethyldisilazane/silicone oil. US-A-5 714 299 discloses a method of treating the surface of a metal oxide such as silica, said method comprising the step of contacting the surface of said metal oxide with an alkylsilane in liquid carbon dioxide. The surface-treated metal oxide may be used as an additive in a toner composition comprising a resin binder and a pigment. JP-A-10-020558 discloses a developer composition comprising color particles and fine particles, wherein the color particles have a specific surface area and polar groups on the surface. The fine particles are characterized by a low content of water. EP-A-0 395 061 discloses a method of developing an electrostatic image. US-A-4 585 723 discloses a developer composition comprising a binder, colored particles and a silica powder, said silica powder having been rendered hydrophobic by treating with an organosilicon compound such as an alkylsilane. JP-A-06-019190 discloses a toner composition comprising a resin binder and a fine silica powder having an alkylsilane-based coating. The present invention provides a toner comprised of binder, colorant, and a silica containing a coating of an alkylsilane, wherein said alkylsilane is an alkylsilane polymer present in an amount of from to 10 weight percent based on the amount of silica, and wherein said coated silica possesses a primary particle size of from 25 to 55 nanometers, and an aggregate size of from 225 to 400 nanometers. The present invention further provides a developer comprised of the above toner and a carrier. Moreover, the present invention is directed to a process for the preparation of toner comprising the mixing of resin, colorant, and silica containing a coating of an alkylsilane, wherein said alkylsilane is an alkylsilane polymer present in an amount of from 3 to 10 weight percent based on the amount of silica, and wherein sai coated silica possesses a primary particle size of from 25 to 55 nanometers, and an aggregate size of from 225 to 400 nanometers. Preferred embodiments of the invention are set forth in the sub-claims. It is a feature of the present invention to provide toner and developer compositions with certain surface additives, such as a coated alkylsilane and wherein the toners possess a number of advantages, as indicated herein. Additionally, in another feature of the present invention there are provided negatively charged toner compositions useful for the development of electrostatic latent images including color images. A further feature of the present invention is to provide certain surface additives that enable toners with fast admix as measured by a charge spectrograph. In yet another feature of the present invention there are provided certain surface additives that enable unimodal toner charge distribution as measured by a charge spectrograph. Also, in another feature of the present invention there are provided certain surface additives that enable substantially no wrong sign positive charged toner and very little low or minimum charged negative toner as measured by a charge spectrograph. Another feature of the present invention resides in the provision of toner and developer compositions with a certain surface additive that enable acceptable high stable triboelectric charging characteristics of from 15 to 55 microcoulombs per gram, and preferably from 25 to 40 microcoulombs per gram. Other features of the present invention include the provision of toner and developer compositions with surface additives and wherein there is enabled toners with humidity insensitivity, from, for example, 20 to 80 percent relative humidity at temperatures of from 15.5 to 26.6°C (60 to 80°F) as determined in a relative humidity testing chamber; negatively charged toner compositions with desirable admix properties of 1 second to 60 seconds as determined by the charge spectrograph, and more preferably less than 30 seconds; toner compositions that fuse at low temperatures, for example, below 176.6°C (350°F) resulting in high quality black and or color images; and the development of images in electrophotographic imaging apparatuses, which images have substantially no background deposits thereon, are substantially smudge proof or smudge resistant, and therefore are of excellent resolution, and further, wherein such toner compositions can be selected for high speed electrophotographic apparatuses, that is those exceeding 60 copies per minute. Aspects of the present invention are a toner comprised of binder, colorant, and a silica containing a coating of an alkylsilane, wherein said alkylsilane is a polyalkylsilane present in an amount of from 3 to 10 weight percent, preferably from 4 to 10 weight and more preferably from 6 to 8 weight percent, wherein the coated silica possesses a primary particle size of from 25 to 55 nanometers, and an aggregate size of from 225 to 400 nanometers; wherein the alkyl of the silane contains from 1 to 25 carbon atoms; wherein the alkylsilane is a decylsilane polymer; wherein the amount of the alkylsilane on the toner surface is determined from the feed rate or feed amount of an alkylalkoxysilane which amount is from 5 to 25 weight percent; wherein the alkylalkoxysilane feed amount is from 5 to 15 weight percent; wherein the toner further includes metal salts of fatty acids such as zinc stearate; wherein the toner further includes a wax; wherein the toner resin is polyester; wherein the toner resin is a polyester formed by condensation of propoxylated bisphenol A and fumaric acid; wherein the toner resin is comprised of a mixture of a polyester formed by condensation of propoxylated bisphenol A and a dicarboxylic acid, and a gelled polyester formed by condensation of propoxylated bisphenol A and fumaric acid; wherein the colorant particles are carbon black, cyan, magenta, yellow, red, orange, green, or violet; wherein the silica is coated with an alkylsilane wherein the alkyl chain length is for example from 4 to 18, and wherein alkyl is butyl, hexyl, octyl, decyl, dodecyl, or stearyl and alkoxy contains from 1 to 10 carbons; wherein the toner further contains a titanium oxide optionally coated with an alkylsilane inclusive of an alkylsilane polymer; wherein the silica is coated with an input feed mixture containing 10 to 25, and preferably about 15 weight percent of an alkylalkoxysilane like decyltrialkoxysilane; wherein the silica has a primary particle size of 30 nanometers to 40 nanometers; wherein the silica has an aggregate size of 300 nanometers to 375 nanometers; wherein the titania or titanium dioxide has a primary particle size of 25 nanometers to 55 nanometers; wherein the coated silica is present in an amount of from 1 weight percent to 6 weight percent; wherein the coated silica is present in an amount of from 2.75 weight percent to 4.75 weight percent; wherein the titania is present in an amount from 1 weight percent to 4.5 weight percent, or is present in an amount from 1.5 weight percent to 3.5 weight percent; wherein the metal salt is zinc stearate and is present in an amount from 0.10 weight percent to 0.60 weight percent; wherein the toner possesses a triboelectric charge of from 15 to 55 microcoulombs per gram, or from 25 to 40 microcoulombs per gram; wherein the toner resin is present in an amount of from 85 weight percent to 99 weight percent and the colorant is present in an amount from 15 weight percent to 1 weight percent; wherein the toner possesses an admix time of less than 30 seconds, or an admix time of from 1 second to 60 seconds; a developer comprised of said toner and carrier; a toner with an unimodal charge distribution as measured by a charge spectrograph; a toner with an unimodal charge distribution and none or very little low charge or wrong sign toner as measured by a charge spectrograph; and a toner composition comprised of a binder, such as resin particles like a polyester resin, colorant, and surface additives comprised of a mixture of metal oxides, like titanium oxides, and certain conductivity aides such as metal salts of fatty acids, like zinc stearate, and optional additives such as charge additives, and a surface additive comprised of silica coated with a polyalkylsilane; and a toner wherein the alkylsilane is of the formula wherein a represents the repeating segment of optionally enabling a crosslinked formula or structure; said repeat segment and hydroxy or hydroxy groups; said repeat segment and alkoxy or alkoxy groups; or said repeat segment and hydroxy and alkoxy groups; b is alkyl with, for example, from 1 to 25, and more specifically, from 5 to 18 carbon atoms; and x is a number of from 1 to 1,000, and more specifically, from 25 to 500. The coated silica possess a primary particle size of from 25 nanometers to 55 nanometers as measured by BET, named for Brunauer, Emmett, and Teller, and which BET is a standard known technical method that measures surface area. The alkylsilane coating can be generated from an alkylalkoxysilane as illustrated herein, and more specifically from a reaction mixture of a silica like silicon dioxide core and an alkylalkoxysilane, such as decyltrimethoxysilane. There results from the reaction mixture the alkylsilane coating contained on the silica core, and which coating is preferably a crosslinked polymer which includes the alkylsilane, like decylsilane, residual alkoxy groups, and/or hydroxy groups. Preferably in embodiments the alkylsilane coating is a polymeric coating that contains crosslinking and which coating may, it is believed, be represented by the formula wherein a represents a repeat segment, that is a is, for example, and which a can be repeated a number of times, and thereby optionally enables a crosslinked formula or structure; a repeat segment and hydroxy or hydroxy groups; a repeat segment and alkoxy or alkoxy groups; a repeat segment and hydroxy and alkoxy groups; b is alkyl with, for example, from 1 to 25, and more specifically, from 5 to 18 carbon atoms; and x is a suitable number of, for example, from 1 to 1,000, and more specifically, from 25 to 500. The titanium dioxide surface additive is of a similar formula or structure illustrated with regard to the alkylsilane except that the Si is replaced with Ti. Based on the weight of silica, the amount of silane, such as decyltrimethoxysilane, used to coat the silica is determined or calculated from, for example, the feed rate of the alkoxysilane, which feed rate is, for example, from 5 weight percent to 25 weight percent. For example, 100 grams of silica can be mixed and reacted with from 5 grams to 25 grams (5 weight percent to 25 weight percent) of decyltrimethoxysilane. The silica is reacted by heating with the decyltrimethoxysilane in a suitable manner to form a coating having a coating weight of from 3 to 10 weight percent based on the amount of silica on the silica surface. These coated silica particles can then be blended on the toner surface in an amount of for example from 0.50 weight percent to 10 weight percent, and preferably from 4 percent to 6 weight percent. The toner may also include further optional surface additives such as certain uncoated or coated titania or titanium dioxide particles present in an amount, for example, of from 0.50 weight percent to 10 weight percent, and preferably from 1.5 to 4 weight percent of titania which can be coated with an alkylsilane such as a decylsilane. Based on the weight of titania, the amount of decyltrimethoxysilane used to coat the titania is from 5 weight percent to 15 weight percent. For example, 100 grams of titanium dioxide can be mixed with from 5 grams to 15 grams (5 weight percent to 15 weight percent) of decyltrimethoxysilane, or similar suitable silane. In addition, the toner may also include additional surface additives such as a conductivity aide like zinc stearate in an amount of, for example, from 0.05 weight percent to 0.60 weight percent. The toner compositions of the present invention can be prepared by admixing and heating resin particles such as styrene polymers, polyesters, and similar thermoplastic resins, colorant, optional wax, especially low molecular weight waxes, with an M w of, for example, from 1,000 to 20,000, and optional charge enhancing additives, or mixtures of charge additives in a toner extrusion device, such as the ZSK53 available from Werner Pfleiderer, and removing the formed toner composition from the device. Subsequent to cooling, the toner composition is subjected to grinding utilizing, for example, a Sturtevant micronizer for the purpose of achieving toner particles with a volume median diameter of for example less than 25 µm (microns), and preferably of from 8 to 12 µm (microns), which diameters are determined by a Coulter Counter. Subsequently toner compositions can be classified utilizing, for example, a Donaldson Model B classifier for the purpose of removing fines, that is toner particles less than 4 µm (microns) volume median diameter. Thereafter, the coated alkylsilane silica and other additives can be added by the blending thereof with the toner obtained. Illustrative examples of suitable binders, include toner resins, especially thermoplastic resins, like styrene methacrylate, polyolefins, styrene acrylates, such as PSB-2700 obtained from Hercules-Sanyo Inc., polyesters, styrene butadienes, crosslinked styrene polymers, epoxies, polyurethanes, vinyl resins. Vinyl monomers include styrene, p-chlorostyrene, unsaturated mono-olefins such as ethylene, propylene, butylene, isobutylene and the like; vinyl esters like esters of monocarboxylic acids including methyl acrylate, ethyl acrylate, n-butylacrylate, isobutyl acrylate, dodecyl acrylate, n-octyl acrylate, phenyl acrylate, methyl methacrylate, ethyl methacrylate, and butyl methacrylate; acrylonitrile, methacrylonitrile, acrylamide; mixtures thereof; and the like, styrene butadiene copolymers with a styrene content of from 70 to 95 weight percent. In addition, crosslinked resins, including polymers, copolymers, and homopolymers of styrene polymers, may be selected. As one toner resin, there can be selected the esterification products of a dicarboxylic acid and a diol comprising a diphenol. These resins are illustrated in U.S. Patent 3,590,000. Other specific toner resins include styrene/methacrylate copolymers, and styrene/butadiene copolymers; Pliolites; suspension polymerized styrene butadienes, reference U.S. Patent 4,558,108; polyester resins obtained from the reaction of bisphenol A and propylene oxide; followed by the reaction of the resulting product with fumaric acid, and branched polyester resins resulting from the reaction of dimethylterephthalate, 1,3-butanediol, 1,2-propanediol, and pentaerythritol; reactive extruded resins, especially reactive extruded polyesters with crosslinking as illustrated in U. S. Patent, 5,352,556, styrene acrylates, and mixtures thereof. Also, waxes with a molecular weight M w of from 1,000 to 20,000, such as polyethylene, polypropylene, and paraffin waxes, can be included in, or on the toner compositions as fuser roll release agents. The resin is present in a sufficient, but effective amount, for example from 50 to 95 or from 70 to 90 weight percent. Colorant includes pigment, dyes, mixtures thereof, mixtures of dyes, mixtures of pigments and the like. Examples of colorants present in suitable amounts such as from 1 to 20 and preferably from 2 to 10 weight percent, are carbon black like REGAL 330®; magnetites, such as Mobay magnetites MO8029™, MO8060™ Columbian magnetites; MAPICO BLACKS™ and surface treated magnetites; Pfizer magnetites CB4799™, CB5300™, CB5600™, MCX6369™; Bayer magnetites, BAYFERROX 8600™, 8610™; Northern Pigments magnetites, NP-604™, NP-608™; Magnox magnetites TMB-100™, or TMB-104™; and the like. As colored pigments, there can be selected cyan, magenta, yellow, red, green, brown, blue or mixtures thereof. Magnetites selected include a mixture of iron oxides (FeO·Fe 2 O 3 ), including those commercially available as MAPICO BLACK™, and are present in the toner composition in various effective amounts, such as an amount of from 10 percent by weight to 75 percent by weight, and preferably in an amount of from 30 percent by weight to 55 percent by weight. There can be included in the toner compositions of the present invention charge additives as indicated herein in various effective amounts, such as from 1 to 15, and preferably from 1 to 3 weight percent, and waxes, such as polypropylenes and polyethylenes commercially available from Allied Chemical and Petrolite Corporation, Epolene N-15 commercially available from Eastman Chemical Products, Inc., Viscol 550-P, a low weight average molecular weight polypropylene available from Sanyo Kasei K.K., and the like. The commercially available polyethylenes selected possess, for example, a molecular weight of from 1,000 to 1,500, while the commercially available polypropylenes utilized are believed to have a molecular weight of from 4,000 to 7,000. Many of the polyethylene and polypropylene compositions useful in the present invention are illustrated in British Patent No. 1,442,835. The wax is present in the toner composition of the present invention in various amounts, however, generally these waxes are present in the toner composition in an amount of from 1 percent by weight to 15 percent by weight, and preferably in an amount of from 2 percent by weight to 10 percent by weight. The toners of the present invention may also in embodiments thereof contain polymeric alcohols, such as UNILINS®, reference U.S. Patent 4,883,736, and which UNILINS® are available from Petrolite Corporation. Developer compositions can be prepared by mixing the toners with known carrier particles, including coated carriers, such as steel, ferrites, and the like, reference U.S. Patents 4,937,166 and 4,935,326, and for example from 2 percent toner concentration to 8 percent toner concentration. The carriers can include coatings thereon, such as those illustrated in the 4,937,166 and 4,935,326 patents, and other known coatings. There can be selected a single coating polymer, or a mixture of polymers. Additionally, the polymer coating, or coatings may contain conductive components therein, such as carbon black in an amount for example, of from 10 to 70 weight percent, and preferably from 20 to 50 weight percent. Specific examples of coatings are fluorocarbon polymers, acrylate polymers, methacrylate polymers, silicone polymers, and the like. Imaging methods are also envisioned with the toners of the present invention, reference for example a number of the patents mentioned herein, and U.S. Patents 4,585,884, 4,584,253, 4,563,408, and 4,265,990. PREPARATION EXAMPLE I Preparation of Coated Silica 200 Milliliters of dry n-propanol solvent were placed in a three neck 500 milliliter round bottom flask. The solvent was sparged or purged with dry nitrogen to remove excess oxygen. One 10 milliliters aliquot of solvent were removed to a small 2 dram vial and set aside. A second 20 milliliters aliquot were also removed and placed in a scintillation vial. 15 Grams of untreated hydrophilic SiO 2 silica TL90 available from Cab-O-Sil Corp. with a primary size of 30 nanometers as measured by BET and an aggregate size of about 300 nanometers as measured by Brownian Motion were added to the flask and mixed with a mechanical mixer until wetted. An inert atmosphere was maintained during this mixing. A few drops of diethylamine were added to the 10 milliliters aliquot of solvent and the resulting mixture was added to the 500 milliliters flask. The mixture was then stirred for approximately 1 hour. To the 20 milliliters of solvent in the scintillation vial were added 2.25 grams of decyltrimethoxysilane. This was added to the 500 milliliters flask containing the SiO 2 after the 1 hour of pretreatment was completed. A heating mantle was attached, and the mixture was heated to reflux with stirring and under an inert atmosphere. Heat was applied for approximately 5 hours and then was turned off and the mixture was allowed to cool down to room temperature, about 25°C, throughout. The resulting mixture was then transferred to a tear shaped flask and the flask was then attached to a rotovapor evaporator and the solvent stripped off with heat and vacuum. The flask was transferred to a vacuum oven and drying was completed over night, about 18 hours throughout under full vacuum and a moderate temperature of 40°C. The resulting decylsilane polymer coated silica was crushed with a mortar and pestle, and had a primary particle size of 30 nanometers as measured by BET and an aggregate size of about 300 nanometers as measured by Brownian Motion. PREPARATION EXAMPLE II Preparation of Coated Silica Thirty (30) grams of an untreated hydrophilic SiO 2 silica powder with a primary particle size of about 40 nanometers and an aggregate size of about 300 nanometers were placed in a Buechi 2 liter autoclave reactor, and the reactor was sealed. An inert gas, argon, was then purged for 30 minutes through the reactor to remove atmospheric gases. The reactor was then evacuated of atmospheric gases using a vacuum pump and warmed to 28°C, the vacuum valve was then closed and an ampoule of triethylamine was connected to the reactor such that the vapor space of the ampoule and the upper portion of the reactor were connected, thereby allowing the vapor phase transport of triethylamine to the bed of silica for 15 minutes. The valve from the ampoule to the reactor was then closed and the valve to the vacuum reopened to remove the triethylamine that was not physisorbed to the surface of silica. The reactor was then cooled to 0°C with the aide of a Laude circulating bath connected to the reactor jacket. After achieving a temperature of 0°C, 570 grams of carbon dioxide (bone-dry grade obtained from Praxair) were then added to the chilled reactor with the assistance of an ISCO Model 260D motorized syringe pump. Agitation of the reactor was then initiated at 10 rpm. 4.5 Grams of decyltrimethoxysilane from Shin-Etsu Silicones were then dissolved in a separate variable volume pressure cell using carbon dioxide as the solvent. The pressure in the cell was 10 6 Pa (100 bar) which is sufficient to generate a homogeneous solution of silane in carbon dioxide. The decyltrimethoxysilane solution was then injected into the Buechi 2 liter reactor. The temperature of the reactor was maintained at 0°C and agitated at 100 rpm for 30 minutes, and the agitation was then stopped, and the carbon dioxide was vented off from the upper portion of the reactor, the vapor space. Subsequent to the aforementioned depressurization, the reactor temperature was increased to 28 to 30°C. After equilibration at this temperature, the resulting decylsilane polymer coated silica product was removed for overnight vacuum treatment (about 18 hours) and then spectroscopically characterized via infrared spectroscopy. PREPARATION EXAMPLE III A toner resin was prepared by the polycondensation reaction of bisphenol A and fumaric acid to form a linear polyester referred to as Resapol HT. A second polyester was prepared by selecting Resapol HT and adding it to an extruder with a sufficient amount of benzoyl peroxide to form a crosslinked polyester with a high gel concentration of about 30 weight percent gel, reference U.S. Patents 5,376,494; 5,395,723; 5,401,602; 5,352,556, and 5,227,460, and more specifically, the polyester of the '494 patent. PREPARATION EXAMPLE IV 75 Parts by weight of the resin Resapol HT from Example III, 14 parts by weight of the 30 weight percent gel polyester from Example III, and 11.0 parts by weight of Sun Blue Flush, which is a mixture of 30 weight percent P.B.15:3 copper phthalocyanine and 70 weight percent Resapol HT prepared at Sun Chemicals by flushing to obtain a high quality pigment dispersion, were blended together and extruded in a ZSK-40 extruder. The extruded blend was jetted and classified to form a cyan toner with about 8 weight percent of 15:3 copper phthalocyanine with a toner particle size of about 6.5 microns as measured by a Layson Cell. The final cyan toner had a gel concentration of 5 weight percent. COMPARATIVE EXAMPLE V A thirty (30) gram sample of the toner from Example IV was added to a 9 ounce jar with 150 grams of stainless steel beads. To this was added 0.6 weight percent TS530 (15 nanometers of primary particle size fumed silica coated with hexamethyldisilazane and which coated silica is available from Cab-O-Sil Division of Cabot Corp.), 0.9 weight percent TD3103 (15 nanometers of primary particle size titanium dioxide coated with decylsilane generated from decyltrimethoxysilane obtained from Tayca Corp.), and 0.3 weight percent zinc stearate L obtained from Synthetic Products Company. After mixing on a roll mill for 30 minutes, the steel beads were removed from the jar. A developer was prepared by mixing 4 parts of the above prepared blended toner with 100 parts of a carrier of a Hoeganaes steel core coated with 80 weight percent of polymethylmethacrylate and 20 weight percent of a conductive carbon black. Testing of this developer in, for example, a Xerox Corporation 5090 breadboard resulted in poor image quality due primarily to a loss in developability of the toner caused by, for example, the coated silica, the small size 15 nanometers TS530 silica and/or small size 15 nanometers of TD3103 titanium dioxide. COMPARATIVE EXAMPLE VI A toner blend was prepared as in Example V except 4.2 weight percent RX50 (40 nanometers of primary particle size and about 300 nanometers of aggregate size fumed silica coated with hexamethyldisilazane from Nippon Aerosil Corp.), 2.5 weight percent SMT5103 (30 nanometers of primary particle size titanium dioxide coated with decylsilane from Tayca Corp.), and 0.3 weight percent zinc stearate L from Synthetic Products Company were blended onto the toner surface. After mixing on a roll mill for 30 minutes, the steel beads are removed from the jar. A developer was then prepared by mixing 4 parts of the blended toner with 100 parts of a carrier of Hoeganaes steel core coated with polymethylmethacrylate and 20 weight percent of a conductive carbon black. A 90 minute paint shake time track was completed for this developer resulting in a toner tribo of -39.2 microcoulombs/gram after 15 minutes and dropping to -18.8 microcoulombs/gram after 90 minutes. This resulted in a degradation of toner charge of greater than 50 percent over 90 minutes of total paint shaking time, and thus this toner exhibited a significant instability, that is a decrease, in triboelectric charge. COMPARATIVE EXAMPLE VII The developer in Comparative Example VI was further evaluated for admix properties. This was accomplished at the end of the 90 minutes of paint shaking resulting in a unimodal charge distribution. By 15 seconds, the incumbent toner had moved toward zero charge with some wrong sign toner. The admix was completed in two minutes, and the amount of low charge (<0.2 fc/u) femtocoulombs per micron and wrong sign positively charged toner had increased to, for example, about 5 percent. Upon breadboard machine testing in a fixture similar to the Xerox 5090, freshly blended toner from above, low quality images resulted after about 2,000 thousand copies were made. The poor images were caused by the low charge (<0.2 fc/u) and wrong sign oppositely charged toner that occured in the machine developer housing, which was simulated by the paint shake time track/admix. The low and/or less than zero q/d (toner tribo charge divided by toner diameter in microns) charge toner resulted in dirt and background on the image. EXAMPLE VIII A toner blend was generated as in Example VI except the RX50 was replaced with 3.2 weight percent of a 30 nanometer primary particle size and about 300 nanometer aggregate size silica core (L90) coated with a feed of 15 weight percent decyltrimethoxysilane and available from Cab-O-Sil division of Cabot Corp. A developer was then prepared by mixing 4 parts of the above blended toner with 100 parts of a carrier of Hoeganaes steel core coated with 80 weight percent polymethylmethacrylate and 20 weight percent of a Vulcan conductive carbon black. A 90 minute paint shake time track was completed for this developer resulting in a tribo of -34.6 microcoulombs/gram after 15 minutes and which tribo was -35.4 microcoulombs/gram after 90 minutes. There resulted no charge degradation over time and excellent charge stability compared to the toner in Example VI. EXAMPLE IX The developer in Example VIII was further evaluated for admix properties. This was accomplished at the end of the 90 minutes of paint shaking resulting in a unimodal charge distribution at 15 seconds, with no low charge or wrong sign toner with a q/d (fc/u) near zero or less than zero. Throughout 2 minutes of additional paint shaking, the toner remains highly charged with no low charge (<0.2 fc/u) or wrong sign oppositely charged toner. Upon breadboard machine testing with freshly blended toner from above, excellent quality images resulted with excellent image density and low and less than 1 percent acceptable background. EXAMPLE X A toner blend was prepared as in Example V except that 3.5 weight percent of a 30 nanometer primary particle size and about 300 nanometer aggregate size silica core (L90) coated with a feed of 15 weight percent decyltrimethoxysilane available from Cab-O-Sil division of Cabot Corp., and 2.5 weight percent SMT5103 (30 nanometers of primary particle size titanium dioxide coated with a feed of decyltrimethoxysilane from Tayca Corp.) was used. Two identical developers were prepared by mixing 4 parts of the blended toner with 100 parts of a carrier of Hoeganaes steel core coated with polymethylmethacrylate. These developers were equilibrated in a Relative Humidity chamber. One developer was equilibrated at 80 percent RH 26.6°C (80°F) and the other at 20 percent RH 15.5°C (60°F) overnight. Roll mill time tracks were accomplished for both developers resulting in average tribos over 30 minutes of mixing time of -35 microcoulombs/gram at 20 percent RH and -20 microcoulombs/gram at 80 percent RH. This resulted in a dry:wet zone (20 percent:80 percent) ratio of 1.75. The toner exhibited excellent environmental charge stability for the trimethoxydecylsilane treated silica developer.

Claims: A toner comprised of binder, colorant, and a silica containing a coating of an alkylsilane, wherein said alkylsilane is an alkylsilane polymer present in an amount of from 3 to 10 weight percent based on the amount of silica, and wherein said coated silica possesses a primary particle size of from 25 to 55 nanometers, and an aggregate size of from 225 to 400 nanometers. The toner of claim 1, wherein the binder is a mixture of a polyester formed by the condensation of propoxylated bisphenol A and fumaric acid, and a gelled polyester formed by condensation of propoxylated bisphenol A and fumaric acid. The toner of claim 1 or 2, wherein the alkylsilane is of the formula wherein a represents the repeating segment of optionally enabling a crosslinked formula or structure; said repeat segment and hydroxy or hydroxy groups; said repeat segment and alkoxy or alkoxy groups; or said repeat segment and hydroxy and alkoxy groups; b is alkyl and x is a number of from 1 to 1,000. The toner of claim 3, wherein alkyl contains from 4 to 20 carbon atoms, and X is from 25 to 500. The toner of any of claims 1 to 4, further containing a titanium oxide optionally coated with an alkylsilane. The toner of any of claims 1 to 5, wherein the silica is coated with an input feed mixture containing 10 to 15 percent by weight of an alkyltrialkoxysilane. The toner of any of claims 1 to 6, possessing a triboelectric charge of from 15 to 55 microcoulombs per gram, or a triboelectric charge of from 25 to 40 microcoulombs per gram. A developer comprised of the toner of any of claims 1 to 7 and a carrier. 9. A process for the preparation of toner comprising the mixing of resin, colorant, and silica containing a coating of an alkylsilane, wherein said alkylsilane is an alkylsilane polymer present in an amount of from 3 to 10 weight percent based on the amount of silica, and wherein said coated silica possesses a primary particle size of from 25 to 55 nanometers, and an aggregate size of from 225 to 400 nanometers.

Inventors: BAYLEY DENIS R, BERTRAND JACQUES C, CICCARELLI ROGER N, PICKERING THOMAS R, BAYLEY, DENIS R., BERTRAND, JACQUES C., CICCARELLI, ROGER N., PICKERING, THOMAS R.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1999
Main classification: G03G9
IPC codes: G03G9