Toner for developing electrostatic images, electrostatic image developer, toner cartridge, process cartridge, image forming apparatus, and image forming method

Abstract

To provide an electrostatic charge image development toner that is crush-resistant.SOLUTION: An electrostatic charge image development toner provided herein comprises toner particles containing a binder resin and a mold release agent, and satisfies the following requirement (1) in cross-sectional observation of the toner particles. Requirement (1): the average of seven or more mold release agent domains with a major axis in a range of 500-1000 nm, inclusive, exist per toner particle.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present disclosure relates to a toner for developing electrostatic images, an electrostatic image developer, a method for producing a toner for developing electrostatic images, a toner cartridge, a process cartridge, an image forming apparatus, and an image forming method. [Background technology]

[0002] Patent Document 1 discloses a method for producing a toner containing at least a colorant and a binder resin mainly composed of a crystalline resin, the method comprising an aggregation step of mixing and aggregating a resin particle dispersion in which crystalline resin particles having carboxylic acid groups are dispersed and which has physical properties of a pH of 6.0 to 10.0 and a zeta potential of -60 mV to -30 mV with a colorant particle dispersion in which colorant particles are dispersed, to obtain an aggregated particle dispersion in which aggregated particles in which crystalline resin particles and colorant particles are mixed, and a fusion step of heating the aggregated particle dispersion to fuse the aggregated particles to obtain toner particles. Patent Document 2 discloses a toner having toner particles containing a binder resin and a wax, in which, when a cross-section of the toner is observed using a transmission electron microscope, As is the ratio of the area occupied by the wax in a region from the surface of the toner particle to 0.5 μm, As is 15.0% or less, when a cross-section of the toner is observed using a transmission electron microscope, wax domains are observed on the cross-section of the toner particle and the average number of domains per cross-section of one toner particle is 10 to 2000, when a mass concentration of polyvalent metal elements in the toner particles measured by X-ray fluorescence analysis is Mi (ppm), Mi is 3.5 ppm to 1100 ppm, and when a mass concentration of polyvalent metal elements in the toner particles measured by X-ray photoelectron spectroscopy analysis is Ms (ppm), Mi>Ms. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2005-140987 A [Patent Document 2] JP 2020-076992 A Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present disclosure is to provide a toner for developing electrostatic images which is less prone to crushing than a toner particle having an average of less than 7 domains of a release agent with a major axis of 500 nm or more and 1000 nm or less. [Means for solving the problem]

[0005] Means for solving the above problems include the following aspects. <1> The toner particles include a binder resin and a release agent, The toner particle satisfies the following requirement (1) in a cross-sectional observation thereof, Toner for developing electrostatic images. Requirement (1): There are an average of 7 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less per toner particle. <2> The toner particle further satisfies the following requirement (A) upon cross-sectional observation: <1> 2. The toner for developing electrostatic images according to claim 1 . Requirement (A): The distance between domains of the release agent having a major axis of 50 nm or more is an average of 200 nm or more. <3> The toner particle further satisfies the following requirement (2) upon cross-sectional observation: <1> or <2> 2. The toner for developing electrostatic images according to claim 1 . Requirement (2): The aspect ratio of the domains of the release agent having a major axis of 500 nm or more and 1,000 nm or less is an average of 3 or more and 10 or less. <4> The toner particle further satisfies the following requirement (3) upon cross-sectional observation: <1> ~ <3> 2. The toner for developing an electrostatic image according to claim 1 . Requirement (3): The percentage of toner particles having 10 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less is 30% or more by number. <5> The toner particle further satisfies the following requirement (3') upon cross-sectional observation: <4> 2. The toner for developing electrostatic images according to claim 1 . Requirement (3'): The toner particles having 10 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less constitute 50% or more by number. <6> The toner particle further satisfies the following requirement (B) upon cross-sectional observation: <1> ~ <5> 2. The toner for developing an electrostatic image according to claim 1 . Requirement (B): The area ratio of release agent domains having a major axis of 50 nm or more is 3% or more and 10% or less on average. <7> The melting temperature of the release agent is 80° C. or higher and 95° C. or lower. <1> ~ <6> 2. The toner for developing an electrostatic image according to claim 1 . <8> <1> ~ <7> 2. An electrostatic image developer comprising the toner for developing electrostatic images according to claim 1. <9> a mixing step of mixing a binder resin particle dispersion liquid containing binder resin particles and a release agent particle dispersion liquid containing release agent particles to prepare a mixed dispersion liquid containing the binder resin particles and the release agent particles; an aggregation step of aggregating the binder resin particles and the release agent particles in the mixed dispersion to form aggregated particles; a coalescence step of heating the dispersion liquid containing the aggregated particles to fuse and coalesce the aggregated particles to form toner particles, a zeta potential of the binder resin particle dispersion liquid and a zeta potential of the release agent particle dispersion liquid are both negative values, and a difference between the zeta potential value of the binder resin particle dispersion liquid and the zeta potential value of the release agent particle dispersion liquid is 0 mV or more and 30 mV or less; A method for producing a toner for developing electrostatic images. <10> The zeta potential value of the release agent particle dispersion liquid is -70 mV or more and -30 mV or less. <9> 2. A method for producing the toner for developing electrostatic images according to claim 1 . <11> The mixed dispersion contains a surfactant, and the content of the surfactant is 1% by mass or more and 3% by mass or less with respect to the total mass of the mixed dispersion. <9> or <10> 2. A method for producing the toner for developing electrostatic images according to claim 1 . <12> <9> ~ <11> 13. A toner for developing electrostatic images, produced by the method for producing a toner for developing electrostatic images according to any one of claims 1 to 12. <13> <9> ~ <11> 2. An electrostatic image developer comprising a toner for developing electrostatic images produced by the method for producing a toner for developing electrostatic images according to any one of claims 1 to 11. <14> <1> ~ <7> and <12> 13. A toner cartridge which contains the toner for developing electrostatic images according to claim 12 and is detachably mounted on an image forming apparatus. <15> <8> or <13> and a developing means for developing an electrostatic image formed on a surface of an image carrier by using the electrostatic image developer into a toner image. <16> An image carrier; a charging means for charging the surface of the image carrier; an electrostatic image forming means for forming an electrostatic image on the charged surface of the image carrier; <8> or <13> a developing means for developing the electrostatic image formed on the surface of the image carrier into a toner image by using the electrostatic image developer; a transfer means for transferring the toner image formed on the surface of the image carrier to a surface of a recording medium; a fixing means for fixing the toner image transferred onto the surface of the recording medium; An image forming apparatus comprising: <17> a charging step of charging the surface of the image carrier; an electrostatic image forming step of forming an electrostatic image on the charged surface of the image carrier; <8> or <13> a developing step of developing the electrostatic image formed on the surface of the image carrier into a toner image by using the electrostatic image developer according to claim 1; a transfer step of transferring the toner image formed on the surface of the image carrier onto a surface of a recording medium; a fixing step of fixing the toner image transferred onto the surface of the recording medium; The image forming method according to claim 1, Effect of the Invention

[0006] <1> According to the invention, there is provided a toner for developing electrostatic images which is less likely to be crushed than a toner particle having an average of less than 7 domains of the release agent with a major axis of 500 nm or more and 1000 nm or less. <2> According to the invention, there is provided a toner for developing electrostatic images which is less likely to be crushed than when the distance between release agent domains having a major axis of 50 nm or more is less than 200 nm on average. <3> According to the present invention, a toner for developing electrostatic images is provided which is less prone to crushing than when the aspect ratio of the release agent domains having a major axis of 500 nm or more and 1000 nm or less is less than 3 on average or more than 10 on average. <4> According to the invention, there is provided a toner for developing electrostatic images which is less prone to crushing than when the proportion of toner particles having 10 or more release agent domains with a major axis of 500 nm or more and 1000 nm or less is less than 30% by number. <5> According to the invention, there is provided a toner for developing electrostatic images which is less prone to crushing than when less than 50% by number of toner particles have 10 or more release agent domains with a major axis of 500 nm or more and 1000 nm or less. <6> According to the present invention, there is provided a toner for developing electrostatic images which is less prone to crushing, compared with a toner in which the area ratio of release agent domains having a major axis of 50 nm or more is less than 3% on average or more than 10% on average. <7> According to the present invention, a toner for developing electrostatic images is provided which is less prone to crushing than when the melting temperature of the release agent is lower than 80°C. <8> According to the present invention, there is provided an electrostatic image developer containing a toner for developing electrostatic images that is resistant to crushing. <9> , <10> and <11> According to the present invention, there is provided a method for producing a toner for developing electrostatic images, which produces a toner for developing electrostatic images that is less likely to be crushed than when the difference in zeta potential between the binder resin particle dispersion and the release agent particle dispersion exceeds 30 mV. <12> According to the present invention, a toner for developing electrostatic images that is resistant to crushing is provided. <13> According to the present invention, there is provided an electrostatic image developer containing a toner for developing electrostatic images that is resistant to crushing. <14> According to the present invention, a toner cartridge is provided that contains crush-resistant toner for developing electrostatic images. <15> According to the present invention, there is provided a process cartridge that accommodates an electrostatic image developer that includes a crush-resistant toner for developing an electrostatic image. <16> According to the present invention, there is provided an image forming apparatus that employs an electrostatic image developer that contains a toner for developing electrostatic images that is not easily crushed. <17> According to the present invention, there is provided an image forming method using an electrostatic image developer containing a toner for developing electrostatic images that is not easily crushed. [Brief description of the drawings]

[0007] [Figure 1] 1 is a schematic configuration diagram illustrating an example of an image forming apparatus according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic diagram illustrating an example of a process cartridge that is detachably mounted to the image forming apparatus according to the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, embodiments of the present disclosure will be described. These descriptions and examples are merely illustrative of the embodiments, and are not intended to limit the scope of the embodiments.

[0009] In the present disclosure, a numerical range indicated using "~" indicates a range that includes the numerical values ​​before and after "~" as the minimum and maximum values, respectively.

[0010] In the numerical ranges described in the present disclosure in stages, the upper or lower limit value described in one numerical range may be replaced with the upper or lower limit value of another numerical range described in stages. In addition, in the numerical ranges described in the present disclosure, the upper or lower limit value of the numerical range may be replaced with a value shown in the examples.

[0011] In the present disclosure, the term "step" includes not only an independent step, but also a step that cannot be clearly distinguished from other steps, as long as the intended purpose of the step is achieved.

[0012] In the present disclosure, each component may contain multiple types of corresponding substances. When referring to the amount of each component in a composition in the present disclosure, if multiple substances corresponding to each component are present in the composition, the total amount of the multiple substances present in the composition is meant unless otherwise specified.

[0013] In the present disclosure, the particles corresponding to each component may include multiple types. When multiple types of particles corresponding to each component are present in the composition, the particle size of each component means the value for a mixture of the multiple types of particles present in the composition, unless otherwise specified.

[0014] In the present disclosure, "(meth)acrylic" means at least one of acrylic and methacrylic, and "(meth)acrylate" means at least one of acrylate and methacrylate.

[0015] In this disclosure, "toner" refers to "toner for developing electrostatic images", "developer" refers to "electrostatic image developer", and "carrier" refers to "carrier for developing electrostatic images".

[0016] In the present disclosure, a method for producing toner particles by aggregating and coalescing material particles in a solvent is referred to as an EA (emulsion aggregation) method.

[0017] <Toner for developing electrostatic images> The toner according to the present embodiment includes toner particles containing a binder resin and a release agent, and satisfies the following requirement (1) in cross-sectional observation of the toner particles. Requirement (1): There are an average of 7 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less per toner particle.

[0018] The toner according to the present embodiment is less likely to be crushed by satisfying requirement (1). For the toner to satisfy requirement (1), it means that the release agent is not contained in the toner particles in the form of large lumps, nor is the release agent contained in the toner particles in the form of finely divided particles, but is contained in the toner particles in the form of particles divided into particles of appropriate size. It is presumed that when a mechanical force is applied to a toner of this type, the force is dispersed within the toner particles, and the release agent domains of appropriate size act as a support, making the toner less likely to be crushed.

[0019] In the requirement (1), the upper limit of the average number of the release agent domains having a major axis of 500 nm or more and 1000 nm or less per toner particle is not limited, but is, for example, 15 or less.

[0020] The requirement (1) can be controlled by the zeta potential of the release agent particle dispersion, the content of the release agent particles in the release agent particle dispersion, the content of the surfactant in the release agent particle dispersion, and the amount of the release agent particle dispersion used when producing toner particles by the EA method.

[0021] In the toner according to the present embodiment, the release agent domains are dispersed with high uniformity in the toner particles, and as a result, from the viewpoint of the toner being less likely to be crushed, it is preferable that the toner satisfies the following requirement (A) when observed through a cross section of a toner particle, and it is more preferable that the toner satisfies requirement (A').

[0022] Requirement (A): The distance between domains of the release agent having a major axis of 50 nm or more is an average of 200 nm or more. Requirement (A'): The distance between domains of the release agent having a major axis of 50 nm or more is an average of 220 nm or more.

[0023] In the requirements (A) and (A'), the upper limit of the average distance between domains of the release agent having a major axis of 50 nm or more is, but is not limited to, for example, 400 nm or less.

[0024] The requirements (A) and (A') can be controlled by the zeta potential of the release agent particle dispersion, the content of the release agent particles in the release agent particle dispersion, the content of the surfactant in the release agent particle dispersion, and the amount of the release agent particle dispersion used when producing toner particles by the EA method.

[0025] From the viewpoint of preventing the toner from being crushed, the toner according to the present embodiment preferably satisfies the following requirement (2), and more preferably satisfies requirement (2'), when a cross section of a toner particle is observed.

[0026] Requirement (2): The aspect ratio of the domains of the release agent having a major axis of 500 nm or more and 1,000 nm or less is an average of 3 or more and 10 or less. Requirement (2'): The aspect ratio of the domains of the release agent having a major axis of 500 nm or more and 1000 nm or less is 3 or more and 8 or less on average.

[0027] The requirements (2) and (2') can be controlled by the zeta potential of the release agent particle dispersion, the content of the release agent particles in the release agent particle dispersion, the content of the surfactant in the release agent particle dispersion, and the amount of the release agent particle dispersion used when producing toner particles by the EA method.

[0028] From the viewpoint of preventing the toner from being crushed, the toner according to the present embodiment preferably satisfies the following requirement (3) when a cross section of a toner particle is observed, and more preferably satisfies requirement (3').

[0029] Requirement (3): The percentage of toner particles having 10 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less is 30% or more by number. Requirement (3'): The toner particles having 10 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less constitute 50% or more by number.

[0030] In the requirements (3) and (3'), the upper limit of the proportion by number of toner particles having 10 or more release agent domains with a major axis of 500 nm or more and 1000 nm or less is not limited, but is, for example, 90% by number or less.

[0031] The requirements (3) and (3') can be controlled by the zeta potential of the release agent particle dispersion, the content of the release agent particles in the release agent particle dispersion, the content of the surfactant in the release agent particle dispersion, and the amount of the release agent particle dispersion used when producing toner particles by the EA method.

[0032] From the viewpoint of preventing the toner from being crushed, the toner according to this embodiment preferably satisfies the following requirement (B), and more preferably satisfies requirement (B'), when a cross section of a toner particle is observed.

[0033] Requirement (B): The area ratio of release agent domains having a major axis of 50 nm or more is 3% or more and 10% or less on average. Requirement (B'): The area ratio of release agent domains having a major axis of 50 nm or more is 5% or more and 10% or less on average.

[0034] The requirements (B) and (B') can be controlled by the zeta potential of the release agent particle dispersion, the release agent particle content in the release agent particle dispersion, the surfactant content in the release agent particle dispersion, and the amount of the release agent particle dispersion used when producing toner particles by the EA method.

[0035] The method for checking each of the requirements is described below. In this disclosure, the major axis is the length of the longest straight line among all straight lines connecting two points on the contour line.

[0036] The toner particles (which may have external additives attached) are mixed into the epoxy resin, and the epoxy resin is solidified. The solidified product is cut using an ultramicrotome (Ultracut UCT manufactured by Leica) to prepare a thin section sample with a thickness of 80 nm to 130 nm. The thin section sample is stained with ruthenium tetroxide for 3 hours in a desiccator at 30°C. An SEM image of the dyed thin sample is obtained using an ultra-high resolution field emission scanning electron microscope (FE-SEM) (e.g. Hitachi High-Technologies Corporation S-4800). Generally, release agents are more easily stained by ruthenium tetroxide than binder resins, so the release agent can be identified by the shade caused by the degree of staining. If it is difficult to distinguish the shade due to the condition of the sample, adjust the staining time. In the cross section of a toner particle, the colorant domains are generally less than 50 nm in length, so they can be distinguished by size.

[0037] The SEM image contains toner particle cross sections of various sizes, and toner particle cross sections whose major axis is 80% or more of the volume average particle size of the toner particles are selected, and from these, 300 toner particle cross sections are randomly selected and observed. The reason for selecting a cross section in which the major axis is 80% or more of the volume average particle diameter is that a cross section in which the major axis is less than 80% of the volume average particle diameter is predicted to be a cross section of the end of a toner particle, but the cross section of the end of a toner particle does not well reflect the state of the release agent domain in the toner particle.

[0038] -Requirement (1)- The total number of release agent domains having a major axis of 500 nm or more and 1000 nm or less contained in the cross sections of 300 toner particles is counted, and the average number per toner particle is calculated.

[0039] -Requirement (2)- The aspect ratios are measured for all release agent domains having a major axis of 500 nm or more and 1000 nm or less contained in the cross sections of 300 toner particles, and an average value is calculated. The aspect ratio is the ratio of the major axis to the minor axis (major axis / minor axis). The minor axis is the length of the longest straight line among the straight lines that are perpendicular to the major axis and connect the opposing contour lines.

[0040] -Requirement (3)- The number of release agent domains with a major axis of 500 nm to 1000 nm contained in one toner particle cross section is counted. This is performed for 300 toner particle cross sections. The percentage of toner particles having 10 or more release agent domains with a major axis of 500 nm to 1000 nm is calculated.

[0041] -Requirement (A)- For all release agent domains with a major axis of 50 nm or more in the cross section of one toner particle, the distance (nm) between two domains is measured. The distance between two domains is the shortest distance connecting their contours. Furthermore, measurements are made on the cross sections of 300 toner particles, and the average value (nm) is calculated.

[0042] -Requirement (B)- The total area of ​​the cross sections of 300 toner particles and the total area of ​​the release agent domains having a major axis of 50 nm or more contained in the cross sections of 300 toner particles are measured, and the latter is divided by the former to calculate the area ratio.

[0043] The toner according to this embodiment will be described in detail below.

[0044] The toner according to the present embodiment is configured to contain toner particles and, if necessary, an external additive.

[0045] [Toner particles] The toner particles are configured to contain, for example, a binder resin, and, if necessary, a colorant, a release agent, and other additives.

[0046] -Binding resin- Examples of the binder resin include vinyl resins made of homopolymers of monomers such as styrenes (e.g., styrene, parachlorostyrene, α-methylstyrene, etc.), (meth)acrylic acid esters (e.g., methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, lauryl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, lauryl methacrylate, 2-ethylhexyl methacrylate, etc.), ethylenically unsaturated nitriles (e.g., acrylonitrile, methacrylonitrile, etc.), vinyl ethers (e.g., vinyl methyl ether, vinyl isobutyl ether, etc.), vinyl ketones (e.g., vinyl methyl ketone, vinyl ethyl ketone, vinyl isopropenyl ketone, etc.), and olefins (e.g., ethylene, propylene, butadiene, etc.), or copolymers of two or more of these monomers. Examples of the binder resin include non-vinyl resins such as epoxy resins, polyester resins, polyurethane resins, polyamide resins, cellulose resins, polyether resins, and modified rosin, mixtures of these with the vinyl resins, and graft polymers obtained by polymerizing vinyl monomers in the coexistence of these. These binder resins may be used alone or in combination of two or more kinds.

[0047] The binder resin is preferably a polyester resin. The polyester resin may be, for example, a known amorphous polyester resin. The polyester resin may be used in combination with a crystalline polyester resin together with the amorphous polyester resin. However, the content of the crystalline polyester resin is preferably in the range of 2% by mass to 40% by mass (preferably 2% by mass to 20% by mass) based on the total binder resin.

[0048] The "crystallinity" of a resin refers to the presence of a clear endothermic peak rather than a stepwise change in the amount of endothermic heat in differential scanning calorimetry (DSC); specifically, it refers to the half-width of the endothermic peak being within 10°C when measured at a heating rate of 10°C / min. The term "amorphous" for a resin refers to a half-width exceeding 10° C., a stepwise change in endothermic heat quantity, or no clear endothermic peak being observed.

[0049] Amorphous polyester resin The amorphous polyester resin may be, for example, a condensation polymer of a polyvalent carboxylic acid and a polyhydric alcohol. As the amorphous polyester resin, a commercially available product or a synthesized product may be used.

[0050] Examples of polyvalent carboxylic acids include aliphatic dicarboxylic acids (e.g., oxalic acid, malonic acid, maleic acid, fumaric acid, citraconic acid, itaconic acid, glutaconic acid, succinic acid, alkenylsuccinic acid, adipic acid, sebacic acid, etc.), alicyclic dicarboxylic acids (e.g., cyclohexanedicarboxylic acid, etc.), aromatic dicarboxylic acids (e.g., terephthalic acid, isophthalic acid, phthalic acid, naphthalenedicarboxylic acid, etc.), anhydrides thereof, and lower alkyl esters thereof (e.g., having 1 to 5 carbon atoms). Among these, aromatic dicarboxylic acids are preferable as polyvalent carboxylic acids. The polyvalent carboxylic acid may be a trivalent or higher carboxylic acid having a crosslinked or branched structure in combination with a dicarboxylic acid. Examples of the trivalent or higher carboxylic acid include trimellitic acid, pyromellitic acid, anhydrides thereof, and lower (e.g., carbon number 1 to 5) alkyl esters thereof. The polyvalent carboxylic acids may be used alone or in combination of two or more kinds.

[0051] Examples of polyhydric alcohols include aliphatic diols (e.g., ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, butanediol, hexanediol, neopentyl glycol, etc.), alicyclic diols (e.g., cyclohexanediol, cyclohexanedimethanol, hydrogenated bisphenol A, etc.), and aromatic diols (e.g., ethylene oxide adducts of bisphenol A, propylene oxide adducts of bisphenol A, etc.). Among these, examples of polyhydric alcohols include aromatic diols and alicyclic diols, and more preferably aromatic diols. As the polyhydric alcohol, a trihydric or higher polyhydric alcohol having a crosslinked or branched structure may be used in combination with the diol. Examples of the trihydric or higher polyhydric alcohol include glycerin, trimethylolpropane, and pentaerythritol. The polyhydric alcohols may be used alone or in combination of two or more kinds.

[0052] The glass transition temperature (Tg) of the amorphous polyester resin is preferably 50°C or higher and 80°C or lower, and more preferably 50°C or higher and 65°C or lower. The glass transition temperature is determined from a DSC curve obtained by differential scanning calorimetry (DSC), and more specifically, is determined from the "extrapolated glass transition onset temperature" described in the method for determining glass transition temperature in JIS K7121-1987 "Method for measuring transition temperature of plastics."

[0053] The weight average molecular weight (Mw) of the amorphous polyester resin is preferably 5,000 or more and 1,000,000 or less, and more preferably 7,000 or more and 500,000 or less. The number average molecular weight (Mn) of the amorphous polyester resin is preferably 2,000 or more and 100,000 or less. The molecular weight distribution Mw / Mn of the amorphous polyester resin is preferably 1.5 or more and 100 or less, and more preferably 2 or more and 60 or less. The weight average molecular weight and number average molecular weight are measured by gel permeation chromatography (GPC). The molecular weight measurement by GPC is performed using a Tosoh GPC HLC-8120GPC as the measuring device, a Tosoh TSKgel SuperHM-M (15 cm) column, and THF solvent. The weight average molecular weight and number average molecular weight are calculated from the measurement results using a molecular weight calibration curve created with a monodisperse polystyrene standard sample.

[0054] The amorphous polyester resin can be obtained by a known production method, for example, by carrying out the reaction while removing water and alcohol generated during condensation by setting the polymerization temperature to 180° C. or higher and 230° C. or lower, and reducing the pressure in the reaction system as necessary. If the raw material monomer is not soluble or compatible at the reaction temperature, a high boiling point solvent may be added as a solubilizing agent to dissolve it. In this case, the polycondensation reaction is carried out while distilling off the solubilizing agent. If a monomer with poor compatibility is present in the copolymerization reaction, it is recommended that the monomer with poor compatibility is condensed in advance with the acid or alcohol to be polycondensed, and then polycondensed with the main component.

[0055] Crystalline polyester resin The crystalline polyester resin may be, for example, a polycondensate of a polyvalent carboxylic acid and a polyhydric alcohol. As the crystalline polyester resin, a commercially available product or a synthesized product may be used. Here, the crystalline polyester resin is preferably a polycondensate using a straight-chain aliphatic polymerizable monomer rather than a polymerizable monomer having an aromatic ring, since it easily forms a crystalline structure.

[0056] Examples of polyvalent carboxylic acids include aliphatic dicarboxylic acids (e.g., oxalic acid, succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, 1,9-nonanedicarboxylic acid, 1,10-decanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, 1,14-tetradecanedicarboxylic acid, 1,18-octadecanedicarboxylic acid, etc.), aromatic dicarboxylic acids (e.g., dibasic acids such as phthalic acid, isophthalic acid, terephthalic acid, naphthalene-2,6-dicarboxylic acid, etc.), anhydrides thereof, and lower alkyl esters thereof (e.g., having 1 to 5 carbon atoms). The polyvalent carboxylic acid may be a trivalent or higher carboxylic acid having a crosslinked or branched structure in combination with a dicarboxylic acid. Examples of the trivalent carboxylic acid include aromatic carboxylic acids (e.g., 1,2,3-benzenetricarboxylic acid, 1,2,4-benzenetricarboxylic acid, 1,2,4-naphthalenetricarboxylic acid, etc.), their anhydrides, and their lower alkyl esters (e.g., carbon number 1 to 5). As the polyvalent carboxylic acid, a dicarboxylic acid having a sulfonic acid group and a dicarboxylic acid having an ethylenic double bond may be used in combination with these dicarboxylic acids. The polyvalent carboxylic acids may be used alone or in combination of two or more kinds.

[0057] Examples of polyhydric alcohols include aliphatic diols (for example, straight-chain aliphatic diols having 7 to 20 carbon atoms in the main chain). Examples of aliphatic diols include ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 1,11-undecanediol, 1,12-dodecanediol, 1,13-tridecanediol, 1,14-tetradecanediol, 1,18-octadecanediol, and 1,14-eicosanedecanediol. Among these, 1,8-octanediol, 1,9-nonanediol, and 1,10-decanediol are preferred as aliphatic diols. The polyhydric alcohol may be a trihydric or higher alcohol having a crosslinked or branched structure in combination with the diol. Examples of the trihydric or higher alcohol include glycerin, trimethylolethane, trimethylolpropane, and pentaerythritol. The polyhydric alcohols may be used alone or in combination of two or more kinds.

[0058] Here, the polyhydric alcohol has an aliphatic diol content of 80 mol % or more, preferably 90 mol % or more.

[0059] The melting temperature of the crystalline polyester resin is preferably 50°C or higher and 100°C or lower, more preferably 55°C or higher and 90°C or lower, and even more preferably 60°C or higher and 85°C or lower. The melting temperature is determined from a DSC curve obtained by differential scanning calorimetry (DSC) based on the "peak melting temperature" as described in the method for determining melting temperature in JIS K7121-1987 "Method for measuring transition temperature of plastics."

[0060] The weight average molecular weight (Mw) of the crystalline polyester resin is preferably 6,000 or more and 35,000 or less.

[0061] The crystalline polyester resin can be obtained, for example, by a known production method, like the amorphous polyester.

[0062] The content of the binder resin is preferably from 40% by mass to 95% by mass, more preferably from 50% by mass to 90% by mass, and even more preferably from 60% by mass to 85% by mass, based on the total mass of the toner particles.

[0063] -Coloring agent- Examples of colorants include carbon black, chrome yellow, Hansa Yellow, benzidine yellow, threne yellow, quinoline yellow, pigment yellow, permanent orange GTR, pyrazolone orange, Balkan orange, watch young red, permanent red, brilliant carmine 3B, brilliant carmine 6B, DuPont oil red, pyrazolone red, lithol red, rhodamine B lake, lake red C, pigment red, rose bengal, aniline blue, Examples of the dyes include pigments such as ultramarine blue, chalcoil blue, methylene blue chloride, phthalocyanine blue, pigment blue, phthalocyanine green, and malachite green oxalate; and dyes such as acridine-based, xanthene-based, azo-based, benzoquinone-based, azine-based, anthraquinone-based, thioindigo-based, dioxazine-based, thiazine-based, azomethine-based, indigo-based, phthalocyanine-based, aniline black-based, polymethine-based, triphenylmethane-based, diphenylmethane-based, and thiazole-based dyes. The colorant may be used alone or in combination of two or more kinds.

[0064] The colorant may be surface-treated as necessary, or may be used in combination with a dispersant. In addition, a plurality of types of colorants may be used in combination.

[0065] The content of the colorant is preferably from 1% by mass to 30% by mass, and more preferably from 3% by mass to 15% by mass, based on the total mass of the toner particles.

[0066] -Release agent- Examples of the release agent include hydrocarbon waxes, natural waxes such as carnauba wax, rice wax, and candelilla wax, synthetic or mineral / petroleum waxes such as montan wax, and ester waxes such as fatty acid esters and montan acid esters. The release agent is not limited to these.

[0067] From the viewpoint of dispersing release agent domains of an appropriate size in the toner particles during the production process, the melting temperature of the release agent is preferably relatively high, and is preferably from 80° C. to 95° C., more preferably from 84° C. to 92° C., and even more preferably from 86° C. to 90° C.

[0068] The melting temperature of the release agent is determined from a DSC curve obtained by differential scanning calorimetry (DSC) based on the "melting peak temperature" described in the method for determining the melting temperature in JIS K7121-1987 "Method for measuring transition temperature of plastics."

[0069] The content of the release agent is preferably from 1% by mass to 20% by mass, and more preferably from 5% by mass to 15% by mass, based on the total mass of the toner particles.

[0070] -Other additives- Examples of other additives include known additives such as magnetic materials, charge control agents, inorganic powders, etc. These additives are contained in the toner particles as internal additives.

[0071] -Characteristics of toner particles, etc.- The toner particles may be toner particles having a single layer structure, or may be toner particles having a so-called core-shell structure composed of a core portion (core particle) and a coating layer (shell layer) that coats the core portion. The toner particles having a core-shell structure may be composed of, for example, a core containing a binder resin and, if necessary, other additives such as a colorant and a release agent, and a coating layer containing the binder resin.

[0072] The volume average particle size (D50v) of the toner particles is preferably from 2 μm to 10 μm, and more preferably from 4 μm to 8 μm.

[0073] The various average particle sizes and particle size distribution indexes of the toner particles are measured using a Coulter Multisizer II (manufactured by Beckman Coulter, Inc.), and the electrolyte is measured using an ISOTON-II (manufactured by Beckman Coulter, Inc.). For the measurement, 0.5 mg to 50 mg of the measurement sample is added to 2 ml of a 5 mass % aqueous solution of a surfactant (preferably sodium alkylbenzene sulfonate) as a dispersant, and this is then added to 100 ml to 150 ml of the electrolyte. The electrolyte with the sample suspended in it is dispersed for 1 minute using an ultrasonic disperser, and the particle size distribution of particles with diameters in the range of 2 μm to 60 μm is measured using a Coulter Multisizer II with an aperture diameter of 100 μm. The number of particles sampled is 50,000. Based on the measured particle size distribution, cumulative distributions of volume and number are drawn for each divided particle size range (channel) from the small diameter side, and the particle size at 16% of the cumulative size is defined as the volume particle size D16v, the number particle size D16p, the particle size at 50% of the cumulative size as the volume average particle size D50v, the cumulative number average particle size D50p, and the particle size at 84% of the cumulative size as the volume particle size D84v and number particle size D84p. Using these, the volumetric particle size distribution index (GSDv) is (D84v / D16v) 1 / 2 The number size distribution index (GSDp) is (D84p / D16p) 1 / 2 It is calculated as:

[0074] The average circularity of the toner particles is preferably 0.94 or more and 1.00 or less, and more preferably 0.95 or more and 0.98 or less.

[0075] The average circularity of toner particles is calculated by (circular equivalent perimeter) / (perimeter) [(perimeter of a circle having the same projected area as the particle image) / (perimeter of the particle projected image)]. Specifically, it is a value measured by the following method. First, the toner particles to be measured are sucked and collected, flattened, and a still image of the particles is captured by instantaneous strobe light emission, and the particle image is analyzed by a flow-type particle image analyzer (FPIA-3000 manufactured by Sysmex Corporation). The number of samples to be taken in order to calculate the average circularity is 3,500. When the toner contains an external additive, the toner (developer) to be measured is dispersed in water containing a surfactant, and then ultrasonic treatment is performed to obtain toner particles from which the external additive has been removed.

[0076] [External additives] Examples of the external additive include inorganic particles. Examples of the inorganic particles include SiO2, TiO2, Al2O3, CuO, ZnO, SnO2, CeO2, Fe2O3, MgO, BaO, CaO, K2O, Na2O, ZrO2, CaO·SiO2, and K2O·(TiO2). n , Al2O3·2SiO2, CaCO3, MgCO3, BaSO4, MgSO4, etc.

[0077] The surface of the inorganic particles as an external additive may be subjected to a hydrophobic treatment. The hydrophobic treatment may be performed, for example, by immersing the inorganic particles in a hydrophobic treatment agent. The hydrophobic treatment agent is not particularly limited, and examples thereof include silane coupling agents, silicone oils, titanate coupling agents, and aluminum coupling agents. These may be used alone or in combination of two or more. The amount of the hydrophobic treatment agent is usually, for example, 1 part by mass or more and 10 parts by mass or less per 100 parts by mass of the inorganic particles.

[0078] Examples of external additives include resin particles (resin particles such as polystyrene, polymethyl methacrylate, and melamine resin), cleaning agents (for example, metal salts of higher fatty acids such as zinc stearate, and fluorine-based polymer particles), and the like.

[0079] The amount of the external additive is preferably from 0.01% by mass to 5% by mass, and more preferably from 0.01% by mass to 2.0% by mass, based on the toner particles.

[0080] <Method of manufacturing toner for developing electrostatic images> The toner production method according to the present embodiment is a toner production method that includes producing toner particles by the EA method, and has the following mixing step, aggregation step, and coalescence step.

[0081] Mixing step: A step of mixing a binder resin particle dispersion liquid containing binder resin particles and a release agent particle dispersion liquid containing release agent particles to prepare a mixed dispersion liquid containing binder resin particles and release agent particles. Aggregation step: A step of aggregating binder resin particles and release agent particles in a mixed dispersion to form aggregated particles. Coalescence process: A process in which the dispersion liquid containing the aggregated particles is heated to fuse and coalesce the aggregated particles to form toner particles.

[0082] In the toner manufacturing method according to the present embodiment, the zeta potential of the binder resin particle dispersion liquid and the zeta potential of the release agent particle dispersion liquid are both negative values, and the difference between the zeta potential value of the binder resin particle dispersion liquid and the zeta potential value of the release agent particle dispersion liquid is 0 mV or more and 30 mV or less. When a plurality of types of binder resin particle dispersion liquids are prepared, it is sufficient that the binder resin particle dispersion liquid having the largest amount of resin brought into the mixed dispersion liquid satisfies the above requirements. When multiple types of release agent particle dispersion liquids are prepared, the release agent particle dispersion liquid containing the largest amount of release agent to be added to the mixed dispersion liquid should satisfy the above requirements.

[0083] If the difference between the zeta potential value of the binder resin particle dispersion and the zeta potential value of the release agent particle dispersion exceeds 30 mV, the release agent particles tend to aggregate in the aggregation step, forming lumps of the release agent which are then included in the toner particles. In order for the release agent to be divided into particles of an appropriate size and included in the toner particles, the difference between the zeta potential value of the binder resin particle dispersion and the zeta potential value of the release agent particle dispersion is 0 mV or more and 30 mV or less, preferably 0 mV or more and 25 mV or less, and more preferably 0 mV or more and 20 mV or less.

[0084] In this embodiment, the zeta potential of the binder resin particle dispersion liquid and the release agent particle dispersion liquid is measured by electrophoresis (also called laser Doppler method). The measurement device is, for example, a zeta potential measurement system ELSZ-2000Z or ELSZ-2000ZS manufactured by Otsuka Electronics Co., Ltd. A part of the particle dispersion is taken and used as a measurement sample without dilution or pH adjustment. The liquid temperature of the measurement sample during measurement is 25°C.

[0085] The steps and materials of the method for producing the toner according to this embodiment will be described in detail below.

[0086] [Mixing process] The mixing step is a step of mixing at least a binder resin particle dispersion liquid and a release agent particle dispersion liquid. In the mixing step, a colorant particle dispersion liquid may be further mixed. The order in which these particle dispersion liquids are mixed is not limited.

[0087] The mixed dispersion liquid prepared in the mixing step contains at least binder resin particles and release agent particles, and may further contain colorant particles.

[0088] Hereinafter, the binder resin particle dispersion liquid, the release agent particle dispersion liquid, and the colorant particle dispersion liquid will be collectively referred to as "particle dispersion liquid" to describe what they have in common.

[0089] An example of an embodiment of a particle dispersion liquid is a dispersion liquid in which a material is dispersed in the form of particles in a dispersion medium by a surfactant.

[0090] The dispersion medium of the particle dispersion liquid is preferably an aqueous medium. Examples of the aqueous medium include water and alcohol. The water is preferably water with a reduced ion content, such as distilled water or ion-exchanged water. These aqueous media may be used alone or in combination of two or more.

[0091] Examples of surfactants for dispersing materials in a dispersion medium include anionic surfactants such as sulfate ester salts, sulfonate salts, phosphate esters, and soaps; cationic surfactants such as amine salts and quaternary ammonium salts; and nonionic surfactants such as polyethylene glycols, alkylphenol ethylene oxide adducts, and polyhydric alcohols. The surfactants may be used alone or in combination of two or more. The nonionic surfactants may be used in combination with an anionic surfactant or a cationic surfactant.

[0092] Methods for dispersing a material in a particulate form in a dispersion medium include known dispersion methods using a rotary shear type homogenizer, a ball mill having media, a sand mill, a dyno mill, and the like.

[0093] The phase inversion emulsification method is a method for dispersing a resin in a dispersion medium in the form of particles. The phase inversion emulsification method involves dissolving the resin in a hydrophobic organic solvent in which the resin is soluble, adding a base to the organic continuous phase (O phase) to neutralize it, and then introducing an aqueous medium (W phase) to invert the phase from W / O to O / W, dispersing the resin in the form of particles in the aqueous medium.

[0094] The volume average particle size of the particles dispersed in the particle dispersion is preferably 30 nm or more and 300 nm or less, more preferably 50 nm or more and 250 nm or less, and even more preferably 80 nm or more and 200 nm or less. The volume average particle size of particles in a particle dispersion refers to the particle size that is 50% cumulative from the smallest diameter side in a particle size distribution measured with a laser diffraction particle size distribution measuring device (for example, LA-700 manufactured by Horiba, Ltd.).

[0095] The content of particles contained in the particle dispersion is preferably from 5% by mass to 50% by mass, more preferably from 10% by mass to 40% by mass, and even more preferably from 15% by mass to 30% by mass.

[0096] The zeta potential value of the binder resin particle dispersion liquid having the largest amount of resin brought into the mixed dispersion liquid is preferably −60 mV or more and −20 mV or less, more preferably −60 mV or more and −30 mV or less, and even more preferably −60 mV or more and −40 mV or less, from the viewpoint of dispersion stability of the binder resin particles in the binder resin particle dispersion liquid and the mixed dispersion liquid. The zeta potential of the binder resin particle dispersion liquid is controlled by, for example, the type of polymerizable component of the resin and the type and amount of the surfactant contained in the resin particle dispersion liquid.

[0097] The zeta potential value of the release agent particle dispersion in which the amount of release agent brought into the mixed dispersion is the largest is, from the viewpoint of the dispersion stability of the release agent particles in the release agent particle dispersion and the mixed dispersion, and from the viewpoint of reducing the difference with the zeta potential of the binder resin particle dispersion, preferably from -70 mV to -30 mV, more preferably from -65 mV to -35 mV, and even more preferably from -60 mV to -40 mV. The zeta potential of the release agent particle dispersion liquid is controlled by, for example, the type of release agent and the type and amount of the surfactant contained in the release agent particle dispersion liquid.

[0098] The zeta potential of the release agent particle dispersion can also be controlled by adjusting the temperature when preparing the release agent particle dispersion. After mixing the release agent and the solvent, the liquid temperature is raised to a temperature equal to or higher than the melting temperature of the release agent to carry out a dispersion treatment, and then cooled to room temperature. During this cooling, the liquid temperature is kept in the range of 35°C to 40°C for 30 minutes to 90 minutes. This operation increases the amount of surfactant attached to the surfaces of the release agent particles, and the zeta potential of the release agent particle dispersion can be reduced.

[0099] From the viewpoint of dispersion stability of the particles, the mixed dispersion liquid preferably contains a surfactant. From the viewpoint of dispersing the material particles with high uniformity in the mixed dispersion and producing a toner that satisfies requirements (1) to (5), the content of the surfactant contained in the mixed dispersion is preferably from 1% by mass to 3% by mass, more preferably from 1.5% by mass to 3% by mass, and even more preferably from 2% by mass to 3% by mass, based on the total mass of the mixed dispersion.

[0100] The mass ratio of the particles contained in the mixed dispersion is preferably within the following range, from the viewpoint of preventing the final toner from being crushed. The ratio of binder resin particles:releasing agent particles is preferably from 97:3 to 85:15, more preferably from 95:5 to 88:12, and even more preferably from 93:7 to 90:10. When the mixed dispersion contains colorant particles, the ratio of binder resin particles:colorant particles is preferably 97:3 to 85:15, more preferably 96:4 to 88:12, and even more preferably 95:5 to 90:10.

[0101] The mixing step preferably includes adjusting the pH of the mixed dispersion to a range of 4.5 to 6.0. When the mixed dispersion having a pH in the range of 4.5 to 6.0 is subjected to the aggregation step, all of the material particles having zeta potential values ​​in the particle dispersion within the above-mentioned ranges tend to aggregate.

[0102] The pH of the mixed dispersion can be adjusted by adding an acidic aqueous solution such as an aqueous nitric acid solution, an aqueous hydrochloric acid solution, or an aqueous sulfuric acid solution.

[0103] [Aggregation step (first aggregation step)] The aggregating step is a step of aggregating at least the binder resin particles and the release agent particles to form aggregated particles. In the aggregating step, the colorant particles may also be aggregated.

[0104] When the toner manufacturing method according to the present embodiment includes a second aggregation step (a step for forming a shell layer) described later, the above aggregation step is referred to as a "first aggregation step." The first aggregation step is a step for forming a core in a toner having a core-shell structure.

[0105] The aggregation step may, for example, be adding a flocculant to the mixed dispersion while stirring the mixed dispersion; After adding the flocculant to the mixed dispersion, the mixed dispersion is heated while being stirred to increase the temperature of the mixed dispersion.

[0106] Examples of the flocculant include a surfactant having a polarity opposite to that of the surfactant contained in the mixed dispersion, an inorganic metal salt, and a divalent or higher metal complex. The flocculant may be used alone or in combination of two or more kinds.

[0107] Examples of inorganic metal salts include metal salts such as calcium chloride, calcium nitrate, barium chloride, magnesium chloride, zinc chloride, aluminum chloride, and aluminum sulfate; and inorganic metal salt polymers such as polyaluminum chloride, polyaluminum hydroxide, and calcium polysulfide.

[0108] The flocculant is preferably a divalent or higher metal salt compound, more preferably a trivalent metal salt compound, and even more preferably a trivalent inorganic aluminum salt compound, such as aluminum chloride, aluminum sulfate, polyaluminum chloride, and polyaluminum hydroxide.

[0109] The amount of the flocculant to be added is not limited. When a trivalent metal salt compound is used as the flocculant, the amount of the trivalent metal salt compound to be added is preferably 0.3 parts by mass or more and 2 parts by mass or less, more preferably 0.5 parts by mass or more and 1.5 parts by mass or less, and even more preferably 0.6 parts by mass or more and 1.3 parts by mass or less, relative to 100 parts by mass of the binder resin.

[0110] The temperature that the mixed dispersion reaches when it is heated is preferably a temperature based on the glass transition temperature (Tg) of the binder resin particles, for example, a temperature not lower than (Tg-30°C) and not higher than (Tg-10°C) of the binder resin particles. When the mixed dispersion contains a plurality of types of binder resin particles having different Tg's, the lowest temperature among the Tg's is determined as the glass transition temperature in the aggregation step.

[0111] [Second flocculation step] The second aggregation step is a step for the purpose of producing a toner having a core-shell structure, and is a step performed after the first aggregation step. The second aggregation step is a step for forming a shell layer.

[0112] The second aggregation step is a step of mixing a dispersion liquid containing aggregated particles with a dispersion liquid containing resin particles that will form the shell layer, and aggregating the resin particles that will form the shell layer on the surfaces of the aggregated particles to form second aggregated particles.

[0113] As the dispersion liquid containing resin particles that will become the shell layer, a binder resin particle dispersion liquid for forming the core is preferable, a polyester resin particle dispersion liquid is more preferable, and a non-crystalline polyester resin particle dispersion liquid is even more preferable.

[0114] The second aggregation step may, for example, adding a dispersion liquid containing resin particles to be a shell layer to the dispersion liquid containing the aggregated particles while stirring the dispersion liquid containing the aggregated particles; and heating, while stirring, the dispersion liquid containing the aggregated particles after adding the dispersion liquid containing the resin particles that will form the shell layer.

[0115] When the dispersion liquid containing the aggregated particles is heated, the temperature that the dispersion liquid containing the aggregated particles reaches is preferably a temperature based on the glass transition temperature (Tg) of the resin particles that form the shell layer, for example, a temperature that is equal to or higher than (Tg-30°C) and equal to or lower than (Tg-10°C) of the resin particles that form the shell layer.

[0116] After the aggregated particles or the second aggregated particles have grown to a predetermined size, a chelating agent for the aggregating agent used in the aggregation step may be added to the dispersion containing the aggregated particles or the second aggregated particles in order to stop the growth of the aggregated particles or the second aggregated particles before the heating in the coalescence step is performed. Examples of the chelating agent include oxycarboxylic acids such as tartaric acid, citric acid, and gluconic acid; and aminocarboxylic acids such as iminodiacetic acid (IDA), nitrilotriacetic acid (NTA), and ethylenediaminetetraacetic acid (EDTA). The amount of the chelating agent added is preferably 0.01 parts by mass or more and 5.0 parts by mass or less, and more preferably 0.1 parts by mass or more and less than 3.0 parts by mass, based on 100 parts by mass of the binder resin particles.

[0117] After the aggregated particles or the second aggregated particles have grown to a predetermined size, the pH of the dispersion containing the aggregated particles or the second aggregated particles may be increased in order to stop the growth of the aggregated particles or the second aggregated particles before the heating in the coalescence step is performed. The means for increasing the pH of the dispersion containing the aggregated particles or the second aggregated particles includes the addition of at least one selected from the group consisting of an aqueous solution of an alkali metal hydroxide and an aqueous solution of an alkaline earth metal hydroxide. The ultimate pH of the dispersion containing the aggregated particles or the second aggregated particles is preferably 8 or more and 10 or less.

[0118] [Combining process] The coalescence step is a step in which the dispersion liquid containing the aggregated particles is heated to fuse and coalesce the aggregated particles to form toner particles.

[0119] When the second aggregation step is performed before the coalescence step, the coalescence step is a step in which the dispersion liquid containing the second aggregated particles is heated to fuse and coalesce the second aggregated particles to form toner particles. By performing the second aggregation step and the coalescence step, toner particles having a core-shell structure can be produced.

[0120] The form described below is common to the aggregated particles and the second aggregated particles.

[0121] The temperature reached by the dispersion liquid containing the aggregated particles is preferably equal to or higher than the glass transition temperature (Tg) of the binder resin, and specifically, is preferably 10° C. to 30° C. higher than the Tg of the binder resin. When the aggregated particles contain a plurality of binder resins having different Tg's, the highest temperature among the Tg's is defined as the glass transition temperature in the coalescence step.

[0122] After the coalescence step, the toner particles in the dispersion are subjected to a known washing step, solid-liquid separation step, and drying step to obtain dried toner particles. In the washing step, from the viewpoint of chargeability, it is preferable to carry out sufficient substitution washing with ion-exchanged water. In the solid-liquid separation step, it is preferable to carry out suction filtration, pressure filtration, etc., from the viewpoint of productivity. In the drying step, it is preferable to carry out freeze drying, air flow drying, fluidized drying, vibration type fluidized drying, etc., from the viewpoint of productivity.

[0123] [Step of adding external additives] The method for producing the toner according to the present embodiment preferably includes a step of externally adding an external additive to the toner particles.

[0124] <Electrostatic image developer> The electrostatic image developer according to this embodiment contains at least the toner according to this embodiment. The electrostatic image developer according to the present embodiment may be a one-component developer containing only the toner according to the present embodiment, or may be a two-component developer in which the toner is mixed with a carrier.

[0125] The carrier is not particularly limited, and may be any known carrier. Examples of the carrier include a coated carrier in which the surface of a core material made of magnetic powder is coated with a resin, a magnetic powder dispersion type carrier in which magnetic powder is dispersed and mixed in a matrix resin, and a resin impregnated type carrier in which porous magnetic powder is impregnated with a resin. The magnetic powder dispersion type carrier and the resin impregnated type carrier may be a carrier in which the constituent particles of the carrier are used as a core material, and the surface of the core material is coated with a resin.

[0126] Examples of the magnetic powder include magnetic metals such as iron, nickel, and cobalt; magnetic oxides such as ferrite and magnetite; and the like.

[0127] Examples of the resin and matrix resin for coating include polyethylene, polypropylene, polystyrene, polyvinyl acetate, polyvinyl alcohol, polyvinyl butyral, polyvinyl chloride, polyvinyl ether, polyvinyl ketone, vinyl chloride-vinyl acetate copolymer, styrene acrylic acid ester copolymer, straight silicone resin or its modified product containing organosiloxane bonds, fluororesin, polyester, polycarbonate, phenolic resin, epoxy resin, etc. The resin and matrix resin for coating may contain other additives such as conductive particles. Examples of the conductive particles include particles of metals such as gold, silver, copper, carbon black, titanium oxide, zinc oxide, tin oxide, barium sulfate, aluminum borate, potassium titanate, etc.

[0128] Examples of methods for coating the surface of the core material with a resin include a method of coating with a coating layer-forming solution in which the coating resin and various additives (used as necessary) are dissolved in a suitable solvent. The solvent is not particularly limited and may be selected taking into consideration the type of resin used, suitability for application, etc. Specific resin coating methods include an immersion method in which the core material is immersed in a solution for forming a coating layer; a spray method in which the solution for forming a coating layer is sprayed onto the surface of the core material; a fluidized bed method in which the solution for forming a coating layer is sprayed onto the core material while it is suspended in flowing air; and a kneader coater method in which the carrier core material and the solution for forming a coating layer are mixed in a kneader coater and then the solvent is removed.

[0129] The mixture ratio (mass ratio) of the toner and the carrier in the two-component developer is preferably toner:carrier=1:100 to 30:100, and more preferably 3:100 to 20:100.

[0130] <Image forming device, image forming method> An image forming apparatus and an image forming method according to the present embodiment will be described. The image forming apparatus according to the present embodiment includes an image carrier, a charging means for charging the surface of the image carrier, an electrostatic image forming means for forming an electrostatic image on the surface of the charged image carrier, a developing means for containing an electrostatic image developer and developing the electrostatic image formed on the surface of the image carrier as a toner image with the electrostatic image developer, a transfer means for transferring the toner image formed on the surface of the image carrier to the surface of a recording medium, and a fixing means for fixing the toner image transferred to the surface of the recording medium. The electrostatic image developer according to the present embodiment is used as the electrostatic image developer.

[0131] In the image forming apparatus according to this embodiment, an image forming method (the image forming method according to this embodiment) is carried out, which includes a charging step of charging the surface of an image carrier, an electrostatic image forming step of forming an electrostatic image on the surface of the charged image carrier, a developing step of developing the electrostatic image formed on the surface of the image carrier as a toner image using the electrostatic image developer according to this embodiment, a transfer step of transferring the toner image formed on the surface of the image carrier to the surface of a recording medium, and a fixing step of fixing the toner image transferred to the surface of the recording medium.

[0132] The image forming apparatus according to the present embodiment may be any of known image forming apparatuses, such as a direct transfer type apparatus in which a toner image formed on the surface of an image holder is directly transferred to a recording medium; an intermediate transfer type apparatus in which a toner image formed on the surface of an image holder is primarily transferred to the surface of an intermediate transfer body, and the toner image transferred to the surface of the intermediate transfer body is secondarily transferred to the surface of a recording medium; an apparatus equipped with a cleaning means for cleaning the surface of the image holder after the transfer of the toner image and before charging; and an apparatus equipped with a discharging means for irradiating the surface of the image holder with discharging light to discharge it after the transfer of the toner image and before charging it. When the image forming apparatus according to the present embodiment is an intermediate transfer type apparatus, the transfer means has, for example, an intermediate transfer body onto whose surface a toner image is transferred, a primary transfer means which primarily transfers the toner image formed on the surface of the image carrier onto the surface of the intermediate transfer body, and a secondary transfer means which secondarily transfers the toner image transferred onto the surface of the intermediate transfer body onto the surface of a recording medium.

[0133] In the image forming apparatus according to the present embodiment, for example, a portion including the developing means may have a cartridge structure (process cartridge) that is detachably attached to the image forming apparatus. As the process cartridge, for example, a process cartridge that contains the electrostatic charge image developer according to the present embodiment and has the developing means is preferably used.

[0134] An example of an image forming apparatus according to the present embodiment will be described below, but the present invention is not limited to this example. In the following description, the main parts shown in the drawings will be described, and the description of the rest will be omitted.

[0135] FIG. 1 is a schematic diagram showing the configuration of an image forming apparatus according to the present embodiment. The image forming apparatus shown in Fig. 1 includes first to fourth image forming units 10Y, 10M, 10C, and 10K (image forming means) of an electrophotographic type that output images of each color of yellow (Y), magenta (M), cyan (C), and black (K) based on color-separated image data. These image forming units (hereinafter sometimes simply referred to as "units") 10Y, 10M, 10C, and 10K are arranged in parallel at predetermined distances from each other in the horizontal direction. These units 10Y, 10M, 10C, and 10K may be process cartridges that are detachably attached to the image forming apparatus.

[0136] Above each of the units 10Y, 10M, 10C, and 10K, an intermediate transfer belt (one example of an intermediate transfer body) 20 is provided, which extends through each unit. The intermediate transfer belt 20 is provided wrapped around a drive roll 22 and a support roll 24, and runs in a direction from the first unit 10Y toward the fourth unit 10K. A force is applied to the support roll 24 by a spring (not shown) or the like in a direction away from the drive roll 22, and tension is applied to the intermediate transfer belt 20 wrapped around them. An intermediate transfer body cleaning device 30 is provided on the image carrier side of the intermediate transfer belt 20, facing the drive roll 22. The developing devices (an example of developing means) 4Y, 4M, 4C, and 4K of the units 10Y, 10M, 10C, and 10K are supplied with yellow, magenta, cyan, and black toners contained in toner cartridges 8Y, 8M, 8C, and 8K, respectively.

[0137] Since the first to fourth units 10Y, 10M, 10C, and 10K have the same configuration and operation, the first unit 10Y that forms a yellow image and is disposed upstream in the direction in which the intermediate transfer belt travels will be described here as a representative.

[0138] The first unit 10Y has a photoconductor 1Y that acts as an image carrier. Around the photoconductor 1Y, a charging roll (an example of a charging means) 2Y that charges the surface of the photoconductor 1Y to a predetermined potential, an exposure device (an example of an electrostatic image forming means) 3 that exposes the charged surface to a laser beam 3Y based on a color-separated image signal to form an electrostatic image, a developing device (an example of a developing means) 4Y that supplies charged toner to the electrostatic image to develop it, a primary transfer roll 5Y (an example of a primary transfer means) that transfers the developed toner image onto an intermediate transfer belt 20, and a photoconductor cleaning device (an example of a cleaning means) 6Y that removes toner remaining on the surface of the photoconductor 1Y after the primary transfer are arranged in this order. The primary transfer roll 5Y is disposed inside the intermediate transfer belt 20, and is provided at a position facing the photoconductor 1Y. A bias power supply (not shown) that applies a primary transfer bias is connected to the primary transfer rolls 5Y, 5M, 5C, and 5K of each unit. Each bias power supply changes the value of the transfer bias applied to each primary transfer roll under the control of a control unit (not shown).

[0139] Hereinafter, the operation of forming a yellow image in the first unit 10Y will be described. First, prior to operation, the surface of the photoconductor 1Y is charged to a potential of −600V to −800V by the charging roll 2Y. The photoconductor 1Y has a conductivity (for example, a volume resistivity of 1×10 at 20° C. -6 The photosensitive layer is formed by laminating a photosensitive layer on a substrate having a resistivity of Ωcm or less. This photosensitive layer is usually highly resistive (the resistance of ordinary resins), but when irradiated with a laser beam, the resistivity of the portion irradiated with the laser beam changes. Therefore, the exposed surface of the charged photoreceptor 1Y is irradiated with a laser beam 3Y from the exposure device 3 in accordance with image data for yellow sent from a control unit (not shown). As a result, an electrostatic charge image of a yellow image pattern is formed on the surface of the photoreceptor 1Y.

[0140] An electrostatic image is an image formed on the surface of the photoconductor 1Y by electrostatic charging. The laser beam 3Y reduces the resistivity of the irradiated parts of the photosensitive layer, causing the charged charges on the surface of the photoconductor 1Y to flow, while the charges remain in the parts not irradiated by the laser beam 3Y. This is a so-called negative latent image. The electrostatic image formed on the photoconductor 1Y rotates to a predetermined developing position as the photoconductor 1Y travels. At this developing position, the electrostatic image on the photoconductor 1Y is developed into a toner image by the developing device 4Y and made visible.

[0141] The developing device 4Y contains an electrostatic image developer including at least yellow toner and a carrier, for example. The yellow toner is triboelectrically charged by being stirred inside the developing device 4Y, and is held on a developer roll (an example of a developer holder) with a charge of the same polarity (negative polarity) as the charge on the photoconductor 1Y. As the surface of the photoconductor 1Y passes through the developing device 4Y, the yellow toner electrostatically adheres to the discharged latent image portion on the surface of the photoconductor 1Y, and the latent image is developed with the yellow toner. The photoconductor 1Y on which the yellow toner image has been formed continues to travel at a predetermined speed, and the toner image developed on the photoconductor 1Y is transported to a predetermined primary transfer position.

[0142] When the yellow toner image on the photoreceptor 1Y is transported to the primary transfer position, a primary transfer bias is applied to the primary transfer roll 5Y, and an electrostatic force from the photoreceptor 1Y toward the primary transfer roll 5Y acts on the toner image, and the toner image on the photoreceptor 1Y is transferred onto the intermediate transfer belt 20. The transfer bias applied at this time has a polarity (+) opposite to the polarity (-) of the toner, and is controlled to, for example, +10 μA by a control unit (not shown) in the first unit 10Y. The toner remaining on the photoreceptor 1Y is removed and collected by the photoreceptor cleaning device 6Y.

[0143] The primary transfer bias applied to the primary transfer rolls 5M, 5C, and 5K subsequent to the second unit 10M is also controlled in accordance with the first unit. In this manner, the intermediate transfer belt 20 onto which the yellow toner image has been transferred by the first unit 10Y is conveyed successively through the second to fourth units 10M, 10C, and 10K, where the toner images of each color are transferred and superimposed.

[0144] The intermediate transfer belt 20 onto which the four color toner images have been transferred in multiple layers through the first to fourth units reaches a secondary transfer section that is composed of the intermediate transfer belt 20, a support roll 24 that contacts the inner surface of the intermediate transfer belt, and a secondary transfer roll (an example of a secondary transfer means) 26 arranged on the image bearing surface side of the intermediate transfer belt 20. Meanwhile, a recording paper (an example of a recording medium) P is fed at a predetermined timing into the gap between the secondary transfer roll 26 and the intermediate transfer belt 20 via a supply mechanism, and a secondary transfer bias is applied to the support roll 24. The transfer bias applied at this time has a (-) polarity that is the same as the (-) polarity of the toner, and an electrostatic force from the intermediate transfer belt 20 toward the recording paper P acts on the toner image, and the toner image on the intermediate transfer belt 20 is transferred onto the recording paper P. The secondary transfer bias at this time is determined according to the resistance detected by a resistance detection means (not shown) that detects the resistance of the secondary transfer section, and is voltage-controlled.

[0145] Thereafter, the recording paper P is sent to a pressure contact portion (nip portion) of a pair of fixing rolls in a fixing device (one example of a fixing means) 28, where the toner image is fixed onto the recording paper P, forming a fixed image.

[0146] The recording paper P onto which the toner image is transferred can be, for example, plain paper used in electrophotographic copying machines, printers, etc. In addition to the recording paper P, other examples of the recording medium include overhead projector sheets and the like. To further improve the smoothness of the image surface after fixing, it is preferable that the surface of the recording paper P is also smooth. For example, coated paper in which the surface of ordinary paper is coated with a resin or the like, art paper for printing, etc. are preferably used.

[0147] After the color image has been fixed, the recording paper P is conveyed toward the discharge section, and the series of color image forming operations is completed.

[0148] <Process cartridges, toner cartridges> The process cartridge according to this embodiment will be described. The process cartridge according to this embodiment is a process cartridge that contains the electrostatic image developer according to this embodiment, is equipped with a developing means that develops an electrostatic image formed on the surface of an image carrier using the electrostatic image developer into a toner image, and is detachably attached to an image forming apparatus.

[0149] The process cartridge according to this embodiment is not limited to the above configuration, and may be configured to include a developing means and, as necessary, at least one other means selected from an image carrier, a charging means, an electrostatic image forming means, and a transfer means.

[0150] An example of a process cartridge according to the present embodiment will be described below, but the present invention is not limited to this example. In the following description, the main parts shown in the drawings will be described, and the description of the rest will be omitted.

[0151] FIG. 2 is a schematic diagram showing the process cartridge according to the present embodiment. The process cartridge 200 shown in FIG. 2 is configured by, for example, a housing 117 having a mounting rail 116 and an opening 118 for exposure, and integrally combining and holding a photoconductor 107 (an example of an image carrier), a charging roll 108 (an example of a charging means) provided around the photoconductor 107, a developing device 111 (an example of a developing means), and a photoconductor cleaning device 113 (an example of a cleaning means), which are assembled into a cartridge. In FIG. 2, 109 denotes an exposure device (an example of an electrostatic image forming means), 112 denotes a transfer device (an example of a transfer means), 115 denotes a fixing device (an example of a fixing means), and 300 denotes a recording paper (an example of a recording medium).

[0152] Next, the toner cartridge according to this embodiment will be described. The toner cartridge according to the present embodiment is a toner cartridge that contains the toner according to the present embodiment and is detachably attached to an image forming apparatus. The toner cartridge contains replenishment toner to be supplied to a developing unit provided in the image forming apparatus.

[0153] 1 is an image forming apparatus having a configuration in which toner cartridges 8Y, 8M, 8C, and 8K are detachably attached, and developing devices 4Y, 4M, 4C, and 4K are connected to toner cartridges corresponding to the respective developing devices (colors) by toner supply pipes (not shown). When the toner contained in a toner cartridge becomes low, the toner cartridge is replaced. EXAMPLES

[0154] Hereinafter, the embodiments of the present invention will be described in detail with reference to examples, but the embodiments of the present invention are not limited to these examples. In the following description, unless otherwise specified, "parts" and "%" are by mass. Synthesis, processing, preparation, etc. were carried out at room temperature (25°C ± 3°C) unless otherwise noted.

[0155] <Preparation of particle dispersion> [Preparation of polyester resin particle dispersion (1)] Terephthalic acid: 33 parts by mole Fumaric acid: 70 parts by mole Trimellitic acid: 2 mol parts Bisphenol A ethylene oxide adduct: 5 mole parts Bisphenol A propylene oxide adduct: 95 parts by mole The above materials were charged into a flask equipped with a stirrer, a nitrogen inlet tube, a temperature sensor, and a distillation column, the temperature was raised to 220°C over 1 hour, and 1 part of titanium tetraethoxide was added per 100 parts of the above materials. The temperature was raised to 230°C over 30 minutes while distilling off the generated water, and the dehydration condensation reaction was continued at that temperature for 1 hour, after which the reaction product was cooled to obtain polyester resin (1) (weight average molecular weight 17000, glass transition temperature 60°C).

[0156] In a vessel equipped with a temperature control means and a nitrogen substitution means, 40 parts of ethyl acetate and 25 parts of 2-butanol were added to prepare a mixed solvent, and then 100 parts of polyester resin (1) were gradually added and dissolved, and a 10% aqueous ammonia solution (equivalent to three times the amount by molar ratio relative to the acid value of the resin) was added thereto and stirred for 30 minutes. Next, the inside of the vessel was substituted with dry nitrogen, the temperature was kept at 40°C, and 400 parts of ion-exchanged water was added dropwise while stirring the mixed liquid, to perform emulsification. After the dropwise addition was completed, the emulsion was returned to 25°C, and a dispersion in which resin particles having a volume average particle size of 170 nm were dispersed was obtained. Ion-exchanged water was added to this dispersion to adjust the solid content to 20%, and a polyester resin particle dispersion (1) was obtained. The zeta potential value of the polyester resin particle dispersion (1) was measured and found to be -64 mV.

[0157] [Preparation of polyester resin particle dispersion (2)] Terephthalic acid: 30 parts by mole Fumaric acid: 70 parts by mole Bisphenol A ethylene oxide adduct: 5 mole parts Bisphenol A propylene oxide adduct: 95 parts by mole The above materials were charged into a flask equipped with a stirrer, a nitrogen inlet tube, a temperature sensor, and a distillation column, and the temperature was raised to 220°C over 1 hour, and 1 part of titanium tetraethoxide was added per 100 parts of the above materials. The temperature was raised to 230°C over 30 minutes while distilling off the generated water, and the dehydration condensation reaction was continued at that temperature for 1 hour, after which the reaction product was cooled to obtain polyester resin (2) (weight average molecular weight 18000, glass transition temperature 59°C).

[0158] In a vessel equipped with a temperature control means and a nitrogen substitution means, 40 parts of ethyl acetate and 25 parts of 2-butanol were added to prepare a mixed solvent, and then 100 parts of polyester resin (2) were gradually added and dissolved, and 10% aqueous ammonia solution (equivalent to 3 times the amount by molar ratio relative to the acid value of the resin) was added thereto and stirred for 30 minutes. Next, the inside of the vessel was substituted with dry nitrogen, the temperature was kept at 40°C, and 400 parts of ion-exchanged water was added dropwise while stirring the mixed liquid, to perform emulsification. After the dropwise addition was completed, the emulsion was returned to 25°C, and a dispersion in which resin particles having a volume average particle size of 180 nm were dispersed was obtained. Ion-exchanged water was added to this dispersion to adjust the solid content to 20%, and polyester resin particle dispersion (2) was obtained. The zeta potential value of polyester resin particle dispersion (2) was measured and found to be -46 mV.

[0159] [Preparation of release agent particle dispersion (1)] Paraffin wax (Nippon Seiro, HNP-0190, melting temperature 89°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 4 parts Ion-exchanged water: 350 parts The above materials were mixed and heated to 110°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, dispersion processing was performed using a pressure discharge type Gaulin homogenizer. Next, the liquid temperature was cooled to 40°C, and kept at that temperature for 1 hour, and then the liquid temperature was cooled to 25°C. Water was added to adjust the solid content to 20%, to obtain release agent particle dispersion liquid (1). The volume average particle diameter of release agent particle dispersion liquid (1) was 210 nm. The zeta potential value of release agent particle dispersion liquid (1) was measured and found to be -62 mV.

[0160] [Preparation of release agent particle dispersion (2)] Paraffin wax (Nippon Seiro, HNP-0190, melting temperature 89°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 2 parts Ion-exchanged water: 350 parts The above materials were mixed and heated to 110°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, dispersion processing was performed using a pressure discharge type Gaulin homogenizer. Next, the liquid temperature was cooled to 40°C, and kept at that temperature for 1 hour, and then the liquid temperature was cooled to 25°C. Water was added to adjust the solid content to 20%, to obtain release agent particle dispersion liquid (2). The volume average particle diameter of release agent particle dispersion liquid (2) was 210 nm. The zeta potential value of release agent particle dispersion liquid (2) was measured and found to be -50 mV.

[0161] [Preparation of release agent particle dispersion (3)] Paraffin wax (Nippon Seiro, HNP-0190, melting temperature 89°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 1.5 parts Ion-exchanged water: 350 parts The above materials were mixed and heated to 110°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, dispersion processing was performed using a pressure discharge type Gaulin homogenizer. Next, the liquid temperature was cooled to 40°C, and kept at that temperature for 30 minutes, and then the liquid temperature was cooled to 25°C. Water was added to adjust the solid content to 20%, to obtain release agent particle dispersion liquid (3). The volume average particle diameter of release agent particle dispersion liquid (3) was 210 nm. The zeta potential value of release agent particle dispersion liquid (3) was measured and found to be -37 mV.

[0162] [Preparation of release agent particle dispersion (4)] Paraffin wax (Nippon Seiro, HNP-0190, melting temperature 89°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 1 part Ion-exchanged water: 350 parts The above materials were mixed and heated to 100°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, a dispersion process was performed using a pressure discharge type Gaulin homogenizer. The liquid temperature was then cooled to 25°C, and water was added to adjust the solid content to 20%, to obtain release agent particle dispersion (4). The volume average particle size of release agent particle dispersion (4) was 220 nm. The zeta potential value of release agent particle dispersion (4) was measured and found to be -20 mV.

[0163] [Preparation of release agent particle dispersion (5)] Ester wax (NOF, WEP-5, melting temperature 85°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 4 parts Ion-exchanged water: 350 parts The above materials were mixed and heated to 110°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, dispersion processing was performed using a pressure discharge type Gaulin homogenizer. Next, the liquid temperature was cooled to 40°C, and kept at that temperature for 1 hour, and then the liquid temperature was cooled to 25°C. Water was added to adjust the solid content to 20%, to obtain release agent particle dispersion liquid (5). The volume average particle diameter of release agent particle dispersion liquid (5) was 200 nm. The zeta potential value of release agent particle dispersion liquid (5) was measured and found to be -59 mV.

[0164] [Preparation of release agent particle dispersion (6)] Paraffin wax (Nippon Seiro, HNP-9, melting temperature 75°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 4 parts Ion-exchanged water: 350 parts The above materials were mixed and heated to 110°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, dispersion processing was performed using a pressure discharge type Gaulin homogenizer. Next, the liquid temperature was cooled to 40°C, and kept at that temperature for 1 hour, and then the liquid temperature was cooled to 25°C. Water was added to adjust the solid content to 20%, to obtain release agent particle dispersion liquid (6). The volume average particle diameter of release agent particle dispersion liquid (6) was 200 nm. The zeta potential value of release agent particle dispersion liquid (6) was measured and found to be -59 mV.

[0165] [Preparation of release agent particle dispersion (7)] Paraffin wax (Nippon Seiro, FT-100, melting temperature 98°C): 100 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 4 parts Ion-exchanged water: 350 parts The above materials were mixed and heated to 110°C, and dispersed using a homogenizer (Ultra Turrax T50, manufactured by IKA). Then, dispersion processing was performed using a pressure discharge type Gaulin homogenizer. Next, the liquid temperature was cooled to 40°C, and kept at that temperature for 1 hour, and then the liquid temperature was cooled to 25°C. Water was added to adjust the solid content to 20%, to obtain release agent particle dispersion liquid (7). The volume average particle diameter of release agent particle dispersion liquid (7) was 200 nm. The zeta potential value of release agent particle dispersion liquid (7) was measured and found to be -63 mV.

[0166] [Preparation of colorant particle dispersion (C)] Cyan pigment (Pigment Blue 15:3, Dainichi Seika Color & Chemicals): 50 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 5 parts Ion-exchanged water: 195 parts The above materials were mixed and dispersed for 60 minutes using a high-pressure impact disperser (Ultimaizer HJP30006, Sugino Machine Co., Ltd.) to obtain a colorant particle dispersion (C) with a solid content of 20%.

[0167] <Example 1> [Mixing process] Ion-exchanged water: 215 parts Polyester resin particle dispersion (1): 290 parts Release agent particle dispersion (3): 40 parts Colorant particle dispersion (C): 20 parts Anionic surfactant (Daiichi Kogyo Seiyaku, Neogen RK): 2.8 parts The above materials were placed in a reaction vessel equipped with a thermometer, a pH meter, and a stirrer. The temperature was controlled at 30°C from the outside of the reaction vessel using a mantle heater, and the mixture was stirred at 150 rpm for 30 minutes. The pH of the mixed dispersion was then adjusted to 3.0 using a 0.3N aqueous nitric acid solution.

[0168] [First flocculation step] An aqueous PAC solution was prepared by dissolving 0.7 parts of polyaluminum chloride (Oji Paper Co., Ltd., active ingredient 30%, powder product) in 7 parts of ion-exchanged water. The aqueous PAC solution was added while dispersing the mixed dispersion with a homogenizer (IKA Ultra Turrax T50). The mixed dispersion was then heated to 50°C while being stirred. When the temperature of the dispersion reached 50°C, the particle size of the aggregated particles was measured with a Coulter Multisizer II (aperture diameter 50 μm), and the volume average particle size was 5.0 μm.

[0169] [Second flocculation step] The pH of 150 parts of polyester resin particle dispersion (1) was adjusted to 4.0 with a 0.3N aqueous nitric acid solution, and added to the dispersion containing the aggregated particles while continuing to stir. The dispersion was then heated to 50° C. while stirring. When the temperature of the dispersion reached 50° C., the particle size of the second aggregated particles was measured with a Coulter Multisizer II (aperture diameter 50 μm), and the volume average particle size was 5.8 μm.

[0170] To the dispersion liquid containing the second aggregated particles, 20 parts of a 10% aqueous solution of sodium nitrilotriacetate (Chilest Co., Ltd., Chelest 70) was added, and the pH was then adjusted to 9.0 with a 1N aqueous solution of sodium hydroxide.

[0171] [Combining process] The dispersion liquid containing the second aggregated particles was heated to 87°C and held for 60 minutes. The dispersion liquid was then cooled to room temperature, and the solids were filtered off. The solids were redispersed in ion-exchanged water, and repeatedly filtered and washed until the electrical conductivity of the filtrate was 20 μS / cm or less. The solids were then vacuum-dried for 5 hours in a vacuum dryer at an internal temperature of 40°C to obtain toner particles. The volume average particle size of the toner particles was 5.8 μm.

[0172] [Addition of external additives] 100 parts of the toner particles and 1.5 parts of hydrophobic silica particles (RY50, Nippon Aerosil Co., Ltd.) were placed in a sample mill and mixed for 30 seconds at a rotation speed of 10,000 rpm. The mixture was then sieved through a vibrating sieve with an opening of 45 μm to obtain a toner.

[0173] [Creating the carrier] Mn-Mg-Sr ferrite particles (average particle size 40 μm): 100 parts Toluene: 14 parts Polymethylmethacrylate: 2 parts Carbon black (Cabot, VXC72): 0.12 parts The above materials except for the ferrite particles were mixed with glass beads (diameter 1 mm, same amount as toluene) and stirred for 30 minutes at a rotation speed of 1200 rpm using a sand mill manufactured by Kansai Paint Co., Ltd. to obtain a dispersion liquid. The dispersion liquid and the ferrite particles were placed in a vacuum degassing kneader, and the carrier was obtained by reducing the pressure and drying while stirring.

[0174] [Preparation of developer] 10 parts of the toner and 100 parts of the carrier were placed in a V-type blender and stirred for 20 minutes, and then sieved through a vibrating sieve with 212 μm openings to obtain a developer.

[0175] <Examples 2 to 21 and Comparative Examples 1 to 3> Toner particles were obtained in the same manner as in Example 1, except that the manufacturing process was changed to the specifications shown in Table 1. Next, in the same manner as in Example 1, external additives were added to the toner particles, and the toner particles were mixed with a carrier to obtain a developer.

[0176] <Performance evaluation> [Toner crushing] The developer was filled into the developing unit of a modified Fuji Xerox DocuCentreColorf450 (an image forming apparatus modified to perform fixing using an external fixing apparatus with a variable fixing temperature). Using this image forming apparatus, 3,000 sheets of A3-sized plain paper were continuously printed with a solid image area ratio of 50% under low temperature and low humidity conditions (temperature 10°C and relative humidity 15%). After printing, the toner crushing on the photoreceptor by the cleaning blade and toner filming on the photoreceptor (the occurrence of film-like streaks due to toner crushing) were visually observed. Furthermore, the surfaces of the center and both ends of the photoreceptor and the cleaning blade were observed under a microscope (100x magnification) and classified as follows:

[0177] A: No toner filming or toner crushing was observed under a microscope. B: One or two faint, thin lines of toner filming are observed under a microscope, but not visible to the naked eye, and no toner crushing is observed on the cleaning blade. C: One or two lines of toner filming are observed under a microscope, but not visible to the naked eye, and no toner crushing is observed on the cleaning blade. D: Three or four toner filmings are observed under a microscope, but not visible to the naked eye, and no toner crushing is observed on the cleaning blade. E: No toner filming was observed with the naked eye, but slight toner crushing was observed on the cleaning blade to the extent that it did not cause any practical problems. F: Toner filming was observed on the photoreceptor, and this was problematic for practical use.

[0178] [Table 1] [Explanation of symbols]

[0179] 1Y, 1M, 1C, 1K Photoconductor (an example of an image carrier) 2Y, 2M, 2C, 2K Charging roll (an example of a charging means) 3 Exposure device (an example of an electrostatic image forming means) 3Y, 3M, 3C, 3K laser beam 4Y, 4M, 4C, 4K developing device (an example of developing means) 5Y, 5M, 5C, 5K Primary transfer roll (an example of a primary transfer means) 6Y, 6M, 6C, 6K Photoconductor cleaning device (an example of a cleaning means) 8Y, 8M, 8C, 8K toner cartridges 10Y, 10M, 10C, 10K Image forming units 20 Intermediate transfer belt (an example of an intermediate transfer body) 22 Driving Roll 24 Support roll 26 Secondary transfer roll (an example of a secondary transfer means) 28 Fixing device (an example of fixing means) 30 Intermediate transfer body cleaning device P Recording paper (an example of a recording medium) 107 Photoconductor (an example of an image carrier) 108 Charging roll (an example of charging means) 109 Exposure device (an example of electrostatic image forming means) 111 Developing device (an example of developing means) 112 Transfer device (an example of a transfer means) 113 Photoconductor cleaning device (an example of a cleaning means) 115 Fixing device (an example of fixing means) 116 Mounting Rail 117 Cabinet 118 Exposure Aperture 200 Process Cartridge 300 Recording paper (an example of a recording medium)

Claims

1. The toner particles include a binder resin and a release agent, The toner particles satisfy the following requirements (1) and (B) in cross-sectional observation: Toner for developing electrostatic images. Requirement (1): Seven or more domains of the release agent having a major axis of 500 nm or more and 1000 nm or less exist per toner particle on average. Requirement (B): The area ratio of release agent domains having a major axis of 50 nm or more is 3% or more and 10% or less on average.

2. The toner for developing electrostatic images according to claim 1 , further satisfying the following requirement (A) in cross-sectional observation of the toner particle: Requirement (A): The distance between domains of the release agent having a major axis of 50 nm or more is 200 nm or more on average.

3. The toner for developing electrostatic images according to claim 1 or 2, further satisfying the following requirement (3) in cross-sectional observation of the toner particle: Requirement (3): The proportion of toner particles having 10 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less is 30% or more by number.

4. The toner for developing electrostatic images according to claim 3, further satisfying the following requirement (3') in cross-sectional observation of the toner particle: Requirement (3'): The proportion of toner particles having 10 or more release agent domains each having a major axis of 500 nm or more and 1000 nm or less is 50% or more by number.

5. 5. The toner for developing electrostatic images according to claim 1, wherein the release agent has a melting temperature of 80° C. or higher and 95° C. or lower.

6. 6. An electrostatic image developer comprising the toner for developing electrostatic images according to claim 1.

7. 6. A toner cartridge which contains the toner for developing electrostatic images according to claim 1 and is detachably mountable to an image forming apparatus.

8. a developing unit that contains the electrostatic image developer according to claim 6 and develops an electrostatic image formed on a surface of an image carrier into a toner image by using the electrostatic image developer, A process cartridge that is detachably attached to an image forming apparatus.

9. An image carrier; a charging means for charging the surface of the image carrier; an electrostatic image forming means for forming an electrostatic image on the charged surface of the image carrier; a developing unit that contains the electrostatic image developer according to claim 6 and develops the electrostatic image formed on the surface of the image carrier into a toner image by the electrostatic image developer; a transfer means for transferring the toner image formed on the surface of the image carrier to a surface of a recording medium; a fixing means for fixing the toner image transferred onto the surface of the recording medium; An image forming apparatus comprising:

10. a charging step of charging the surface of the image carrier; an electrostatic image forming step of forming an electrostatic image on the charged surface of the image carrier; a developing step of developing the electrostatic image formed on the surface of the image carrier into a toner image by using the electrostatic image developer according to claim 6; a transfer step of transferring the toner image formed on the surface of the image carrier onto a surface of a recording medium; a fixing step of fixing the toner image transferred onto the surface of the recording medium; The image forming method according to claim 1,

Images