Abstract:
A toner or a mixture of toners, comprises a pyrogenically synthesized alumina-silica mixed oxide as a component in combination with other components necessary to complete a toner formulation. The surface of the mixed alumina-silica oxide material.

Description:
This application is a Continuation of application Ser. No. 09/461,752 Filed on Dec. 16, 1999, now U.S. Pat. No. 6,197,469. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to toners and/or toner mixtures. 
     2. Discussion of the Background 
     U.S. Pat. No. 5,424,258 discloses powdered silicon-aluminum mixed oxides of amorphous structure, synthesized by flame hydrolysis. The oxide compositions contain 65 to 72.1 wt. % Al 2 O 3  and 27.9 to 35 wt. % SiO 2  and have a BET surface ranging from 20 to 200 m 2 /g. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide a toner and/or toner mixture which contains pyrogenically synthesized alumina-silica mixed oxide which improves the properties of the toner and/or toner mixture. 
     Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by a toner and/or toner mixture which contains a pyrogenically synthesized silica-alumina mixed oxide as a component in addition to other components which complete a toner formulation. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The discovery of the present invention is that the presence of a pyrogenically synthesized silica-alumina mixed oxide as an additive to a toner imparts improved properties to the toner. The amount of the pyrogenically synthesized silica-alumina incorporated in the toner normally ranges from 0.1 to 5.0% by weight based on the weight of toner. Other toner components include a pigment such as Fe 2 O 3 , a binder such as polyester resin and a charge controlling agent in the amounts these ingredients are normally used to prepare a toner. 
     The pyrogenically synthesized alumina-silica mixed oxide of the invention is per se known and can be prepared as described in U.S. Pat. No. 5,424,258 which is hereby incorporated by reference into the application. 
     In an embodiment of the invention, the Al 2 O 3 /SiO 2  mixed oxide may have a ratio of Al 2 O 3  to SiO 2  comprising 65±5 wt. %Al 2 O 3  and 35±5 wt. % SiO 2 . 
     In another embodiment of the invention, the pyrogenically synthesized Al 2 O 3 /SiO 2  mixed oxide can be surface-modified. The surface modification of the mixed alumina-silica oxide material can be achieved by the technique described in European Patent EP 0 722 922, hereby incorporated by reference. Suitable surface treatment compounds include: 
     (a) Organosilanes of the type (RO) 3 Si(C n H 2n+1 ) 
     R=alkyl, such as e.g., methyl-, ethyl-, n-propyl-, i-propyl-, butyl— 
     n=1-20 
     (b) Organosilanes of the type R′ x (RO) y Si(C n H 2+1 ) 
     R=alkyl, such as e.g. methyl-, ethyl-, n-propyl-, i-propyl-, butyl— 
     R′=alkyl such as e.g. methyl-, ethyl-, n-propyl-, i-propyl-, butyl— 
     n=1 -20 
     x+y=3 
     x=1,2 
     y=1,2 
     (c) Organosilanes of the type (RO) 3 Si(CH 2 ) m —R′ 
     R=alkyl, such as methyl-, ethyl-, propyl— 
     m=0, 1 -20 
     R′=methyl-, aryl (e.g., —C 6 H 5 , substituted phenyl groups) 
     —C 4 F 9 , —OCF 2 —CHF—CF 3 , —C 6 F 13 , —O—CF 2 —CHF2 
     —NH2, —N 3 , —SCN, —CH═CH 2 , 
     —OOC(CH 3 )C═CH 2    
     —OCH 2 —CH(O)CH 2                            
     —S x —(CH 2 ) 3 Si(OR) 3   
     (d) Organosilanes of the type (R″) x (RO y Si(CH 2 ) m —R′                          
     R′=methyl-, aryl (e.g. —C 6 H 5 , substituted phenyl groups) 
     —C 4 F 9 , —OCF 2 —CHF—CF 3 , —C 6 F 13 , —O—CF 2 —CHF 2    
     —NH 2 —N 3 , —SCN, —CH═CH 2 , 
     —OOC(CH 3 )C═CH 2 — 
     —OCH 2 —CH(O)CH 2                            
     —NH—COO—CH 3 , —NH—COO—CH 2 —CH 3 , —NH—(CH 2 ) 3 Si(OR) 3    
     —S x —(CH 2 ) 3 Si(OR) 3    
     (e) Halogenorganosilanes of the type X 3 Si(C n H 2n+1 ) 
     X=Cl, Br 
     n=1-20 
     (f) Halogenorganosilanes of the type X 2 (R′)Si(C n H 2+1 ) 
     X=Cl, Br 
     R′=alkyl, such as e.g. methyl-, ethyl-, n-propyl-, i-propyl-, butyl— 
     n=1-20 
     (g) Halogenorganosilanes of the type X(R′) 2 Si(C n H 2n+1 ) 
     X=Cl, Br 
     R′=alkyl, such as e.g. methyl-, ethyl-, n-propyl-, i-propyl-, butyl— 
     n=1-20 
     (h) Halogenorganosilanes of the type X 3 Si(CH 2 ) m —R′ 
     X=Cl, Br 
     m=0, 1-20 
     R′=methyl-, aryl (e.g. —C 6 H 5 , substituted phenyl groups) 
     —C 4 F 9 , —OCF 2 —CHF—CF 3 , —C 6 F 13 , —O—CF 2 —CHF 2    
     —NH2, —N 3 , —SCN, —CH═CH 2 , 
     —OOC(CH 3 )C═CH 2    
     —OCH 2 —CH(O)CH 2                            
     —S x —(CH 2 ) 3 Si(OR) 3    
     (i) Halogenorganosilanes of the type (R)X 2 Si(CH 2 ) m —R′ 
     X=Cl, Br 
     R=alkyl, such as methyl-, ethyl-, propyl— 
     m=0, 1-20 
     R′=methyl-, aryl (e.g. —C 6 H 5 , substituted phenyl groups) 
     —C 4 F 9 , —OCF 2 —CHF—CF 3 , —C 6 F 13 , —O—CF 2 —CHF 2    
     —NH 2 , —N 3 , —SCN, —CH═CH 2 , 
     —OOC(CH 3 )C═CH 2    
     —OCH 2 —CH(O)CH 2                            
      in which R can be =methyl-, ethyl-, propyl-, butyl 
     —S x —(CH 2 ) 3 Si(OR) 3  in which R can be =methyl-, ethyl-, propyl-, butyl— 
     (j) Halogenorganosilanes of the type (R) 2 X Si(CH 2 ) m —R′ 
     X=Cl, Br 
     R=alkyl 
     m=0, 1-20 
     R′=methyl-, aryl (e.g. —C 6 H 5 , substituted phenyl groups) 
     —C 4 F 9 , —OCF 2 —CHF—CF 3 , —C 6 F 13 , —O—CF 2 —CHF 2    
     —NH 2 , —N 3 , —SCN, —CH═CH 2 , 
     —OOC(CH 3 )C═CH 2    
     —OCH 2 —CH(O)CH 2                            
     —S x—(CH   2 ) 3 Si(OR) 3                             
     (1) A preferred silazane in hexamethyldisilazane (HMDS). Cyclic polysiloxanes of the type D 3, D 4, D 5 in which D 3, D 4 and D 5 signify cyclic polysiloxanes with 3, 4 or 5 units of the type —O—Si(CH 3 ) 2 —, e.g., octamethylcyclotetrasiloxane=D 4                          
     (m) polysiloxanes or silicone oils of the type                           
     m=0, 1,2,3. . .∞ 
     n=0, 1,2,3. . .∞ 
     u=0, 1,2,3. . .∞ 
     Y=CH 3 , H, C n H 2n+1  n=1-20 
     Y=Si(CH 3 ) 3 ,Si(CH 3 ) 2 H 
     Si(CH 3 ) 2 OH, Si(CH 3 ) 2 (OCH 3 ) 
     Si(CH 3 ) 2 (CnH 2n+1 )n=1-20 
     R=alkyl such as C n H 2n+1  in which n=1 to 20, aryl such as phenyl- and substituted phenyl groups (CH 2 )n—NH 2 , H 
     R′=alkyl such as C n H 2n+1  in which n=1 to 20, aryl such as phenyl- and substituted phenyl groups (CH 2 )n—NH 2 , H 
     R″=alkyl such as C n H 2n+1  in which n=1 to 20, aryl such as phenyl- and substituted phenyl groups (CH 2 )n—NH 2 , H 
     R′″=alkyl such as C n H 2n+1  in which n=1 to 20, aryl such as phenyl- and substituted phenyl groups (CH 2 )n—NH 2 , H 
     The pyrogenically produced alumina-silica mixed oxide is placed in a suitable mixing container. The mixed oxides are sprayed under intensive mixing optionally with water at first and then with the surface-modifying reagent or a mixture of several surface-modifying reagents. The material is mixed again for 15 to 30 minutes and subsequently tempered at a temperature of 100 to 400° C. for a period of 1 to 6 hours. 
     The water used can be acidified with an acid, e.g., hydrochloric acid, having a pH of 7 to 1. The surface-modifying reagent used can be dissolved in a suitable solvent such as, e.g., ethanol. The mixing and/or tempering can be carried out in an atmosphere of a protective gas such as, for example, nitrogen. 
     As a result of the incorporation of the pyrogenically synthesized, mixed alumina-silica oxide material of the invention, or the oxide material which is surface modified as mentioned above, into a toner formulation and/or toner formulation mixtures, the toner product of the invention has the following advantages: 
     (i) Better flowability of the toner powder; 
     (ii) More stable charging behavior of the toner as characterized by faster chargeability, a higher charge capacity and permitting constant charging over time. 
    
    
     Having now generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified. 
     EXAMPLES 
     Example 1 
     A Al 2 O 3 /SiO 2  mixed oxide is synthesized as follows: 
     In accordance with the burner arrangement described in Example 1 of U.S. Pat. No. 5,424,258, 1.4 m 3 /h (NTP) of nascent hydrogen, or hydrogen of reaction, is mixed together with 5.5 m 3 /h (NTP) of air and 1.30 kg/h of previously evaporated SiCl 4 . Into this mixture, which has a temperature of about 200° C., there is additionally injected 2.34 kg/h of gaseous AlCl 3 , which had been evaporated beforehand at about 300° C. The resulting mixture is burned in a flame tube, into which 12 m 3 /h (NTP) of air is additionally injected. 
     After passing through the flame tube, the resulting powder is separated in a filter or cyclone from the gases, which contain hydrochloric acid. The adhering residues of hydrochloric acid are separated from the collected mixed oxide by treatment at elevated temperature. 
     The mixed oxide is characterized by the following analytical data: 
     Specific BET surface 74 m 2 /g, a 4% dispersion in water having a pH of 4.49, an apparent density of 46 g/l, a tamped density of 56 g/l. The composition of the powder is 65 wt. % Al 2 O 3  and 35 wt. % SiO 2 . 
     Example 2 
     The surface of a mixed alumina-silica oxide,is modified as described in European Patent Application A 0 722 992: 
     A 600 g amount of a mixed alumina-silica oxide material is placed in a plow-type mixer and, while being mixed, is sprayed first with 30 g of distilled H 2 O and then with 90 g of HMDS (hexamethyldisilazane). Thereafter mixing is continued for a further 15 minutes and finally the reaction mixture is dried for 3 hours at 140° C. in a drying cabinet. 
     The physicochemical data of the product are as follows: 
     
       
         
               
               
               
             
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Experiment 1 
                 Experiment 2 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Tamped density [g/l] 
                 96 
                 88 
               
               
                   
                 pH 
                 7.4 
                 7.8 
               
               
                   
                 C content [% m 2 /g] 
                 0.7 
                 0.9 
               
               
                   
                 Surface [m 2 /g 
                 62 
                 65 
               
               
                   
                 Drying loss [%] 
                 0.7 
                 0.3 
               
               
                   
                 Ignition loss [%] 
                 1.4 
                 2.1 
               
               
                   
                   
               
             
          
         
       
     
     Example 3 
     A 1.8 kg amount of the Al 2 O 3 /SiO 2  mixed oxide described above is placed in a mixer and, while being mixed, is sprayed with 0.27 kg of silicone oil. Thereafter, the surface treated mixed alumina-silica oxide is mixed for an additional 15 minutes and finally subjected to a heat treatment at 300° C. for 2 hours under N 2  atmosphere (fluidized bed). 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 Physicochemical data: 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Tamped density Lg/11 
                 106 
               
               
                   
                 BET surface [m 2 /g]: 
                 57 
               
               
                   
                 pH: 
                 4.2 
               
               
                   
                 C content [%]: 
                 1.3 
               
               
                   
                 Drying loss [%]: 
                 0.2 
               
               
                   
                 Ignition loss [%]: 
                 1.6 
               
               
                   
                   
               
             
          
         
       
     
     The disclosure of German priority Application No. 198 57 912.8 filed Dec. 16, 1998 is hereby incorporated by reference into the present application. 
     Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.