JP2008070598A - Carrier and method for manufacturing the same, developer, process cartridge, image forming apparatus, and image forming method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method capable of manufacturing a stable carrier by which carrier coat particles having a coating layer of a structure having no boundaries in the coating layer, and having a gentle concentration gradient can be obtained, durability is high, toner splashing and background contamination do not occur, the image of high image concentration can be formed, the degradation in electrostatic charging characteristics dose not occur in spite of wear of the carrier coating layer. <P>SOLUTION: In the method for manufacturing the carrier, the solubility of a solution dissolved with a material for coating composed of a plurality of kinds is decreased by controlling any one of the pressure and temperature in a fluid including any one of a supercritical fluid and a subcritical fluid, thereby forming the coating layer on the core material surface. The embodiment that the coating on the core material surface is performed under conditions under which the material for coating consisting of the plurality of the kinds coexist and the embodiment in which any one of the supercritical fluid and the subcritical fluid, and the like is carbon dioxide are preferable. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention uses a carrier for developing an electrostatic latent image suitably used for electrophotography, electrostatic recording method, electrostatic printing method and the like, a production method thereof, a developer using the carrier, and the developer. The present invention relates to a process cartridge, an image forming apparatus, and an image forming method.

  The dry development method used in electrophotography forms a visible image by electrostatically attaching toner rubbed with a charging member to an electrostatic latent image. In such a dry development method, a one-component development method mainly composed of toner, a glass bead, a magnetic carrier, or a carrier whose surface is coated with a resin and a toner are mixed and used. There is a component development system.

  The developer used in the two-component development system holds a small toner on the surface of a relatively large core material by an electric force generated by friction between the two, and this developer is brought close to the electrostatic latent image. Then, the toner overcomes the binding force with the core material by the electric field formed by the electrostatic latent image, and is developed on the electrostatic latent image. The developer is repeatedly used while replenishing the toner consumed by the development. For this reason, the core material must always be triboelectrically charged with a desired polarity and a sufficient charge amount during long-time use. However, collision between the particles, mechanical stirring in the particles and the developing device, or heat generated by them generates a so-called spent toner in which the toner is fused to the surface of the core material, and the charging characteristics of the core material decrease with use time. To do. As a result, the background of the image and toner scattering occur, so that the entire developer needs to be replaced.

  In order to prevent such spending, the life of the carrier is extended by coating the surface of the core material with a resin having a low surface energy, such as a fluororesin or a silicone resin. For example, a carrier coated with a room temperature curable silicone resin and a positively chargeable nitrogen resin (see Patent Document 1), a carrier coated with a coating material containing at least one modified silicone resin (see Patent Document 2), a room temperature curable silicone A carrier having a coating layer containing a resin and a styrene-acrylic resin (see Patent Document 3), a carrier in which the core particle surface is coated with two or more layers of silicone resin so that there is no adhesion between the layers (see Patent Document 4) ), A carrier in which silicone resin is applied in multiple layers on the core particle surface (see Patent Document 5), a carrier whose surface is coated with a silicon resin containing silicon carbide (see Patent Document 6), and exhibits a critical surface tension of 20 dyn / cm or less. A positively chargeable carrier coated with a material (see Patent Document 7), coated with a coating material containing a fluorine alkyl acrylate And Yaria, developer comprising a toner containing a containing chromium azo dye (see Patent Document 8), and the like.

  Recently, in order to improve image quality, the toner tends to have a smaller particle size, and as a result, toner spent on the carrier is likely to occur. In addition, in conventional spray coating, it is difficult to uniformly wet the carrier surface with a coating material, and therefore it is difficult to produce a carrier having a coating film and a core material with a uniform film thickness and film quality. It is. Furthermore, in the case of a full-color toner, a resin having a low softening point is used to obtain a sufficient color tone, so that the spent amount to the carrier is increased compared to the black toner, and the toner charge amount is reduced. Toner scattering and background contamination occur. As described above, in the full-color electrophotographic system, when the toner charge amount is lowered, there is a problem that the image density particularly in the highlight portion is easily changed and the high image quality cannot be maintained.

  In order to improve the durability of the carrier, it is proposed to provide a coating layer in which fine particles and conductivity-imparting materials are dispersed in a resin matrix of low surface energy substances to control the spent resistance, film strength, and electrical characteristics. (See Patent Documents 9 to 11). However, in these proposals, since the dispersion liquid in which the fine particles are added to the organic solvent is spray-coated at a high temperature, there is a problem that it is difficult to make the charge amount uniform due to aggregation of the fine particles.

Conventional spray coating also has manufacturing problems such as regulation of volatile organic compounds (VOC) by organic solvents used when forming a coating layer on the surface of the core material, generation of waste liquid, and the need for drying energy. Yes.
For these problems, for example, a carrier particle production method using a supercritical fluid has been proposed as a carrier production method using a dry powder process that does not use an organic solvent (see Patent Document 12). However, this proposal is to melt and coat a coating resin polymerized in a supercritical fluid in a heated state, and since the resin material is an acrylic resin, the above-mentioned problem of spent has not been solved.

  In order to improve the durability of the carrier, the silane coupling agent in the coating layer has a concentration gradient as a stable carrier with no deterioration in charging characteristics even when the carrier coating layer is worn during continuous use. A carrier having a laminated structure has been proposed (see Patent Document 13). However, since it is necessary to dissolve silane coupling agents having different concentrations in an organic solvent and sequentially perform spray coating, an interface is generated in the coating. There is a problem that film scraping is easily deteriorated and it is difficult to control the laminated structure.

  Accordingly, carrier-coated particles having a coating layer having a structure having a gentle density gradient without an interface in the coating layer can be obtained, and the durability is high, there is no scattering of toner and background contamination, and an image with a high image density is obtained. There is no sufficiently satisfactory carrier manufacturing method and related technology that can be formed and can produce a stable carrier that does not deteriorate charging characteristics even when the carrier coating layer is worn during continuous use. Furthermore, from the viewpoint of global environmental load and resource saving, there are many problems to be improved in the conventional carrier manufacturing method and carrier.

Japanese Patent Laid-Open No. 55-127469 Japanese Patent Laid-Open No. 55-157751 JP-A-56-140358 JP-A-57-96355 JP 57-96356 A JP 58-207054 A JP-A-61-1110161 JP-A-62-273576 JP-A-9-319161 JP-A-9-269614 Japanese Patent Laid-Open No. 10-186731 US Pat. No. 5,514,512 Japanese Patent No. 328649

  An object of the present invention is to solve various problems in the prior art and achieve the following objects. That is, the present invention can provide carrier-coated particles having a coating layer having a structure having a gentle concentration gradient without an interface in the coating layer, has high durability, is free from toner scattering and scumming, and has a high image quality. A carrier manufacturing method capable of forming an image having a density and capable of manufacturing a stable carrier without deterioration in charging characteristics even when the carrier coating layer is worn during continuous use, and a carrier manufactured using the manufacturing method, Another object of the present invention is to provide a developer capable of forming an image with a high image density without toner scattering and background contamination using the carrier, a process cartridge, an image forming apparatus, and an image forming method using the developer. To do.

Means for solving the problems are as follows. That is,
<1> In a fluid containing at least one of a supercritical fluid and a subcritical fluid, the solubility of a liquid in which a plurality of coating materials are dissolved is controlled by controlling at least one of pressure and temperature. Thus, a carrier manufacturing method is characterized in that a coating layer is formed on the surface of a core material.
<2> The method for producing a carrier according to <1>, wherein the coating material is coated on the surface of the core under a condition in which a plurality of coating materials coexist.
<3> The carrier production method according to any one of <1> to <2>, wherein either the supercritical fluid or the subcritical fluid is carbon dioxide.
<4> The carrier manufacturing method according to any one of <1> to <3>, wherein the coating material is made of 3 to 5 types of materials.
<5> The carrier manufacturing method according to any one of <1> to <4>, wherein the coating material is formed of five kinds of materials.
<6> The carrier production method according to any one of <1> to <5>, wherein the coating material is made of materials having different solubility in a supercritical fluid and a subcritical fluid.
<7> The carrier production method according to any one of <1> to <6>, wherein the coating material is made of a material having a different number of functional groups.
<8> The carrier production method according to any one of <1> to <7>, wherein the coating material has a silicone resin represented by the following structural formula (i) as a main skeleton.
However, in the structural formula (i), R represents a hydrogen atom, a hydroxyl group, an alkoxy group, an alkyl group, an aryl group, or an amino group.
<9> The carrier production method according to any one of <1> to <8>, wherein the coating material has an amino-modified silicone resin as a main skeleton.
<10> The method for producing a carrier according to <9>, wherein the coating material is made of a resin having a different amino modification rate.
<11> The method for producing a carrier according to any one of <8> to <10>, wherein the silicone resin has a mass average molecular weight (Mw) of 500 to 100,000.

<12> A carrier manufactured by the method for manufacturing a carrier according to any one of <1> to <11>.
<13> A developer comprising the carrier according to <12> and a toner.

<14> An electrostatic latent image carrier, and a developing unit that develops the electrostatic latent image formed on the electrostatic latent image carrier using the developer according to <13> to form a visible image. Is a process cartridge characterized by having at least.
<15> An electrostatic latent image carrier, an electrostatic latent image forming unit that forms an electrostatic latent image on the electrostatic latent image carrier, and the developer described in <13> above At least developing means for forming a visible image by developing the toner, transfer means for transferring the visible image to a recording medium, and fixing means for fixing the transferred image transferred to the recording medium. An image forming apparatus.
<16> An electrostatic latent image forming step of forming an electrostatic latent image on the electrostatic latent image carrier, and developing the electrostatic latent image using the developer described in <13> to form a visible image The image forming method includes at least a developing step for forming the image, a transfer step for transferring the visible image to a recording medium, and a fixing step for fixing the transferred image transferred to the recording medium.

  In the carrier production method of the present invention, a liquid in which a coating material composed of a plurality of types is dissolved in a fluid containing one of a supercritical fluid and a subcritical fluid, by controlling either pressure or temperature. Since the coating layer is formed on the surface of the core material by reducing the solubility, the surface of the core material can be sequentially and selectively coated under the conditions in which the above-mentioned multiple types of coating materials coexist, and there is no interface in the coating layer. Carrier coated particles with a coating layer with a gradual density gradient can be obtained, high durability, no toner scattering and dirt, high image density images can be formed, and carrier coating during continuous use Stable carrier that does not deteriorate charging characteristics even when the layer wears out, can meet volatile organic compound (VOC) regulations, does not generate waste liquid, requires almost no drying energy, and can be manufactured efficiently .

  The developer of the present invention includes the carrier of the present invention and a toner. By using the developer, it is possible to form an image with a high image density without toner scattering and background contamination.

  The process cartridge of the present invention comprises an electrostatic latent image carrier and developing means for developing a latent image formed on the electrostatic latent image carrier using the developer of the present invention to form a visible image. And at least. As a result, it can be attached to and detached from the image forming apparatus, is excellent in convenience, and uses the developer of the present invention, so it has high mechanical strength, no toner scattering and no background stain, and high image density and high density. A sharp high quality image can be obtained.

  The image forming apparatus of the present invention includes at least an electrostatic latent image carrier, an electrostatic latent image forming unit, a developing unit, a transfer unit, and a fixing unit. In the image forming apparatus of the present invention, the electrostatic latent image forming unit forms an electrostatic latent image on the electrostatic latent image carrier. The developing means develops the electrostatic latent image using the developer of the present invention to form a visible image. The transfer means transfers the visible image to a recording medium. The fixing unit fixes the transferred image transferred to the recording medium. As a result, it is possible to obtain a high-quality image with high mechanical strength, high toner density, and high sharpness without toner scattering and background contamination.

  The image forming method of the present invention includes at least an electrostatic latent image forming step, a developing step, a transfer step, and a fixing step. In the image forming method of the present invention, an electrostatic latent image is formed on the electrostatic latent image carrier in the electrostatic latent image forming step. In the developing step, the electrostatic latent image is developed using the developer of the present invention to form a visible image. In the transfer step, the visible image is transferred to a recording medium. In the fixing step, the transferred image transferred to the recording medium is fixed. As a result, it is possible to obtain a high-quality image with high mechanical strength, high toner density, and high sharpness without toner scattering and background contamination.

According to the present invention, conventional problems can be solved, carrier-coated particles having a coating layer having a structure having a gentle concentration gradient without an interface in the coating layer, and having high durability, A carrier production method capable of producing a stable carrier free of toner scattering and background contamination, capable of forming an image with a high image density, and capable of producing a stable carrier with no deterioration in charging characteristics even when the carrier coating layer is worn during continuous use; and Carrier manufactured using the manufacturing method, developer using the carrier without toner scattering and background contamination, and capable of forming an image with high image density, process cartridge, image forming apparatus using the developer, and An image forming method can be provided.
In addition, the volatile organic compound (VOC) regulations can be cleared, no waste liquid is generated, almost no drying energy is required, and the carrier can be produced efficiently.

(Carrier manufacturing method and carrier)
In the carrier production method of the present invention, a liquid in which a coating material composed of a plurality of types is dissolved in a fluid containing one of a supercritical fluid and a subcritical fluid, by controlling either pressure or temperature. The solubility is lowered to form a coating layer on the surface of the core material.
The carrier of the present invention is produced by the method for producing a carrier of the present invention.
Hereinafter, the details of the carrier of the present invention will be clarified through the description of the method for producing the carrier of the present invention.

  The method for reducing the solubility of the liquid in which the coating material is dissolved by controlling either the pressure or the temperature is not particularly limited. For example, as described later, the coating material is dissolved. The method of returning a liquid to a normal pressure etc. are mentioned.

-Supercritical fluid and subcritical fluid-
The supercritical fluid has an intermediate property between gas and liquid, and has such properties as mass transfer and heat transfer (like liquid) and low viscosity (like gas), and temperature and pressure. It means a fluid whose density, dielectric constant, solubility parameter, free volume, etc. can be changed continuously and greatly by changing it. Furthermore, since the supercritical fluid has an extremely small interfacial tension as compared with an organic solvent, even a minute undulation (surface) can follow and can be wetted (contacted with the supercritical fluid).

  The supercritical fluid exists as a non-condensable high-density fluid in a temperature and pressure range that exceeds the limit (critical point) where gas and liquid can coexist, does not cause condensation even when compressed, and exceeds the critical temperature. And, as long as it is a fluid in a state of a critical pressure or higher, it can be used without any particular limitation.In the present invention, it can be appropriately selected according to the purpose, but those having a low critical temperature and critical pressure are preferred, The subcritical fluid can be used without particular limitation as long as it exists as a high-pressure liquid in the temperature and pressure regions near the critical point, and can be appropriately selected according to the purpose in the present invention.

Examples of the supercritical fluid or subcritical fluid include carbon monoxide, carbon dioxide, ammonia, nitrogen, water, methanol, ethanol, ethane, propane, 2,3-dimethylbutane, benzene, chlorotrifluoromethane, and dimethyl ether. Is mentioned. Among these, carbon dioxide can easily be in a supercritical state with a critical pressure of 7.3 MPa and a critical temperature of 31 ° C., and is nonflammable and highly safe, and since it is a non-aqueous solvent, a carrier with a hydrophobic surface can be obtained. In addition, since it is gasified simply by returning to normal pressure (releasing the pressure), it can be easily recovered and reused. The obtained carrier does not need to be dried, and since it does not generate waste liquid, it is friendly to the global environment. preferable.
The supercritical fluid or the subcritical fluid may be used alone or as a mixture of two or more. When two or more kinds are used in combination, it is only necessary to hold a supercritical fluid or a subcritical fluid.

The critical temperature and critical pressure of the supercritical fluid are not particularly limited and may be appropriately selected depending on the intended purpose. However, the critical temperature is preferably −273 to 300 ° C., more preferably 0 to 200 ° C. preferable. The lower the critical pressure, the more advantageous, for example, in terms of apparatus load, equipment cost, operating energy, etc., but in practice, 1-100 MPa is preferable, and 1-50 MPa is more preferable.
In the present invention, the coating layer can be formed on the surface of the core material by positively utilizing the properties of the supercritical fluid or the subcritical fluid.
Furthermore, fine particles of an inorganic substance can be uniformly present in the coating layer.
In addition, since the supercritical fluid can be easily separated from the target product and can be recovered and reused, it is possible to realize an innovative carrier production method with low environmental load that does not use conventional water or organic solvents.

In addition to the supercritical fluid or the subcritical fluid, other fluids can be used in combination. Such other fluid is preferably one that can easily control the solubility of the coating resin. Specifically, methane, ethane, propane, ethylene, and the like are preferable.
In addition to the supercritical fluid or the subcritical fluid, an entrainer (azeotropic agent) may be added. By adding this entrainer, the solubility of the coating resin can be improved. There is no restriction | limiting in particular as said entrainer, Although it can select suitably according to the objective, A polar organic solvent is preferable. Examples of the polar organic solvent include methanol, ethanol, propanol, butanol, hexane, toluene, ethyl acetate, chloroform, dichloromethane, ammonia, melamine, urea, thioethylene glycol, and the like. Among these, lower alcohol solvents having 1 to 6 carbon atoms (preferably 1 to 4 carbon atoms) exhibiting poor solvent properties at normal temperature and normal pressure are suitable.

<Coating layer>
The coating layer contains at least a coating material, and further contains other components as necessary. The coating layer is made of a plurality of types of coating materials, and materials having different solubilities in the supercritical fluid and subcritical fluid are used.
The coating material is preferably composed of 3 to 5 types of materials from the viewpoint of obtaining a sharp image with a higher image density and more effectively preventing toner scattering and soiling. From the viewpoint of obtaining a sharp image, it is more preferable to use five materials.

−Coating material−
The coating material (hereinafter sometimes referred to as “coating resin”) is not particularly limited and may be appropriately selected from known resins according to the purpose. , Polyvinyl resin, polystyrene resin, halogenated olefin resin, polyester resin, polycarbonate resin, polyethylene resin, polyvinyl fluoride resin, polyvinylidene fluoride resin, polytrifluoroethylene resin, polyhexafluoropropylene resin, vinylidene fluoride Copolymers of acrylic monomers with acrylic monomers, copolymers of vinylidene fluoride and vinyl fluoride, terpolymers of tetrafluoroethylene, vinylidene fluoride and non-fluorinated monomers (fluorinated) Triple (multi) copolymer), silicone resin and the like. These may be used individually by 1 type and may use 2 or more types together. Among these, a silicone resin is particularly preferable because of its high effect. The coating resin is preferable because the solubility in the supercritical fluid and subcritical fluid can be changed by changing the number of functional groups as necessary. The number of functional groups is not particularly limited and can be appropriately selected depending on the purpose.

There is no restriction | limiting in particular as said silicone resin, Although it can select suitably according to the objective from generally known silicone resins, For example, the straight silicone resin represented by following Structural formula (i) Is preferred.

In the structural formula (i), R represents a hydrogen atom, a hydroxyl group, an alkoxy group, an alkyl group, an aryl group, or an amino group.
Examples of the alkoxy group include a methoxy group and an ethoxy group. Examples of the alkyl group include a methyl group, an ethyl group, and a propyl group. Examples of the aryl group include a phenyl group, a tolyl group, and a xylyl group.
Examples of the amino group include an aminopropyl group, an iminopropyl group, and an aminophenoxymethyl group.

The mass average molecular weight (Mw) of the silicone resin is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 500 to 100,000, and more preferably 1,000 to 10,000.
Here, the mass average molecular weight of the silicone resin can be measured by the following method.
Gel permeation chromatography (GPC) measuring device: GPC-8220 GPC (manufactured by Tosoh Corporation)
Column: TSKgel SuperHZM-H 15cm triple (made by Tosoh Corporation)
Temperature: 40 ° C
Solvent: tetrahydrofuran (THF)
Flow rate: 0.35 ml / min
Sample: 0.4 ml of 0.15 mass% sample was injected Sample pretreatment: The toner was dissolved in tetrahydrofuran (THF: Wako Pure Chemical Industries, Ltd.) in 0.15 mass%, and the filtrate was filtered through a 0.2 μm filter. Used as a sample solution.
100 μl of the sample solution is injected and measured. When measuring the molecular weight of a sample, the molecular weight distribution of the sample is calculated from the relationship between the logarithmic value of a calibration curve prepared from several types of monodisperse polystyrene standard samples and the number of counts (that is, the molecular weight calculated in terms of polystyrene). . As a standard polystyrene sample for preparing a calibration curve, Showd STANDARD Std. No. S-7300, S-210, S-390, S-875, S-1980, S-10.9, S-629, S-3.0, and S-0.580 toluene were used. An RI (refractive index) detector was used as the detector.

Further, the silicone resin as the coating resin is preferably a solid at 25 ° C. and normal pressure from the viewpoint of superior handling property, film formability, and film thickness controllability than liquid. Here, the normal pressure refers to a pressure in a standard state, and is 0.1 MPa in the present invention.
The silanol concentration of the silicone resin is preferably 1 to 40% by mass, more preferably 1 to 20% by mass, and still more preferably 1 to 10% by mass for crosslinking after film formation. When the silanol concentration exceeds 40% by mass, the crosslinked film tends to be hard and brittle, the durability is deteriorated, and unreacted silanol groups remain, so that the environmental stability of the carrier may be deteriorated. On the other hand, when the silanol concentration is less than 1% by mass, the coating performance as a coating resin may be inferior.

As said silicone resin, what was synthesize | combined suitably may be used and a commercial item may be used. As this commercial item, as a straight silicone resin, KR271, KR255, KR220L, KR152 manufactured by Shin-Etsu Chemical Co., Ltd .; SR2400, SR2406, SR2410, SR213, 217 Flakes Resin, 220 Flakes Resin, 233 manufactured by Toray Dow Corning Flakes Resin, 249 Flakes Resin, Z-6018 Intermediate, and the like.
Further, as the silicone resin, a modified silicone resin can be used. For example, KR206 (alkyd modified), KR5208 (acrylic modified), ES1001N (epoxy modified), KR305 (urethane modified) manufactured by Shin-Etsu Chemical Co., Ltd .; SR2115 (epoxy-modified), SR2110 (alkyd-modified), SF8417, BY16-850, BY16-872 (amino-modified) manufactured by Dow Corning and the like can be mentioned.

In addition, although the said silicone resin can also be used alone, it is also possible to use simultaneously the component which carries out a crosslinking reaction, or a charge amount adjustment component. Examples of the component that undergoes the crosslinking reaction include a silane coupling agent. Examples of the silane coupling agent include methyltrimethoxysilane, methyltriethoxysilane, octyltrimethoxysilane, aminosilane coupling agent and the like.
As said aminosilane coupling agent, what is represented by a following formula is suitable. 0.001-30 mass% is preferable and, as for content of this aminosilane coupling agent, 0.001-15 mass% is more preferable. By containing an aminosilane coupling agent in the coating layer, the stability of the carrier over time is improved and the durability is improved.

-Fine particles-
Fine particles can be added to the coating layer as necessary. The fine particles are not particularly limited and can be appropriately selected from those known as two-component carriers for electrophotography according to the purpose. For example, inorganic fine particles such as metal powders and various metal oxide particles are preferable. Used. Among these, metal oxide particles such as silicon oxide, titanium oxide, and alumina can easily obtain particles having a uniform fine particle diameter, and various electrical characteristics and mechanical strength can be obtained depending on the particles used. it can. It is also important that the fine particles are thermally stable even when the carrier is heated to a high temperature during the condensation curing of the silicone resin.

Further, the coating layer for the purpose of the electrical resistance adjusting to, conductive ZnO, metal powder such as Al, SnO ₂ doped with various SnO ₂ or various elements manufactured by the method; borides (e.g. _TLB 2, ZnB 2, _{MoB 2);} silicon carbide, conductive polymers (e.g. polyacetylene, polyparaphenylene, poly (para - phenylene sulfide), polypyrrole, parylene, etc.), may contain fine particles such as carbon black.
The amount of the fine particles added is preferably 1 to 100 parts by mass and more preferably 1 to 70 parts by mass with respect to 100 parts by mass of the coating resin.

The most suitable silicone resin for the coating layer has a high electric resistance, and is generally known to have a high resistance. Therefore, it is preferable that at least one type of particles having a volume resistance of 10 ⁻⁶ Ωcm or less is used as the resistance adjusting agent for resistance in the coating layer. It is important that such conductive fine particles have a sufficiently small particle size with respect to the coating layer and can be uniformly dispersed in the coating layer. For this reason, it is not preferable to disturb the uneven shape of the coating layer by introducing these conductive fine particles. In order to achieve the effects expected from the coating layer configuration to uniform chargeability, toner retention and developability. is important. Examples of materials that satisfy these conditions include conductively treated metal oxide fine particles and carbon black.

  In addition, when an extremely low-resistance substance such as carbon black is dispersed in the coating layer, the electrical characteristics of the coating layer are sensitively changed with respect to the carbon black content, and thus handling thereof is necessary. For example, it is difficult to handle, such as non-uniformity in electrical resistance between carriers, and difficulty in stabilizing the characteristics of carriers obtained in response to slight process variations in the manufacturing process. This can be avoided by accurate control of the carbon black content and uniform dispersibility in the coating layer, but the electrical resistance control material contained in the coating layer is made of conductive carbon particles and non-conductive metal oxide. These fine particles may be mixed and used.

−Core material−
There is no restriction | limiting in particular as said core material, According to the objective, it can select suitably from what is known as a two-component carrier for electrophotography, For example, a ferrite, magnetite, iron, nickel is mentioned suitably. In addition, in consideration of the environmental aspects that have advanced remarkably in recent years, if ferrite, for example, Mn ferrite, Mn-Mg ferrite, Mn-Mg-Sr ferrite, etc. should be used instead of conventional copper-zinc ferrite. Is preferred.
The core material preferably has a volume average particle size of 20 μm or more from the viewpoint of prevention of carrier adhesion (scattering) to the electrostatic latent image carrier, and is intended to prevent deterioration of image quality such as prevention of occurrence of carrier streaks. To 100 [mu] m or less is preferable, and in particular, a volume average particle size of 20 to 50 [mu] m is more preferable for high image quality in recent years.
Here, the volume average particle diameter of the core material can be measured, for example, using “Microtrac particle size analyzer SRA” manufactured by Nikkiso Co., Ltd., with a range setting of 0.7 to 125 μm.

  When the obtained carrier is used as a two-component developer, it is preferable that LogR of the measured electric resistance is 7 to 16 Ω · cm. The electrical resistance can be appropriately selected according to the development process using a carrier, and when the LogR is less than 7 Ω · cm, the rising shape of the carrier brush (magnetic brush) held on the developer carrying member Becomes darker and becomes more conspicuous, and if LogR exceeds 16 Ω · cm, the density difference between the edge part and the solid part of the image or the density difference between the line image and the solid image may occur. In some cases, problems such as a decrease in developing ability due to charge-up and carrier development (carrier adhesion) on a non-image portion of a latent image may occur.

  Here, the electric resistance of the carrier is, for example, a value obtained from a current value and an applied voltage when a carrier is filled between two parallel electrodes and a potential difference is provided between the electrodes. Specifically, a container having electrodes arranged in parallel at an interval of 2 mm is filled with a carrier, and a direct current resistance at a potential difference of 50 V between both electrodes is measured by a 4329A High Resistance Meter manufactured by Yokogawa Hewlett-Packard Co., Ltd.

Moreover, the thickness of the coating layer of the carrier is preferably set as appropriate so that the electric resistance falls within an appropriate range. However, since silicone has volume shrinkage during the condensation reaction, the coating layer becomes thicker as the thickness of the coating layer increases. There is a drawback that non-uniform reaction within the layer tends to occur. Therefore, the thickness of the coating layer is preferably 1.0 μm or less, and more preferably 0.02 to 0.8 μm.
Here, the thickness of the coating layer can be measured by observing the cross section of the carrier using, for example, a transmission electron microscope (TEM).

  The carrier manufacturing apparatus is not particularly limited and may be appropriately selected depending on the intended purpose. For example, at least a pressure-resistant container for dissolving or dispersing the coating resin and an additive for supplying the supercritical fluid may be used. A device including a pressure pump is preferably exemplified. As a treatment method using the apparatus, first, at least a coating resin is charged in the pressure vessel, the supercritical fluid is supplied into the pressure vessel by a pressure pump, and the supercritical fluid is supplied to the coating resin. A contact layer is formed on the surface of the core material by contact. When the supercritical fluid is returned to normal temperature and normal pressure, the supercritical fluid becomes a gas, so that removal of the solvent is unnecessary and waste water generated by washing is unnecessary, reducing the environmental load. The

The conditions at the time of injecting the fine particles or the precursor thereof into the coating layer on the surface of the core material are not particularly limited as long as the conditions are equal to or higher than the critical pressure of the supercritical fluid or the subcritical fluid to be used. Although it can be selected, the pressure is preferably 1 to 60 MPa.
The pressure for forming the coating layer on the surface of the core material is not particularly limited as long as it is equal to or higher than the critical pressure of the supercritical fluid or the subcritical fluid to be used, and can be appropriately selected according to the purpose. However, 1-60 MPa is preferable and 5-40 MPa is more preferable.
The temperature at which the coating layer is formed on the surface of the core material is not particularly limited as long as it is equal to or higher than the critical temperature of the supercritical fluid or subcritical fluid to be used, and can be appropriately selected according to the purpose. For example, when carbon dioxide is used, 35 to 90 ° C. is preferable.

In the carrier manufacturing method of the present invention, for example, a coating layer can be formed on the surface of the core material using the apparatus shown in FIG.
More specifically, referring to FIG. 1, a coating resin and a core material are charged into a carrier processing tank, the valve 3 is opened while stirring, and carbon dioxide is supplied by a pressure pump 1 to 25 MPa and 40 ° C. After that, the valve 3 is closed. After maintaining the inside of the carrier treatment tank at 25 MPa and 80 ° C. for 2 hours, the valves 5 and 6 are opened, and the pressure is reduced to normal pressure by the vacuum pump 1 over 2 hours. Furthermore, the carrier treatment tank can be heat-treated at 160 ° C. for 2 hours to produce a carrier. Moreover, after supplying an entrainer (azeotropic agent) with a pressure pump from an entrainer tank as needed, you may close the valve | bulb 2 and the valve | bulb 4. FIG.

(Developer)
The developer of the present invention is a two-component developer containing the carrier of the present invention and a toner.
The mixing ratio of the toner and the carrier in the developer is preferably 1.0 to 10.0 parts by mass of the toner with respect to 100 parts by mass of the carrier.
The toner includes at least a binder resin and a colorant, and further includes a release agent, a charge control agent, and other components as necessary.

<Toner>
The method for producing the toner is not particularly limited and may be appropriately selected depending on the intended purpose. It is a pulverization method, a suspension in which an oil phase is emulsified, suspended or aggregated in an aqueous medium to form toner base particles. There are a polymerization method, an emulsion polymerization method, a polymer suspension method, and the like. Among these, a pulverization method is particularly preferable.

-Binder resin-
The binder resin is not particularly limited and may be appropriately selected from known ones according to the purpose. For example, styrene such as polystyrene, poly-p-styrene, polyvinyltoluene, or a homopolymer of a substituted product thereof. Styrene-p-chlorostyrene copolymer, styrene-propylene copolymer, styrene-vinyltoluene copolymer, styrene-methyl acrylate copolymer, styrene-ethyl acrylate copolymer, styrene-methacrylic acid copolymer Polymerization unit, styrene-methyl methacrylate copolymer, styrene-ethyl methacrylate copolymer, styrene-butyl methacrylate copolymer, styrene-α-chloromethyl methacrylate copolymer, styrene-acrylonitrile copolymer Polymer, styrene-vinyl methyl ether copolymer, styrene-vinyl methyl ketone Copolymer, styrene-butadiene copolymer, styrene-isopropyl copolymer, styrene-copolymer such as styrene-maleic ester copolymer, polythyme methacrylate resin, polybutyl methacrylate resin, polyvinyl chloride resin , Polyvinyl acetate resin, polyethylene resin, polyester resin, polyurethane resin, epoxy resin, polyvinyl butyral resin, polyacrylic acid resin, rosin resin, modified rosin resin, terpene resin, phenol resin, aliphatic or aromatic hydrocarbon resin, aromatic Family petroleum resin. These may be used individually by 1 type and may use 2 or more types together.

-Colorant-
The colorant is not particularly limited and may be appropriately selected from known dyes and pigments according to the purpose. For example, carbon black, nigrosine dye, iron black, naphthol yellow S, Hansa yellow (10G, 5G, G), cadmium yellow, yellow iron oxide, ocher, yellow lead, titanium yellow, polyazo yellow, oil yellow, Hansa yellow (GR, A, RN, R), pigment yellow L, benzidine yellow (G, GR), Permanent Yellow (NCG), Vulcan Fast Yellow (5G, R), Tartrazine Lake, Quinoline Yellow Lake, Anthrazan Yellow BGL, Isoindolinone Yellow, Bengala, Lead Red, Lead Red, Cadmium Red, Cad Muum Mercury Red, Antimon Zhu, Permanent Red 4R, PA Red, Faise Red, Parachlor Ortho Nitroaniline Red, Resol Fast Scarlet G, Brilliant Fast Scarlet, Brilliant Carmine BS, Permanent Red (F2R, F4R, FRL, FRLL, F4RH), Fast Scarlet VD, Belkan Fast Rubin B, Brilliant Scarlet G, Risor Rubin GX, Permanent Red F5R, Brilliant Carmine 6B, Pogment Scarlet 3B, Bordeaux 5B, Toluidine Maroon, Permanent Bordeaux F2K, Helio Bordeaux BL, Bordeaux 10B, Bon Maroon Light, Bon Maroon Medium, Eosin Lake, Rhodamine Lake B, Rhodamine Lake Y, Alizarin Lake, Thioindigo Red B, Thioindigo Maroon, Oh Lured, Quinacridone Red, Pyrazolone Red, Polyazo Red, Chrome Vermilion, Benzidine Orange, Perinone Orange, Oil Orange, Cobalt Blue, Cerulean Blue, Alkaline Blue Lake, Peacock Blue Lake, Victoria Blue Lake, Metal Free Phthalocyanine Blue, Phthalocyanine Blue, Fast Sky Blue, Indanthrene Blue (RS, BC), Indigo, Ultramarine Blue, Bitumen, Anthraquinone Blue, Fast Violet B, Methyl Violet Lake, Cobalt Purple, Manganese Purple, Dioxane Violet, Anthraquinone Violet, Chrome Green, Zinc Green, Oxidation Chrome, Pyridian, Emerald Green, Pigment Green B, Naphthol Green B, Green Gold, Ash Examples include degreen lake, malachite green lake, phthalocyanine green, anthraquinone green, titanium oxide, zinc white, and litbon. These may be used individually by 1 type and may use 2 or more types together.
The content of the colorant in the toner is preferably 1 to 15% by mass, and more preferably 3 to 10% by mass.

  The colorant may be used as a master batch combined with a resin. The resin is not particularly limited and may be appropriately selected from known ones according to the purpose. For example, styrene or a substituted polymer thereof, styrene copolymer, polymethyl methacrylate resin, polybutyl Methacrylate resin, polyvinyl chloride resin, polyvinyl acetate resin, polyethylene resin, polypropylene resin, polyester resin, epoxy resin, epoxy polyol resin, polyurethane, polyamide, polyvinyl butyral, polyacrylic acid resin, rosin, modified rosin, terpene resin, fat Aromatic hydrocarbon resin, alicyclic hydrocarbon resin, aromatic petroleum resin, chlorinated paraffin, paraffin and the like. These may be used individually by 1 type and may use 2 or more types together.

-Release agent-
There is no restriction | limiting in particular as said mold release agent, According to the objective, it can select suitably from well-known things, For example, waxes etc. are mentioned suitably.
Examples of the waxes include carbonyl group-containing waxes, polyolefin waxes, and long-chain hydrocarbons. These may be used individually by 1 type and may use 2 or more types together. Among these, a carbonyl group-containing wax is preferable.
Examples of the carbonyl group-containing wax include polyalkanoic acid esters, polyalkanol esters, polyalkanoic acid amides, polyalkylamides, dialkyl ketones, and the like. Examples of the polyalkanoic acid ester include carnauba wax, montan wax, trimethylolpropane tribehenate, pentaerythritol tetrabehenate, pentaerythritol diacetate dibehenate, glycerin tribehenate, and 1,18-octadecane. Examples thereof include diol distearate. Examples of the polyalkanol ester include tristearyl trimellitic acid and distearyl maleate. Examples of the polyalkanoic acid amide include dibehenyl amide. Examples of the polyalkylamide include trimellitic acid tristearylamide. Examples of the dialkyl ketone include distearyl ketone. Of these carbonyl group-containing waxes, polyalkanoic acid esters are particularly preferred.
Examples of the polyolefin wax include polyethylene wax and polypropylene wax.
Examples of the long chain hydrocarbon include paraffin wax and sazol wax.

There is no restriction | limiting in particular as melting | fusing point of the said mold release agent, Although it can select suitably according to the objective, 40-160 degreeC is preferable, 50-120 degreeC is more preferable, 60-90 degreeC is especially preferable.
When the melting point is less than 40 ° C., the wax may adversely affect the heat-resistant storage stability, and when it exceeds 160 ° C., cold offset may easily occur during fixing at a low temperature.
The melt viscosity of the release agent is preferably 5 to 1000 cps, more preferably 10 to 100 cps, as a measured value at a temperature 20 ° C. higher than the melting point of the wax.
If the melt viscosity is less than 5 cps, the releasability may be lowered, and if it exceeds 1000 cps, the effect of improving hot offset resistance and low-temperature fixability may not be obtained.

There is no restriction | limiting in particular as content in the said toner of the said mold release agent, Although it can select suitably according to the objective, 1-40 mass% is preferable and 3-30 mass% is more preferable.
When the content exceeds 40% by mass, the fluidity of the toner may be deteriorated.

-Charge control agent-
The charge control agent is not particularly limited, and a positive or negative charge control agent can be appropriately selected and used depending on whether the charge charged on the photoconductor is positive or negative.
As the negative charge control agent, for example, a resin or compound having an electron donating functional group, an azo dye, a metal complex of an organic acid, or the like can be used. Specifically, Bontron (product numbers: S-31, S-32, S-34, S-36, S-37, S-39, S-40, S-44, E-81, E-82, E -84, E-86, E-88, A, 1-A, 2-A, 3-A) (all manufactured by Orient Chemical Industry Co., Ltd.), Kaya Charge (product numbers: N-1, N-2), Kaya Set Black (Part No .: T-2, 004) (all manufactured by Nippon Kayaku Co., Ltd.); Eisenspiron Black (T-37, T-77, T-95, TRH, TNS-2) (all FCA-1001-N, FCA-1001-NB, FCA-1001-NZ (all manufactured by Fujikura Kasei Co., Ltd.), and the like.
As the positive charge control agent, for example, a basic compound such as a nigrosine dye, a cationic compound such as a quaternary ammonium salt, a metal salt of a higher fatty acid, or the like can be used. Specifically, Bontron (part numbers: N-01, N-02, N-03, N-04, N-05, N-07, N-09, N-10, N-11, N-13, P -51, P-52, AFP-B) (all manufactured by Orient Chemical Co., Ltd.); TP-302, TP-415, TP-4040 (all manufactured by Hodogaya Chemical Co., Ltd.); Copy Blue PR, copy Charge (product number: PX-VP-435, NX-VP-434) (all manufactured by Hoechst); FCA (product number: 201, 201-B-1, 201-B-2, 201-B-3, 201) -PB, 201-PZ, 301) (all manufactured by Fujikura Kasei Co., Ltd.); PLZ (product numbers: 1001, 2001, 6001, 7001) (all manufactured by Shikoku Kasei Kogyo Co., Ltd.).
These may be used individually by 1 type and may use 2 or more types together.

  The addition amount of the charge control agent is determined by the toner production method including the type of the binder resin and the dispersion method, and is not uniquely limited. However, with respect to 100 parts by mass of the binder resin. 0.1-10 mass parts is preferable and 0.2-5 mass parts is more preferable. When the addition amount exceeds 10 parts by mass, the chargeability of the toner is too large, the effect of the charge control agent is reduced, the electrostatic attraction with the developing roller is increased, the developer fluidity is reduced, and the image density is increased. If the amount is less than 0.1 parts by mass, the charge rise and charge amount are insufficient, and the toner image may be easily affected.

  In addition to the binder resin, the release agent, the colorant, and the charge control agent, the toner material includes inorganic fine particles, a fluidity improver, a cleaning property improver, a magnetic material, a metal soap, and the like as necessary. Can be added.

Examples of the inorganic fine particles include silica, titania, alumina, cerium oxide, strontium titanate, calcium carbonate, magnesium carbonate, calcium phosphate, etc., and silica hydrophobized with silicone oil, hexamethyldisilazane, or the like. It is more preferable to use fine particles or titanium oxide subjected to a specific surface treatment.
Examples of the silica fine particles include, for example, Aerosil (product numbers: 130, 200 V, 200 CF, 300, 300 CF, 380, OX50, TT600, MOX80, MOX170, COK84, RX200, RY200, R972, R974, R976, R805, R811, R812, T805, R202, VT222, RX170, RXC, RA200, RA200H, RA200HS, RM50, RY200, REA200) (above, manufactured by Nippon Aerosil Co., Ltd.), HDK (product numbers: H20, H2000, H3004, H2000 / 4, H2050EP, H2015EP, H3050EP) , KHD50), HVK2150 (above, manufactured by Wacker Chemical Co., Ltd.), Cabogil (Part No .: L-90, LM-130, LM-150, M-5, PTG, MS-55, H-5) HS-5, EH-5, LM-150D, M-7D, MS-75D, TS-720, TS-610, TS-530) (or, can be used Cabot Corp.).
The addition amount of the inorganic fine particles is preferably 0.1 to 5.0 parts by mass, more preferably 0.8 to 3.2 parts by mass with respect to 100 parts by mass of the toner base particles.

  The method for producing the toner is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include a pulverization method, a monomer containing a specific crystalline polymer and a polymerizable monomer. A polymerization method (suspension polymerization method, emulsion polymerization method) for directly polymerizing the composition in an aqueous phase, a composition containing a specific crystalline polymer and an isocyanate group-containing prepolymer in an aqueous phase with amines Examples include a direct addition / crosslinking polyaddition reaction method, a polyaddition reaction method using an isocyanate group-containing prepolymer, a method of dissolving in a solvent, removing the solvent, and pulverizing, and a melt spraying method.

The pulverization method is, for example, a method of obtaining the toner base particles by melting or kneading the toner material, pulverizing, classifying or the like. In the case of the pulverization method, for the purpose of increasing the average circularity of the toner, the shape may be controlled by applying a mechanical impact force to the obtained toner base particles. In this case, the mechanical impact force can be applied to the toner base particles using a device such as a hybridizer or mechanofusion.
The above toner materials are mixed, and the mixture is charged into a melt kneader and melt kneaded. As the melt kneader, for example, a uniaxial continuous kneader, a biaxial continuous kneader, or a batch kneader using a roll mill can be used. For example, KTK type twin screw extruder manufactured by Kobe Steel, TEM type extruder manufactured by Toshiba Machine Co., Ltd., twin screw extruder manufactured by Casey Kay, PCM type twin screw extruder manufactured by Ikegai Iron Works Co., Ltd. Preferably used. This melt-kneading is preferably performed under appropriate conditions so as not to cause the molecular chains of the binder resin to be broken. Specifically, the melt kneading temperature is performed with reference to the softening point of the binder resin. If the temperature is higher than the softening point, cutting is severe, and if the temperature is too low, dispersion may not proceed.

  In the pulverization, the kneaded product obtained by the kneading is pulverized. In this pulverization, it is preferable that the kneaded material is first coarsely pulverized and then finely pulverized. At this time, a method of pulverizing by colliding with a collision plate in a jet stream, pulverizing particles by colliding with each other in a jet stream, or pulverizing with a narrow gap between a mechanically rotating rotor and a stator is preferably used.

In the classification, the pulverized product obtained by the pulverization is classified and adjusted to particles having a predetermined particle diameter. The classification can be performed, for example, by removing the fine particle portion by a cyclone, a decanter, centrifugation, or the like.
After the pulverization and classification are completed, the pulverized product is classified into an air stream by centrifugal force or the like to produce a toner having a predetermined particle size.

The suspension polymerization method is an oil-soluble polymerization initiator, emulsification described later in an aqueous medium in which a colorant, a release agent, and the like are dispersed in a polymerizable monomer and a surfactant and other solid dispersant are contained. Emulsified and dispersed by the method. Thereafter, a polymerization reaction is performed to form particles, and then wet processing for attaching inorganic fine particles to the toner particle surfaces in the present invention may be performed. At that time, it is preferable to treat the toner particles from which excess surfactant and the like are removed by washing.
Examples of the polymerizable monomer include acrylic acids, methacrylic acid, α-cyanoacrylic acid, α-cyanomethacrylic acid, itaconic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, and other acids, acrylamide, By using a part of acrylate or methacrylate having amino group such as methacrylamide, diacetone acrylamide or their methylol compounds, vinyl pyridine, vinyl pyrrolidone, vinyl imidazole, ethyleneimine, dimethylaminoethyl methacrylate, etc. Functional groups can be introduced.
Further, by selecting a dispersant having an acid group or a basic group as the dispersant to be used, the dispersant can be adsorbed and left on the particle surface to introduce a functional group.

  As the emulsion polymerization method, a water-soluble polymerization initiator and a polymerizable monomer are emulsified in water using a surfactant, and a latex is synthesized by a usual emulsion polymerization method. Separately, a dispersion in which a colorant, a release agent and the like are dispersed in an aqueous medium is prepared, and after mixing, the toner is aggregated to a toner size and heat-fused to obtain a toner. Thereafter, wet processing of inorganic fine particles described later may be performed. A functional group can be introduced on the surface of the toner particles by using a latex similar to the monomer used in the suspension polymerization method.

Among these, since the selectivity of the resin is high, the low-temperature fixability is high, the granulation property is excellent, and the particle size, particle size distribution, and shape can be easily controlled. And a polymer capable of reacting with the active hydrogen group-containing compound is dissolved or dispersed in an organic solvent to prepare a toner solution, and then the toner solution is emulsified or dispersed in an aqueous medium. In the aqueous medium, the active hydrogen group-containing compound and a polymer capable of reacting with the active hydrogen group-containing compound are reacted to form an adhesive substrate in the form of particles, and the organic solvent is What is obtained by removing is suitable.
Examples of the toner material include an adhesive base obtained by reacting an active hydrogen group-containing compound, a polymer capable of reacting with the active hydrogen group-containing compound, a binder resin, a charge control agent, and a colorant. And, if necessary, other components such as resin fine particles and a release agent.

  Further, in order to improve the fluidity, storage stability, developability and transferability of the toner, inorganic fine particles such as hydrophobic silica fine powder may be further added to and mixed with the toner base particles produced as described above. For mixing the additives, a general powder mixer is used, but it is preferable to equip a jacket or the like to adjust the internal temperature. In order to change the load history applied to the additive, the additive may be added midway or gradually. In this case, you may change the rotation speed, rolling speed, time, temperature, etc. of a mixer. Alternatively, a strong load may be applied first, then a relatively weak load, or vice versa. Examples of the mixing equipment that can be used include a V-type mixer, a rocking mixer, a Ladige mixer, a Nauter mixer, and a Henschel mixer. Next, the toner is obtained by passing through a sieve of 250 mesh or more to remove coarse particles and aggregated particles.

  The shape, size, etc. of the toner are not particularly limited and can be appropriately selected according to the purpose. The average circularity, volume average particle size, volume average particle size and number are as follows. It is preferable to have a ratio to the average particle size (volume average particle size / number average particle size).

The average circularity is a value obtained by dividing the perimeter of an equivalent circle having the same projected shape as the toner shape by the perimeter of the actual particles, and is preferably 0.900 to 0.980, for example, 0.950 to 0 .975 is more preferred. Note that particles having an average circularity of less than 0.94 are preferably 15% or less.
If the average circularity is less than 0.900, satisfactory transferability and a high-quality image free from dust may not be obtained. If the average circularity exceeds 0.980, image formation employing blade cleaning or the like is employed. In the system, defective cleaning occurs on the photoconductor and the transfer belt, and in the case of image formation with a high image area ratio such as a photographic image, an untransferred image is formed due to defective paper feeding, etc. The accumulated toner may become a transfer residual toner on the photoconductor, resulting in background smearing of the image, or it may contaminate the charging roller for charging the photoconductor in contact with the original charging ability. It may become impossible to demonstrate.

  The average circularity is measured using a flow particle image analyzer (“FPIA-2100”, manufactured by Sysmex Corporation), and analyzed using analysis software (FPIA-2100 Data Processing Program for FPIA version 00-10). It was. Specifically, 0.1 to 0.5 ml of 10% by weight surfactant (alkylbenzene sulfonate, Neogen SC-A, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) is added to a 100 ml glass beaker, and each toner 0 is added. 0.1 to 0.5 g was added, and the mixture was mixed with a micropartel, and then 80 mL of ion-exchanged water was added. The obtained dispersion was subjected to a dispersion treatment for 3 minutes with an ultrasonic disperser (manufactured by Honda Electronics Co., Ltd.). The shape and distribution of the toner were measured using the FPIA-2100 until the concentration of 5000 to 15000 / μL was obtained. In this measurement method, it is important that the concentration of the dispersion is 5,000 to 15,000 / μL from the viewpoint of measurement reproducibility of average circularity. In order to obtain the concentration of the dispersion, it is necessary to change the conditions of the dispersion, that is, the amount of surfactant to be added and the amount of toner. The amount of the surfactant varies depending on the hydrophobicity of the toner as in the measurement of the toner particle diameter described above. If it is added in a large amount, noise due to bubbles is generated, and if it is too small, the toner cannot be sufficiently wetted. It will be enough. Further, the amount of toner added varies depending on the particle size, and it is small for small particle sizes and needs to be increased for large particle sizes. When the toner particle size is 3 to 10 μm, the toner amount is 0.1 to 0.3. By adding 5 g, the dispersion concentration can be adjusted to 5,000 to 15,000 / μl.

The volume average particle diameter of the toner is not particularly limited and may be appropriately selected depending on the intended purpose. For example, it is preferably 3 to 10 μm, and more preferably 3 to 8 μm.
When the volume average particle size is less than 3 μm, in the case of a two-component developer, the toner may be fused to the surface of the carrier during a long period of stirring in the developing device, and the charging ability of the carrier may be reduced. Therefore, it becomes difficult to obtain a high-resolution and high-quality image, and when the balance of the toner in the developer is performed, the fluctuation of the toner particle diameter may increase.

  The ratio of the volume average particle diameter to the number average particle diameter (volume average particle diameter / number average particle diameter) in the toner is preferably 1.00 to 1.25, more preferably 1.10 to 1.25.

  The volume average particle diameter and the ratio between the volume average particle diameter and the number average particle diameter (volume average particle diameter / number average particle diameter) are measured using a particle size measuring device (“Multisizer III” manufactured by Beckman Coulter, Inc.). Then, measurement was performed with an aperture diameter of 100 μm, and analysis was performed with analysis software (Beckman Coulter Multisizer 3 Version 3.51). Specifically, 0.5 ml of 10% by weight surfactant (alkylbenzene sulfonate Neogen SC-A, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) is added to a glass 100 ml beaker, and 0.5 g of each toner is added to make microscopic. The mixture was stirred with a spatula, and then 80 ml of ion exchange water was added. The obtained dispersion was subjected to a dispersion treatment for 10 minutes with an ultrasonic disperser (W-113MK-II, manufactured by Honda Electronics Co., Ltd.). The dispersion was measured using the Multisizer III and Isoton III (manufactured by Beckman Coulter, Inc.) as the measurement solution. In the measurement, the toner sample dispersion was dropped so that the concentration indicated by the apparatus was 8 ± 2%. In this measurement method, it is important that the concentration is 8 ± 2% from the viewpoint of the reproducibility of the particle size. Within this concentration range, no error occurs in the particle size.

  The coloration of the toner is not particularly limited and may be appropriately selected according to the purpose, and may be at least one selected from black toner, cyan toner, magenta toner, and yellow toner. Can be obtained by appropriately selecting the type of the colorant, and is preferably a color toner.

<Container with developer>
The developer-containing container contains the developer of the present invention in a container.
There is no restriction | limiting in particular as said container, It can select suitably from well-known things, For example, what has a developer container main body and a cap etc. are mentioned suitably.
The size, shape, structure, material and the like of the developer container body are not particularly limited and can be appropriately selected according to the purpose. For example, the shape is preferably cylindrical. A spiral irregularity is formed on the peripheral surface, and the toner as the contents can be transferred to the discharge port side by rotating, and part or all of the spiral part has a bellows function, etc. Is particularly preferred.
The material of the developer container main body is not particularly limited, and those having good dimensional accuracy are preferable. For example, a resin is preferable, and among them, for example, polyester resin, polyethylene resin, polypropylene resin, polystyrene resin, Preferable examples include vinyl chloride resin, polyacrylic acid, polycarbonate resin BS resin, and polyacetal resin.
Such a container containing a developer is easy to store and transport, has excellent handleability, and is preferably used for replenishing the developer by being detachably attached to the process cartridge and image forming apparatus of the present invention described later. Can do.

(Process cartridge)
The process cartridge of the present invention develops an electrostatic latent image carrier carrying an electrostatic latent image and the electrostatic latent image carried on the electrostatic latent image carrier using a developer to form a visible image. And at least developing means for forming the film, and other means appropriately selected as necessary.
The developing means includes at least a developer container that contains the developer of the present invention, and a developer carrier that carries and conveys the developer contained in the developer container. In addition, a layer thickness regulating member for regulating the thickness of the toner layer to be carried may be provided as necessary.
The process cartridge of the present invention can be detachably provided in various electrophotographic apparatuses, and is preferably provided detachably in the image forming apparatus of the present invention described later.

Here, for example, as shown in FIG. 2, the process cartridge includes a photosensitive member 101, and includes a charging unit 102, a developing unit 104, a transfer unit 108, and a cleaning unit 107, and other members as necessary. It has. In FIG. 2, reference numeral 103 denotes exposure by exposure means, and a light source capable of writing with high resolution is used. Reference numeral 105 denotes a recording medium. As the photoreceptor 101, the same one as an image forming apparatus described later can be used. An arbitrary charging member is used for the charging means 102.
Next, the image forming process using the process cartridge shown in FIG. 2 will be described. The photoconductor 101 is exposed to the surface by charging by the charging means 102 and exposure 103 by the exposure means (not shown) while rotating in the direction of the arrow. An electrostatic latent image corresponding to the image is formed. The electrostatic latent image is developed with toner by the developing unit 104, and the toner development is transferred to the recording medium 105 by the transfer unit 108 and printed out. Next, the surface of the photoconductor after the image transfer is cleaned by the cleaning unit 107 and further neutralized by a neutralizing unit (not shown), and the above operation is repeated again.

(Image forming method and image forming apparatus)
The image forming method of the present invention includes at least an electrostatic latent image forming step, a developing step, a transfer step, and a fixing step, and other steps appropriately selected as necessary, for example, a static elimination step, a cleaning step. , Including recycling process, control process, etc.
The image forming apparatus of the present invention includes at least an electrostatic latent image carrier, an electrostatic latent image forming unit, a developing unit, a transfer unit, and a fixing unit, and further appropriately selected as necessary. It has other means, for example, static elimination means, cleaning means, recycling means, control means and the like.

The electrostatic latent image forming step is a step of forming an electrostatic latent image on the electrostatic latent image carrier.
The electrostatic latent image carrier (sometimes referred to as “electrophotographic photosensitive member” or “photosensitive member”) is not particularly limited in terms of material, shape, structure, size, etc. Although it can be selected as appropriate, the shape thereof is preferably a drum shape, and examples of the material thereof include inorganic photoreceptors such as amorphous silicon and selenium, organic photoreceptors (OPC) such as polysilane and phthalopolymethine, and the like. Is mentioned. Among these, amorphous silicon or the like is preferable in terms of long life.

  The formation of the electrostatic latent image can be performed, for example, by uniformly charging the surface of the electrostatic latent image carrier and then performing imagewise exposure, and is performed by the electrostatic latent image forming unit. be able to. The electrostatic latent image forming means includes, for example, at least a charger that uniformly charges the surface of the electrostatic latent image carrier and an exposure device that exposes the surface of the electrostatic latent image carrier imagewise. Prepare.

The charging can be performed, for example, by applying a voltage to the surface of the electrostatic latent image carrier using the charger.
The charger is not particularly limited and may be appropriately selected depending on the purpose. For example, a known contact charging device including a conductive or semiconductive roll, brush, film, rubber blade, etc. And non-contact chargers utilizing corona discharge such as corotrons and corotrons.
The charger is preferably one that is arranged in contact or non-contact with the electrostatic latent image carrier and charges the surface of the electrostatic latent image carrier by applying a direct current and an alternating voltage.
Further, the charger is a charging roller disposed in a non-contact proximity to the electrostatic latent image carrier via a gap tape, and the electrostatic latent image is carried by applying a direct current and an alternating voltage to the charging roller. Those that charge the body surface are preferred.

The exposure can be performed, for example, by exposing the surface of the latent electrostatic image bearing member imagewise using the exposure device.
The exposure device is not particularly limited as long as it can expose the surface of the electrostatic latent image carrier charged by the charger so as to form an image to be formed, and is appropriately selected according to the purpose. For example, various exposure devices such as a copying optical system, a rod lens array system, a laser optical system, and a liquid crystal shutter optical system can be used.
In the present invention, a back light system in which imagewise exposure is performed from the back side of the electrostatic latent image carrier may be employed.

-Development process and development means-
The developing step is a step of developing the electrostatic latent image using the developer of the present invention to form a visible image.
The visible image can be formed, for example, by developing the electrostatic latent image using the developer of the present invention, and can be performed by the developing unit.
The developing means is not particularly limited as long as it can be developed using, for example, the developer of the present invention, and can be appropriately selected from known ones. For example, the developer of the present invention is accommodated. A developer having at least a developer capable of bringing the developer into contact or non-contact with the electrostatic latent image is suitable, and a developer equipped with the developer-containing container is more preferred.

  The developing unit may be a dry developing type, a wet developing type, a single color developing unit, or a multi-color developing unit. For example, a developer having a stirrer for charging the developer by frictional stirring and a rotatable magnet roller is preferable.

In the developing device, for example, the toner and the carrier are mixed and agitated, and the toner is charged by friction at that time, and held on the surface of the rotating magnet roller in a raised state to form a magnetic brush. . Since the magnet roller is disposed in the vicinity of the electrostatic latent image carrier (photoconductor), a part of the toner constituting the magnetic brush formed on the surface of the magnet roller is electrically attracted. It moves to the surface of the electrostatic latent image carrier (photoconductor) by force. As a result, the electrostatic latent image is developed with the toner, and a visible image is formed with the toner on the surface of the electrostatic latent image carrier (photoconductor).
The developer accommodated in the developing device is the developer of the present invention.

-Transfer process and transfer means-
The transfer step is a step of transferring the visible image onto a recording medium. After the primary transfer of the visible image onto the intermediate transfer member using an intermediate transfer member, the visible image is transferred onto the recording medium. A primary transfer step of forming a composite transfer image by transferring a visible image onto an intermediate transfer body using two or more colors, preferably full color toner as the toner, and a composite transfer image; A mode including a secondary transfer step of transferring the transfer image onto the recording medium is more preferable.
The transfer can be performed, for example, by charging the latent electrostatic image bearing member (photoconductor) of the visible image using a transfer charger, and can be performed by the transfer unit. The transfer means includes a primary transfer means for transferring a visible image onto an intermediate transfer member to form a composite transfer image, and a secondary transfer means for transferring the composite transfer image onto a recording medium. Embodiments are preferred.
The intermediate transfer member is not particularly limited and may be appropriately selected from known transfer members according to the purpose. For example, a transfer belt and the like are preferable.

The transfer means (the primary transfer means, the secondary transfer means) is a transfer for peeling and charging the visible image formed on the electrostatic latent image carrier (photoconductor) to the recording medium side. It is preferable to have at least a vessel. The number of the transfer means may be one, or two or more.
Examples of the transfer device include a corona transfer device using corona discharge, a transfer belt, a transfer roller, a pressure transfer roller, and an adhesive transfer device.
The recording medium is not particularly limited and can be appropriately selected from known recording media (recording paper).

The fixing step is a step of fixing the visible image transferred to the recording medium using a fixing device, and may be performed each time the developer of each color is transferred to the recording medium, or the developer of each color. On the other hand, it may be carried out at the same time in a state where these are laminated.
There is no restriction | limiting in particular as said fixing device, Although it can select suitably according to the objective, A well-known heating-pressing means is suitable. Examples of the heating and pressing means include a combination of a heating roller and a pressure roller, a combination of a heating roller, a pressure roller, and an endless belt.
The fixing device includes a heating body including a heating element, a film in contact with the heating body, and a pressure member in pressure contact with the heating body through the film, and the film and the pressure member It is preferably a unit that heats and fixes a recording medium on which an unfixed image is formed. The heating in the heating and pressing means is usually preferably 80 to 200 ° C.
In the present invention, for example, a known optical fixing device may be used together with or in place of the fixing step and the fixing unit depending on the purpose.

The neutralization step is a step of performing neutralization by applying a neutralization bias to the electrostatic latent image carrier, and can be suitably performed by a neutralization unit.
The neutralization means is not particularly limited, and may be appropriately selected from known neutralizers as long as it can apply a neutralization bias to the electrostatic latent image carrier. Preferably mentioned.

The cleaning step is a step of removing the toner remaining on the electrostatic latent image carrier, and can be suitably performed by a cleaning unit.
The cleaning unit is not particularly limited, and may be selected from known cleaners as long as it can remove the toner remaining on the electrostatic latent image carrier. For example, a magnetic brush cleaner Suitable examples include electrostatic brush cleaners, magnetic roller cleaners, blade cleaners, brush cleaners, web cleaners, and the like.

The recycling step is a step of recycling the toner removed by the cleaning step to the developing unit, and can be suitably performed by the recycling unit.
There is no restriction | limiting in particular as said recycling means, A well-known conveyance means etc. are mentioned.

The control means controls the steps, and each step can be suitably performed by the control means.
The control means is not particularly limited as long as the movement of each means can be controlled, and can be appropriately selected according to the purpose. Examples thereof include devices such as a sequencer and a computer.

  An embodiment of the image forming method of the present invention will be described with reference to FIG. An image forming apparatus 100 shown in FIG. 3 includes a photosensitive drum 10 (hereinafter referred to as “photosensitive member 10”) as the electrostatic latent image carrier, a charging roller 20 as the charging unit, and an exposure as the exposure unit. The apparatus 30 includes a developing device 40 as the developing means, an intermediate transfer member 50, a cleaning device 60 as the cleaning means having a cleaning blade, and a static elimination lamp 70 as the static elimination means.

  The intermediate transfer member 50 is an endless belt, and is designed to be movable in the direction of an arrow by three rollers 51 that are arranged inside and stretched. Part of the three rollers 51 also functions as a transfer bias roller that can apply a predetermined transfer bias (primary transfer bias) to the intermediate transfer member 50. The intermediate transfer body 50 is provided with a cleaning device 90 having a cleaning blade in the vicinity thereof, and for transferring (secondary transfer) a developed image (toner image) to a transfer sheet 95 as a final transfer material. A transfer roller 80 serving as a transfer unit to which a transfer bias can be applied is disposed to face the transfer roller 80. Around the intermediate transfer member 50, a corona charger 58 for applying a charge to the toner image on the intermediate transfer member 50 is arranged between the photosensitive member 10 and the intermediate transfer member 50 in the rotation direction of the intermediate transfer member 50. It is disposed between the contact portion and the contact portion between the intermediate transfer member 50 and the transfer paper 95.

  The developing device 40 includes a developing belt 41 as the developer carrying member, and a black developing unit 45K, a yellow developing unit 45Y, a magenta developing unit 45M, and a cyan developing unit 45C provided around the developing belt 41. . The black developing unit 45K includes a developer accommodating portion 42K, a developer supplying roller 43K, and a developing roller 44K. The yellow developing unit 45Y includes a developer accommodating portion 42Y, a developer supplying roller 43Y, and a developing roller 44Y. The magenta developing unit 45M includes a developer accommodating portion 42M, a developer supplying roller 43M, and a developing roller 44M, and the cyan developing unit 45C includes a developer accommodating portion 42C and a developer supplying roller 43C. And a developing roller 44C. The developing belt 41 is an endless belt, is rotatably stretched around a plurality of belt rollers, and a part thereof is in contact with the photoconductor 10.

  In the image forming apparatus 100 shown in FIG. 3, for example, the charging roller 20 charges the photosensitive drum 10 uniformly. The exposure device 30 performs imagewise exposure on the photosensitive drum 10 to form an electrostatic latent image. The electrostatic latent image formed on the photosensitive drum 10 is developed by supplying toner from the developing device 40 to form a visible image (toner image). The visible image (toner image) is transferred (primary transfer) onto the intermediate transfer body 50 by the voltage applied from the roller 51, and further transferred (secondary transfer) onto the transfer paper 95. As a result, a transfer image is formed on the transfer paper 95. The residual toner on the photoconductor 10 is removed by the cleaning device 60, and the charge on the photoconductor 10 is temporarily removed by the charge eliminating lamp 70.

  Another mode for carrying out the image forming method of the present invention by the image forming apparatus of the present invention will be described with reference to FIG. The image forming apparatus 100 shown in FIG. 4 does not include the developing belt 41 in the image forming apparatus 100 shown in FIG. 3, and a black developing unit 45K, a yellow developing unit 45Y, a magenta developing unit 45M, and the like around the photoconductor 10. Except for the fact that the cyan developing unit 45C is arranged directly opposite, it has the same configuration as the image forming apparatus 100 shown in FIG. In FIG. 4, the same components as those in FIG. 3 are denoted by the same reference numerals.

Another mode for carrying out the image forming method of the present invention by the image forming apparatus of the present invention will be described with reference to FIG. The tandem image forming apparatus shown in FIG. 5 is a tandem type color image forming apparatus. The tandem image forming apparatus includes a copying apparatus main body 150, a paper feed table 200, a scanner 300, and an automatic document feeder (ADF) 400.
The copying apparatus main body 150 is provided with an endless belt-like intermediate transfer member 50 at the center. The intermediate transfer member 50 is stretched around the support rollers 14, 15 and 16, and can be rotated clockwise in FIG. 5. An intermediate transfer member cleaning device 17 for removing residual toner on the intermediate transfer member 50 is disposed in the vicinity of the support roller 15. The intermediate transfer body 50 stretched by the support roller 14 and the support roller 15 is a tandem type in which four image forming means 18 of yellow, cyan, magenta, and black are arranged in parallel and facing each other along the conveyance direction. A developing device 120 is disposed. An exposure device 21 is disposed in the vicinity of the tandem developing device 120. A secondary transfer device 22 is disposed on the side of the intermediate transfer member 50 opposite to the side on which the tandem developing device 120 is disposed. In the secondary transfer device 22, a secondary transfer belt 24, which is an endless belt, is stretched around a pair of rollers 23, and the transfer paper conveyed on the secondary transfer belt 24 and the intermediate transfer body 50 are in contact with each other. Is possible. A fixing device 25 is disposed in the vicinity of the secondary transfer device 22. The fixing device 25 includes a fixing belt 26 that is an endless belt, and a pressure roller 27 that is pressed against the fixing belt 26.
In the tandem image forming apparatus, a sheet reversing device 28 for reversing the transfer paper for image formation on both sides of the transfer paper is disposed in the vicinity of the secondary transfer device 22 and the fixing device 25. .

  Next, formation of a full-color image (color copy) using the tandem developing device 120 will be described. That is, first, a document is set on the document table 130 of the automatic document feeder (ADF) 400, or the automatic document feeder 400 is opened and the document is set on the contact glass 32 of the scanner 300. 400 is closed.

  When a start switch (not shown) is pressed, when the document is set on the automatic document feeder 400, the document is transported and moved onto the contact glass 32, and then the document is set on the contact glass 32. Immediately after that, the scanner 300 is driven, and the first traveling body 33 and the second traveling body 34 travel. At this time, light from the light source is irradiated by the first traveling body 33 and reflected light from the document surface is reflected by the mirror in the second traveling body 34 and is received by the reading sensor 36 through the imaging lens 35 to be color. An original (color image) is read and used as black, yellow, magenta, and cyan image information.

  Each image information of black, yellow, magenta and cyan is stored in each image forming unit 18 (black image forming unit, yellow image forming unit, magenta image forming unit, and cyan image forming unit) in the tandem type developing device 120. Each of the image forming means forms toner images of black, yellow, magenta, and cyan. That is, each image forming means 18 (black image forming means, yellow image forming means, magenta image forming means, and cyan image forming means) in the tandem developing device 120 is respectively shown in FIG. A photoconductor 10 (black photoconductor 10K, yellow photoconductor 10Y, magenta photoconductor 10M, and cyan photoconductor 10C), a charger 60 for uniformly charging the photoconductor, and each color image information An exposure unit that exposes the photoconductor on each color image-corresponding image (L in FIG. 6) to form an electrostatic latent image corresponding to each color image on the photoconductor, and the electrostatic latent image Are developed with each color toner (black toner, yellow toner, magenta toner, and cyan toner) to form a toner image with each color toner, and the toner image is intermediately transferred. A transfer charger 62 for transferring onto the body 50, a photoconductor cleaning device 63, and a static eliminator 64 are provided, and each single color image (black image, yellow image, Magenta image and cyan image) can be formed. The black image, the yellow image, the magenta image, and the cyan image formed in this way are formed on the black photoconductor 10K on the intermediate transfer member 50 that is rotationally moved by the support rollers 14, 15, and 16, respectively. The black image, the yellow image formed on the yellow photoconductor 10Y, the magenta image formed on the magenta photoconductor 10M, and the cyan image formed on the cyan photoconductor 10C are sequentially transferred (primary transfer). Is done. Then, the black image, the yellow image, the magenta image, and the cyan image are superimposed on the intermediate transfer member 50 to form a composite color image (color transfer image).

  On the other hand, in the paper feed table 200, one of the paper feed rollers 142 is selectively rotated to feed out a sheet (recording paper) from one of the paper feed cassettes 144 provided in multiple stages in the paper bank 143. Each sheet is separated and sent to the paper feed path 146, transported by the transport roller 147, guided to the paper feed path 148 in the copying machine main body 150, and abutted against the registration roller 49 and stopped. Alternatively, the sheet feed roller 142 is rotated to feed out sheets (recording paper) on the manual feed tray 54, separated one by one by the separation roller 52, put into the manual feed path 53, and abutted against the registration roller 49 and stopped. . The registration roller 49 is generally used while being grounded, but may be used in a state where a bias is applied to remove paper dust from the sheet. Then, the registration roller 49 is rotated in synchronization with the synthesized color image (color transfer image) synthesized on the intermediate transfer member 50, and a sheet (recording paper) is interposed between the intermediate transfer member 50 and the secondary transfer device 22. The secondary color transfer device 22 transfers the composite color image (color transfer image) onto the sheet (recording paper), thereby transferring the color image onto the sheet (recording paper). Is formed. The residual toner on the intermediate transfer member 50 after image transfer is cleaned by the intermediate transfer member cleaning device 17.

  The sheet (recording paper) on which the color image has been transferred is conveyed by the secondary transfer device 22 and sent to the fixing device 25, where the combined color image (color) is generated by heat and pressure. (Transfer image) is fixed on the sheet (recording paper). Thereafter, the sheet (recording paper) is switched by the switching claw 55 and discharged by the discharge roller 56 and stacked on the discharge tray 57, or switched by the switching claw 55 and reversed by the sheet reversing device 28 and transferred again. After being guided to the position and recording an image on the back surface, the image is discharged by the discharge roller 56 and stacked on the discharge tray 57.

  In the image forming apparatus and the image forming method according to the present invention, since the developer including the carrier according to the present invention that has high mechanical strength, is free from toner scattering and scumming, and can form an image with high image density is used, Image quality images can be formed efficiently.

  Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Production Example 1)
-Production of Toner 1-
100 parts by mass of a polyester resin (mass average molecular weight = 12,000), 2 parts by mass of a copper phthalocyanine pigment, and the following structural formula (A) (iodine salt of nonylene perfluoroether p-trimethylaminopropylamidophenyl) 2 parts by mass of the charge control agent is kneaded at 120 ° C. using a heat roll, cooled and solidified, then pulverized and classified to have a volume average particle diameter of 7.1 μm, a number average particle diameter of 5.8 μm, an average Toner base particles having a circularity of 0.953 were obtained.
Next, 0.5 parts by mass of silica R972 (manufactured by Nippon Aerosil Co., Ltd.) was added to and mixed with 100 parts by mass of the obtained toner base particles to prepare “Toner 1”.

(Production Example 2)
-Production of Toner 2-
100 parts by mass of a polyester resin (mass average molecular weight = 12,000), 5 parts by mass of carbon black, and 2 parts by mass of a chromium-containing azo dye represented by the following structural formula (B) were kneaded at 120 ° C. using a hot roll. After cooling and solidifying, the mixture was pulverized and classified to obtain toner base particles having a volume average particle size of 7.3 μm, a number average particle size of 6.0 μm, and an average circularity of 0.955.
Next, 0.5 parts by mass of silica R972 (manufactured by Nippon Aerosil Co., Ltd.) was added to 100 parts by mass of the obtained toner base particles and mixed to prepare “Toner 2”.

(Production Example 3)
<Preparation of Toner 3>
-Synthesis of organic fine particle emulsion-
In a reaction vessel equipped with a stir bar and a thermometer, 683 parts by mass of water, 11 parts by mass of sodium salt of ethylene oxide methacrylate adduct sulfate (Eleminol RS-30, manufactured by Sanyo Chemical Industries, Ltd.), 83 parts by mass of styrene Part, 83 parts by weight of methacrylic acid, 110 parts by weight of butyl acrylate, and 1 part by weight of ammonium persulfate were added and stirred at 400 rpm for 15 minutes to obtain a white emulsion. This emulsion was heated to raise the system temperature to 75 ° C. and reacted for 5 hours. Next, 30 parts by mass of a 1% by mass ammonium persulfate aqueous solution was added, and the mixture was aged at 75 ° C. for 5 hours to form a vinyl resin (a copolymer of methacrylic acid-butyl acrylate-methacrylic acid ethylene oxide adduct sulfate sodium salt). An aqueous dispersion was obtained. This is designated as [fine particle dispersion 1].
The volume average particle diameter of the fine particles contained in the obtained [fine particle dispersion 1] was measured with a particle size distribution measuring apparatus (“LA-920”, manufactured by Horiba, Ltd.) using a laser scattering method, and found to be 105 nm. It was. In addition, a part of [Fine Particle Dispersion 1] was dried to isolate only the resin component. The glass transition temperature (Tg) of this resin was 59 ° C., and the mass average molecular weight (Mw) was 150,000.

-Preparation of aqueous phase-
990 parts by mass of water, 83 parts by mass of [fine particle dispersion 1], 37 parts by mass of a 48.5% aqueous solution of dodecyl diphenyl ether disulfonate (Eleminol MON-7, manufactured by Sanyo Chemical Industries), and 90 parts by mass of ethyl acetate The mixture was stirred to obtain a milky white liquid. This liquid is designated [Aqueous Phase 1].

-Synthesis of low molecular weight polyester-
In a reaction vessel equipped with a cooling tube, a stirrer, and a nitrogen introduction tube, 229 parts by mass of bisphenol A ethylene oxide 2 mol adduct, 529 parts by mass of bisphenol A propylene oxide 3 mol adduct, 208 parts by mass of terephthalic acid, 46 adipic acid 46 Part by mass and 2 parts by mass of dibutyltin oxide were charged and reacted at 230 ° C. for 8 hours under normal pressure. Subsequently, after reacting under reduced pressure of 10 to 15 mmHg for 5 hours, 44 parts by mass of trimellitic anhydride was put in the reaction vessel and reacted at 180 ° C. and normal pressure for 2 hours to synthesize [low molecular weight polyester 1].
The obtained [low molecular weight polyester 1] has a glass transition temperature (Tg) of 45 ° C., a weight average molecular weight (Mw) of 5,800, a number average molecular weight of 2,600, and an acid value of 24 mgKOH / g.

-Synthesis of polyester prepolymer-
In a reaction vessel equipped with a cooling tube, a stirrer, and a nitrogen introduction tube, 682 parts by mass of bisphenol A ethylene oxide 2 mol adduct, 81 parts by mass of bisphenol A propylene oxide 2 mol adduct, 283 parts by mass of terephthalic acid, 22 parts by mass of merit acid and 2 parts by mass of dibutyltin oxide were added and reacted at 230 ° C. for 8 hours under normal pressure. Subsequently, it reacted for 5 hours under the reduced pressure of 10-15 mmHg, and the [intermediate polyester 1] was synthesize | combined.
The obtained [Intermediate polyester 1] had a number average molecular weight of 2,100, a weight average molecular weight of 9,500, a glass transition temperature (Tg) of 55 ° C., an acid value of 0.5 mgKOH / g, and a hydroxyl value of 51.
Next, 410 parts by mass of [Intermediate Polyester 1], 89 parts by mass of isophorone diisocyanate and 500 parts by mass of ethyl acetate are placed in a reaction vessel equipped with a cooling tube, a stirrer, and a nitrogen introduction tube, and 5 parts at 100 ° C. The reaction was performed for a while to obtain [Prepolymer 1].
The obtained [Prepolymer 1] had a free isocyanate mass% of 1.74%.

-Synthesis of ketimine-
In a reaction vessel equipped with a stir bar and a thermometer, 170 parts by mass of isophoronediamine and 75 parts by mass of methyl ethyl ketone were charged and reacted at 50 ° C. for 5 hours to synthesize [ketimine compound 1]. The amine value of the obtained [ketimine compound 1] was 418.

-Preparation of masterbatch (MB)-
1,200 parts by mass of water, 540 parts by mass of carbon black (PBk-7: Printex 60, manufactured by Degussa) [DBP oil absorption = 114 ml / 100 mg, pH = 10], and polyester resin (manufactured by Sanyo Chemical Industries, RS801) 1,200 parts by mass was added and mixed with a Henschel mixer (Mitsui Mining Co., Ltd.). The obtained mixture was kneaded at 150 ° C. for 30 minutes using two rolls, rolled and cooled, and pulverized with a pulverizer to obtain a master batch. This is designated as [Masterbatch 1].

-Preparation of oil phase-
In a reaction vessel equipped with a stir bar and a thermometer, 300 parts by weight of [low molecular weight polyester 1], 90 parts by weight of carnauba wax, 10 parts by weight of rice wax, and 1,000 parts by weight of ethyl acetate are charged and stirred. However, after dissolving at 79 ° C., it was rapidly cooled to 4 ° C. at once. Using a bead mill (Ultra Visco Mill, manufactured by Imex Co., Ltd.), the liquid feeding speed is 1 kg / hr, the disk peripheral speed is 6 m / sec, and 0.5 mm zirconia beads are filled by 80% by volume, and dispersion is performed under conditions of 3 passes. And a wax dispersion having a volume average particle size of 0.6 μm was obtained.
Next, 500 parts by weight of “Masterbatch 1” and 640 parts by weight of a 70% by weight ethyl acetate solution of “Low molecular weight polyester 1” were added, mixed for 10 hours, then 5 passes through the bead mill, and ethyl acetate was added to obtain a solid content. “Oil phase 1” adjusted to a concentration of 50% by mass was produced.

-Preparation of polymerized toner-
[Oil Phase 1] 73.2 parts by mass, [Prepolymer 1] 6.8 parts by mass, and [Ketimine Compound 1] 0.48 parts by mass were placed in a container and mixed well with [Emulsified oil phase 1]. 120 parts by mass of aqueous phase 1] was added, mixed for 1 minute with a homomixer, and then allowed to converge with a paddle for 1 hour with gentle stirring to obtain [Emulsion slurry 1].
The obtained [Emulsion slurry 1] was desolvated at 30 ° C. for 1 hour, further aged at 60 ° C. for 5 hours, washed with water, filtered and dried, and then sieved with a mesh of 75 μm, and the volume average particle diameter Toner base particles having a particle size of 6.1 μm, a number average particle size of 5.4 μm, and an average circularity of 0.972 were prepared.
Next, 0.7 parts by mass of hydrophobic silica and 0.3 parts by mass of hydrophobized titanium oxide were mixed with 100 parts by mass of the obtained toner base particles using a Henschel mixer to prepare “Toner 3”.

(Example 1)
-Production of carrier 1-
Using the apparatus shown in FIG. 1, 0.5 mol% amino-modified methyl silicone resin A (mass average molecular weight (Mw) = 2500, number average molecular weight (Mn) = 1 in a carrier treatment tank (internal volume 400 mL). , 300), 2 mol% amino-modified methyl silicone resin B (mass average molecular weight (Mw) = 2,600, number average molecular weight (Mn) = 1,400), 5 mol% amino-modified methyl silicone resin C (mass average molecular weight (Mw ) = 2,400, number average molecular weight (Mn) = 1,300), 8 mol% amino-modified methyl silicone resin D (mass average molecular weight (Mw) = 2,500, number average molecular weight (Mn) = 1,400), And 10 mol% amino-modified methyl silicone resin E (mass average molecular weight (Mw) = 2,300, number average molecular weight (Mn) = 1,200), respectively Charged parts increments, (saturated magnetic moment = 65 emu / g at 1k Gauss) 1,000 parts by weight ferrite core material having a volume average particle size of 35μm (the surface area 7.27M ^2), opening the valve 3 with stirring, pressure Carbon dioxide (purity = 99.5%, manufactured by Gastec Service Co., Ltd.) was supplied with the pump 1 to 25 MPa and 40 ° C., and then the valve 3 was closed.

At this time, the solubility of the amino-modified methyl silicone resins A to E in carbon dioxide was measured as follows. Amino-modified methyl silicone resin A: 600 mg / mol-CO ₂ , amino-modified methyl silicone resin B: 140 mg / mol-CO ₂ , amino-modified methyl silicone resin C: 60 mg / mol-CO ₂ , amino-modified methyl silicone resin D: 40 mg / mol-CO ₂ , amino-modified methyl silicone resin E: 30 mg / mol-CO ₂ It was.
<Measurement of solubility of amino-modified methyl silicone resin>
Among the apparatuses shown in FIG. 1, the solubility measurement was performed under the following conditions using an apparatus in which the carrier treatment tank was changed to a solubility measuring tank having an internal volume of 50 mL.
Pressure: 25MPa
Temperature: 40 ° C
Fluid: Carbon dioxide Flow rate: 3.0 ml / min Sample: 10 g
A sample is put into a solubility measuring tank, and carbon dioxide is allowed to flow for 2 hours at the predetermined pressure, temperature, and flow rate. The amount of dissolution is calculated from the amount of sample remaining in the solubility measurement tank after distribution, and is used as the value of solubility.

  After maintaining the inside of the carrier treatment tank at 25 MPa and 40 ° C. for 2 hours, the valve 5 and the valve 6 were opened, and the pressure was reduced to normal pressure with the vacuum pump 1 over 2 hours. Further, the carrier treatment tank was heat-treated at 160 ° C. for 2 hours. The amino-modified methyl silicone resin that was not used could be recovered from the raw material recovery tank and reused.

  The thickness of the coating layer of the obtained carrier 1 was 0.35 μm, and the electrical resistance measured as follows was Log R 13.5 Ω · cm. Further, the sample was obliquely cut with a surface interface physical property analyzer Cycus CN type (manufactured by Mekong Co., Ltd.) and observed by a total reflection measurement method using a Fourier transform infrared spectroscopic analyzer Spectrum 100 (manufactured by Perkin Elmer). It was confirmed that there was no interface in the coating layer, and a coating layer having a structure having a gentle concentration gradient due to each amino-modified methyl silicone resin was obtained.

<Measurement of carrier electric resistance>
The electric resistance of the carrier is a value obtained from a current value and an applied voltage when a carrier is filled between two parallel electrodes and a potential difference is provided between the electrodes. Specifically, a container having electrodes arranged in parallel at an interval of 2 mm was filled with a carrier, and the direct current resistance at a potential difference of 50 V between the two electrodes was measured using a 4329A High Resistance Meter manufactured by Yokogawa Hewlett-Packard Co., Ltd.

(Example 2)
-Production of carrier 2-
In Example 1, the resins used were 0.5 mol% amino-modified methyl silicone resin A, 2 mol% amino-modified methyl silicone resin B, 5 mol% amino-modified methyl silicone resin C, and 8 mol% amino-modified methyl silicone resin D, respectively. A carrier 2 was produced in the same manner as in Example 1 except that the amount was changed to 17.5 parts by mass.
The thickness of the coating layer of the obtained carrier 2 was 0.34 μm, and the electric resistance measured in the same manner as in Example 1 was Log R 13.5 Ω · cm. Further, when observed in the same manner as in Example 1, it was confirmed that there was no interface in the coating layer, and a coating layer having a gentle concentration gradient due to each amino-modified methyl silicone resin was obtained.

(Example 3)
-Production of carrier 3-
In Example 1, the resin used was changed to 23.3 parts by mass of 0.5 mol% amino-modified methyl silicone resin A, 5 mol% amino-modified methyl silicone resin C, and 10 mol% amino-modified methyl silicone resin E, respectively. A carrier 2 was prepared in the same manner as in Example 1 except for the above.
The thickness of the coating layer of the obtained carrier 3 was 0.34 μm, and the electrical resistance measured in the same manner as in Example 1 was Log R 13.5 Ω · cm. Further, when observed in the same manner as in Example 1, it was confirmed that there was no interface in the coating layer, and a coating layer having a gentle concentration gradient due to each amino-modified methyl silicone resin was obtained.

Example 4
-Production of carrier 4-
In Example 1, the resin used was changed to 23.3 parts by mass of 0.5 mol% amino-modified methyl silicone resin A, 2 mol% amino-modified methyl silicone resin B, and 5 mol% amino-modified methyl silicone resin C, respectively. Except for the above, a carrier 4 was produced in the same manner as in Example 1.
The thickness of the coating layer of the obtained carrier 4 was 0.36 μm, and the electric resistance measured in the same manner as in Example 1 was Log R 13.6 Ω · cm. Further, when observed in the same manner as in Example 1, it was confirmed that there was no interface in the coating layer, and a coating layer having a gentle concentration gradient due to each amino-modified methyl silicone resin was obtained.

(Example 5)
-Production of carrier 5-
In Example 1, except that the resin used was changed to 35 parts by mass of 0.5 mol% amino-modified methyl silicone resin A and 2 mol% amino-modified methyl silicone resin B, respectively. 5 was produced.
The thickness of the coating layer of the obtained carrier 5 was 0.35 μm, and the electric resistance measured in the same manner as in Example 1 was Log R 13.8 Ω · cm. Further, when observed in the same manner as in Example 1, it was confirmed that there was no interface in the coating layer, and a coating layer having a gentle concentration gradient due to each amino-modified methyl silicone resin was obtained.

(Reference Example 1)
-Preparation of reference carrier 1-
A reference carrier 1 was produced in the same manner as in Example 1 except that the resin used in Example 1 was changed to 70 parts by mass of 0.5 mol% amino-modified methyl silicone resin A.
The thickness of the coating layer of the obtained reference carrier 1 was 0.35 μm, and the electric resistance measured in the same manner as in Example 1 was Log R 13.5 Ω · cm.

(Comparative Example 1)
-Production of comparative carrier 1-
0.5% amino-modified methylsilicone resin A, 2% amino-modified methylsilicone resin B, and 5% amino-modified methylsilicone resin C, a toluene solution in which 28 parts by mass of each were dissolved in toluene (solid content concentration 10% by mass) 840 parts by mass with respect to 1,000 parts by mass of a ferrite core material having a volume average particle size of 35 μm (saturation magnetic moment at 1 k gauss = 63 emu / g) using a fluidized bed type coating apparatus in an atmosphere of 100 ° C. Then, the ferrite particles coated at a rate of about 50 g / min for 20 minutes and coated with the obtained silicone resin were heated at 200 ° C. for 1 hour to prepare a comparative carrier 1.
The thickness of the coating layer of the obtained comparative carrier 1 was 0.35 μm, and the electric resistance measured in the same manner as in Example 1 was Log R 13.6 Ω · cm.

(Comparative Example 2)
-Production of comparative carrier 2-
Toluene solution in which 28 parts by mass of 0.5% amino-modified methyl silicone resin A was dissolved in toluene 280 parts by mass of toluene (solid content concentration 10% by mass), 28 parts by mass of 2% amino-modified methyl silicone resin B was dissolved in toluene 280 parts by mass of liquid B (solid content concentration 10% by mass) and 280 parts by mass of toluene solution C (solid content concentration 10% by mass) obtained by dissolving 28 parts by mass of 5% amino-modified methyl silicone resin C in toluene, A ferrite core material having a volume average particle size of 35 μm (saturation magnetic moment at 1 k gauss = 63 emu / g) is about 50 g / 100 m in an atmosphere of 100 ° C. using a fluidized bed type coating apparatus. Amino modified methyl silicone resin C, amino modified methyl silicone resin B, amino modified methyl silicone In the order of over down resin A, was applied at a time of about 5 minutes, the resulting silicone resin coated ferrite particles, by heating 1 hour at 200 ° C., to prepare a comparison carrier 2.
The thickness of the coating layer of the obtained comparative carrier 2 was 0.36 μm, and the electric resistance measured in the same manner as in Example 1 was Log R 13.5 Ω · cm.

(Examples 6 to 12, Reference Example 2, and Comparative Examples 3 to 5)
-Production of developer-
The produced carriers 1 to 5, reference carrier 1 and comparative carriers 1 and 2, and toners 1 to 3 are combined as shown in Table 1 below, and Examples 6 to 12, Reference Example 2 and Each developer of Comparative Examples 3 to 5 was prepared.
Using the obtained developers, image density, toner scattering property, background stain, and comprehensive evaluation were performed as follows. The results are shown in Table 1.

<Image density>
Using the tandem type color image forming apparatus (image Neo 450, manufactured by Ricoh Co., Ltd.), the amount of each developer adhered to the copy paper (TYPE6000 <70W>, manufactured by Ricoh Co., Ltd.). A solid image of 0.000 ± 0.05 mg / cm ² was formed. The solid image was repeatedly formed on 1.5 million copy sheets.
The image density of the obtained solid image was visually observed for the initial stage and after endurance of 1.5 million sheets, and evaluated based on the following criteria. Note that the higher the image density obtained, the higher the density image can be formed. This evaluation corresponds to an embodiment of the process cartridge, the image forming apparatus, and the image forming method of the present invention.
〔Evaluation criteria〕
A: The image density did not change and high image quality was obtained at the initial stage and after endurance of 1.5 million sheets.
○: After enduring 1.5 million sheets, the image density was slightly reduced, but high image quality was obtained.
(Triangle | delta): The image density fell and the image quality fell after 1.5 million sheet endurance.
X: After enduring 1.5 million sheets, the image density was remarkably lowered and the image quality was greatly lowered.

<Toner scattering property>
The extent of toner contamination in the machine when a chart with an image area ratio of 5% is continuously output to 1.5 million sheets using a tandem type color image forming apparatus (Imagio Neo 450, manufactured by Ricoh Co., Ltd.) is visually observed according to the following criteria. Evaluation was made in 4 stages.
〔Evaluation criteria〕
A: There is no toner contamination in the machine and it is in an excellent state.
○: There is no toner contamination in the machine and it is in a good state.
Δ: There is toner contamination in the machine, but it is a practically usable level.
X: Toner contamination in the machine is severe and the level is not practical.

<Soil dirt>
The following criteria are used to visually check the degree of background contamination of the image background when a chart with an image area ratio of 5% is continuously output by using a tandem type color image forming apparatus (Imagio Neo 450, manufactured by Ricoh Co., Ltd.). It was evaluated by.
〔Evaluation criteria〕
○: No background stains in the image background.
Δ: Soil is slightly generated in the background portion of the image.
X: Soil is generated in the background portion of the image.

<Comprehensive evaluation>
From the above evaluation results, the following criteria were used for overall evaluation.
〔Evaluation criteria〕
◎: Very good ○: Good ×: Bad

From the results of Table 1, the developers of Examples 6 to 12 using the carriers 1 to 5 made of a plurality of types of coating materials and processed with a supercritical fluid to form a coating layer are the reference carrier 1 and the comparison Compared to the developers of Reference Example 2 and Comparative Examples 3 to 5 using Carriers 1 and 2, it was confirmed that there was no toner scattering and background staining and a high image density was obtained.

The carrier of the present invention and the method for producing the same can obtain carrier-coated particles having a coating layer having a structure having a gentle concentration gradient without an interface in the coating layer, and have high durability and are free from toner scattering and soiling. Suitable for electrophotographic two-component developers because it can form an image with a high image density and can provide a stable carrier that does not deteriorate charging characteristics even when the carrier coating layer is worn during continuous use. Used for.
The developer of the present invention using the carrier of the present invention is suitably used for a developer-containing container, a process cartridge, an image forming apparatus, and an image forming method, and can perform high-quality image formation.

FIG. 1 is a schematic view showing an example of an apparatus used in the carrier manufacturing method of the present invention. FIG. 2 is a schematic configuration diagram showing an example of the process cartridge of the present invention. FIG. 3 is a schematic explanatory view showing an example in which the image forming method of the present invention is carried out by the image forming apparatus of the present invention. FIG. 4 is a schematic explanatory view showing another example in which the image forming method of the present invention is implemented by the image forming apparatus of the present invention. FIG. 5 is a schematic explanatory view showing an example in which the image forming method of the present invention is implemented by the image forming apparatus (tandem color image forming apparatus) of the present invention. 6 is a partially enlarged schematic explanatory view of the image forming apparatus shown in FIG.

Explanation of symbols

10 Photoconductor (Photoconductor drum)
10K black photoconductor 10Y yellow photoconductor 10M magenta photoconductor 10C cyan photoconductor 14 support roller 15 support roller 16 support roller 17 intermediate transfer cleaning device 18 image forming means 20 charging roller 21 exposure device 22 secondary transfer device 23 Roller 24 Secondary transfer belt 25 Fixing device 26 Fixing belt 27 Pressure roller 28 Sheet reversing device 30 Exposure device 32 Contact glass 33 First traveling member 34 Second traveling member 35 Imaging lens 36 Reading sensor 40 Developing device 41 Developing belt 42K Developer container 42Y Developer container 42M Developer container 42C Developer container 43K Developer supply roller 43Y Developer supply roller 43M Developer supply roller 43C Developer supply roller 44K Developer roller 44Y Developer roller 44M Developer Roller 44C Development roller 45K Black development unit 45Y Yellow development unit 45M Magenta development unit 45C Cyan development unit 49 Registration roller 50 Intermediate transfer member 51 Roller 52 Separation roller 53 Manual feed path 54 Manual feed tray 55 Switching claw 56 Discharge roller 57 discharge tray 58 corona charger 60 cleaning device 61 developing device 62 transfer charger 63 photoconductor cleaning device 64 discharger 70 discharger lamp 80 transfer roller 90 cleaning device 95 transfer paper 100 image forming device 101 photoconductor 102 charging means 103 exposure 104 Developing means 105 Recording medium 107 Cleaning means 108 Transfer means 120 Tandem developer 130 Document table 142 Paper feed roller 143 Paper bank 144 Paper feed cassette 145 Separating roller 14 Feeding path 147 transport rollers 148 feed path 150 copier main body 200 feeder table 300 Scanner 400 automatic document feeder (ADF)

Claims (16)

  In a fluid containing at least one of a supercritical fluid and a subcritical fluid, a solution in which a plurality of coating materials are dissolved is reduced in solubility by controlling at least one of pressure and temperature, and a core is obtained. A method for producing a carrier, comprising forming a coating layer on a material surface.   The method for producing a carrier according to claim 1, wherein the coating material is coated on the surface of the core material under a condition in which a plurality of coating materials coexist.   The carrier production method according to claim 1, wherein one of the supercritical fluid and the subcritical fluid is carbon dioxide.   The method for producing a carrier according to any one of claims 1 to 3, wherein the coating material comprises 3 to 5 types of materials.   The carrier manufacturing method according to any one of claims 1 to 4, wherein the coating material is made of five kinds of materials.   The method for producing a carrier according to any one of claims 1 to 5, wherein the coating material comprises materials having different solubilities in the supercritical fluid and the subcritical fluid.   The method for producing a carrier according to claim 1, wherein the coating material is made of a material having a different number of functional groups. The method for producing a carrier according to any one of claims 1 to 7, wherein the coating material comprises a silicone resin represented by the following structural formula (i) as a main skeleton.
However, in the structural formula (i), R represents a hydrogen atom, a hydroxyl group, an alkoxy group, an alkyl group, an aryl group, or an amino group.   The method for producing a carrier according to any one of claims 1 to 8, wherein the coating material has an amino-modified silicone resin as a main skeleton.   The carrier manufacturing method according to claim 9, wherein the coating material is made of a resin having a different amino modification rate.   The method for producing a carrier according to any one of claims 8 to 10, wherein the silicone resin has a mass average molecular weight (Mw) of 500 to 100,000.   A carrier manufactured by the carrier manufacturing method according to claim 1.   A developer comprising the carrier according to claim 12 and a toner.   An electrostatic latent image carrier that carries an electrostatic latent image and the electrostatic latent image formed on the electrostatic latent image carrier are developed using the developer according to claim 13 to form a visible image. A process cartridge having at least developing means.   An electrostatic latent image carrier, electrostatic latent image forming means for forming an electrostatic latent image on the electrostatic latent image carrier, and developing the electrostatic latent image using the developer according to claim 13. An image characterized by comprising at least developing means for forming a visible image, transfer means for transferring the visible image onto a recording medium, and fixing means for fixing the transferred image transferred to the recording medium. Forming equipment. An electrostatic latent image forming step for forming an electrostatic latent image on the electrostatic latent image carrier, and development for developing the electrostatic latent image using the developer according to claim 13 to form a visible image. An image forming method comprising: a step, a transfer step of transferring the visible image to a recording medium, and a fixing step of fixing the transferred image transferred to the recording medium.