WO2013014969A1 - Ferrite particle production method - Google Patents

Abstract

This ferrite particle production method is characterized by involving: a step for obtaining a slurry by injecting into a medium solution an Mn component raw material and an Fe component raw material adjusted so as to generate ferrite particles having a composition expressed by Mn_xFe_3-XO₄ (wherein 0≦X≦1); a step for obtaining granules by spray-drying said slurry; a first firing step for obtaining a precursor by firing said granules in an oxidizing atmosphere; and a second firing step for obtaining a fired product by further firing the obtained precursor within a firing temperature range of 1050-1300°C in a reducing atmosphere. Here, from the viewpoint of further promote roughening of the surface shape of the ferrite particles, the firing temperature in the first firing step is ideally in the range 1150-1300°C, and the firing time is ideally at least 1.5 hours.

Description

Method for producing ferrite particles

The present invention relates to a method for producing ferrite particles, and more particularly to a method for producing ferrite particles having a concavo-convex surface and predetermined magnetic properties.

For example, in an image forming apparatus such as a facsimile, printer, or copier using an electrophotographic method, an electrostatic latent image formed on the surface of an electrostatic latent image carrier (hereinafter sometimes referred to as “photosensitive member”). Is visualized with a developer, and the visible image is transferred onto paper or the like, and then fixed by heating and pressing. A so-called two-component developer including a carrier and a toner is widely used as a developer from the viewpoint of high image quality and colorization.

In the development using the two-component developer, a plurality of magnetic poles are built in, and a developer carrier (hereinafter sometimes referred to as a “development sleeve”) that carries the developer on the surface and a photosensitive member are spaced at a predetermined interval. In a region where the photosensitive member and the developing sleeve face each other (hereinafter referred to as a “developing region”), a magnetic brush that gathers and stands up is placed on the developing sleeve. In addition to the formation, a developing bias voltage is applied between the photosensitive member and the developing sleeve, and toner is attached to the electrostatic latent image on the surface of the photosensitive member.

In order to improve the image quality, for example, in Patent Document 1, an alternating electric field is formed between the developing sleeve and the photosensitive member, and the electrostatic toner is held by the toner held on the magnetic brush and the toner carried on the developing sleeve. It has been proposed to develop the latent image. Further, Patent Document 2 proposes developing an electrostatic latent image using a carrier having a small particle diameter and low magnetization.

JP-A 62-63970 JP 2010-66490 JP

By the way, in recent years, in order to respond to the market demand for increasing the image forming speed in the image forming apparatus, the rotational speed of the developing sleeve is increased to increase the supply amount of the developer per unit time to the developing region. .

However, when a carrier having a small particle diameter of 50 μm or less is used, a sufficient image density may not be obtained even if the rotation speed of the developing sleeve is increased to increase the amount of developer supplied to the developing area. One reason for this is that only the carrier at the tip of the magnetic brush circulates and moves in the developing region, the carrier at the root does not circulate and the toner held on the carrier at the root does not contribute to development. It is considered one.

In order to greatly circulate and move the carrier at the tip of the magnetic brush and the carrier at the base in the development area, it is considered to make the surface of the carrier uneven and increase the frictional resistance with the surface of the photoreceptor and the frictional resistance between the carriers. It is done.

Accordingly, an object of the present invention is to provide a method capable of stably producing ferrite particles having a concavo-convex surface and having predetermined magnetic characteristics and resistance characteristics.

According to the present invention, an Fe component raw material and a Mn component raw material whose components are adjusted so that ferrite particles having a composition represented by Mn _X Fe _3-X O ₄ (where 0 ≦ X ≦ 1) are generated are used as a medium liquid A step of obtaining a slurry by charging the slurry, a step of obtaining a granulated product by spray drying the slurry, and a first firing step of obtaining a precursor by firing the granulated product in an oxidizing atmosphere. And a second firing step in which the precursor is further fired in a reducing atmosphere at a firing temperature in the range of 1050 ° C. to 1300 ° C. to obtain a fired product.

Here, from the viewpoint of further promoting the unevenness of the surface shape of the ferrite particles, the firing temperature in the first firing step is preferably in the range of 1150 ° C. to 1300 ° C. The firing time is preferably 1.5 hours or longer.

Further, from the viewpoint of imparting desired magnetic properties while maintaining the surface irregularity shape of the ferrite particles, the firing time in the second firing step is preferably 0.5 hours or more.

In addition, the oxygen concentration in the second firing step is preferably 1% or less.

According to the method for producing ferrite particles according to the present invention, the surface can be formed into an uneven shape, and predetermined magnetic characteristics and resistance characteristics can be imparted.

It is the SEM photograph and peak count map image of particle | grains before baking during baking in a 1st baking process, and after baking. It is a figure which shows the XDR pattern of particle | grains before baking during baking in a 1st baking process, and after baking. It is the SEM photograph and peak count map image of the particle | grains after 2nd baking. It is a figure which shows the XDR pattern of the particle | grains before baking after baking in a 2nd baking process. A firing temperature in the second firing step is a graph showing the relationship between magnetization ^{_{σ 1k (Am 2 / kg)}} . 2 is a SEM photograph of ferrite particles of Example 1. 4 is a SEM photograph of ferrite particles of Example 2. 4 is a SEM photograph of ferrite particles of Example 3. 4 is a SEM photograph of ferrite particles of Example 4. 6 is a SEM photograph of ferrite particles of Example 5. 4 is a SEM photograph of ferrite particles of Example 6. 4 is a SEM photograph of ferrite particles of Comparative Example 1.

As a result of intensive investigations to produce ferrite particles having irregularities on the surface and predetermined magnetic properties and resistance properties, the inventors have baked the granulated material containing raw materials in an oxidizing atmosphere. Although the granulated product is once ferritized, it reacts with oxygen in the cooling process and decomposes into Fe oxide and Mn oxide. At this time, the crystal structure changes, and a plurality of angular grains are formed on the particle surface. The surface of the fired product was found to be uneven. However, desired magnetic characteristics such as saturation magnetization and coercive force cannot be obtained by firing in an oxidizing atmosphere. Therefore, in the present invention, the precursor having a concavo-convex shape, which is fired in an oxidizing atmosphere, is sintered again in a reducing atmosphere to impart magnetic properties while maintaining the concavo-convex shape of the surface. Hereafter, the manufacturing method of this invention is demonstrated in order for every process.

First, a Fe component raw material and a Mn component raw material are weighed, put into a dispersion medium, and mixed to prepare a slurry. Fe ₂ O ₃ or the like is preferably used as the Fe component raw material. As the Mn component raw material, MnCO ₃ , Mn ₃ O ₄ or the like can be suitably used.

Water is preferred as the dispersion medium used in the present invention. In addition to the Fe component raw material and the Mn component raw material, a binder, a dispersant and the like may be blended in the dispersion medium as necessary. For example, polyvinyl alcohol can be suitably used as the binder. The binder content is preferably about 0.5 to 2 wt% in the slurry. Moreover, as a dispersing agent, polycarboxylate ammonium etc. can be used conveniently, for example. The blending amount of the dispersant is preferably about 0.5 to 2 wt% in the slurry. In addition, you may mix | blend a lubricant, a sintering accelerator, etc.

The solid content concentration of the slurry is desirably in the range of 50 to 90 wt%. In addition, before introducing the Fe component raw material and the Mn component raw material into the dispersion medium, if necessary, pulverization and mixing may be performed.

Next, the slurry prepared as described above is wet-pulverized as necessary. For example, wet grinding is performed for a predetermined time using a ball mill or a vibration mill. The average particle size of the raw material after pulverization is preferably 3 μm or less, more preferably 1 μm or less. The vibration mill or ball mill preferably contains a medium having a predetermined particle diameter. Examples of the material of the media include iron-based chromium steel and oxide-based zirconia, titania, and alumina. As a form of a grinding | pulverization process, any of a continuous type and a batch type may be sufficient. The particle size of the pulverized product is adjusted depending on the pulverization time and rotation speed, the material and particle size of the media used, and the like.

Then, the pulverized slurry is spray-dried and granulated. Specifically, the slurry is introduced into a spray dryer such as a spray dryer, and granulated into a spherical shape by spraying into the atmosphere. The atmospheric temperature during spray drying is preferably in the range of 100 to 300 ° C. Thereby, a spherical granulated product having a particle size of 10 to 200 μm is obtained. In addition, it is desirable that the obtained granulated product has a sharp particle size distribution by removing coarse particles and fine powder using a vibration sieve or the like.

Next, the granulated material is put into a furnace heated to a predetermined temperature or higher and fired to produce a precursor (first firing step). What is important here is that the granulated product is fired in an oxidizing atmosphere. Specifically, the granulated material may be fired in an air atmosphere. By putting the granulated material into a heating furnace at a predetermined temperature or more, the granulated material becomes ferrite and becomes Mn ferrite particles, but reacts with oxygen and decomposes into iron oxide and manganese oxide in the cooling process. At this time, as the crystal structure changes from the spinel type to the trigonal system, a plurality of angular grains are formed on the particle surface. The firing temperature in the first firing step is preferably in the range of 1150 ° C. to 1300 ° C., and the firing time is preferably 1.5 hours or more.

FIG. 1 shows SEM photographs and peak count map images by EDS analysis of particles before, during and after firing in the first firing step. In addition, FIG. 2 shows a diagram showing an XDR pattern. As understood from FIGS. 1 and 2, it can be seen that by heating the granulated product, Fe and Mn dispersed in the particles react and ferritization proceeds. In addition, grains are exposed as they become ferritic and are exposed on the surface at the same time, and irregularities are formed on the surface of the particles. Next, when the particles are cooled in the atmosphere (oxidizing atmosphere), the formed ferrite reacts with oxygen and decomposes into iron oxide (α-Fe ₂ O ₃ ) and manganese oxide (Mn ₃ O ₄ ). By this decomposition reaction, the crystal structure of the particles changes from the spinel structure of Mn ferrite to the trigonal system of iron oxide (α-Fe ₂ O ₃ ), and the grain angulation on the particle surface further develops.

In the case where the precursor thus obtained is agglomerated by sintering, it may be pulverized if necessary. The pulverization of the precursor can be performed by, for example, a hammer mill. The form of the granulation step may be either a continuous type or a batch type. However, pulverization of the precursor is sufficient to eliminate adhesion between particles, and it is important that the particles themselves are not pulverized.

Next, this precursor is put into a furnace heated to a temperature of 1050 ° C. to 1300 ° C. and fired again (second firing step). What is important here is that the granulated product is fired in a reducing atmosphere. Accordingly, the precursor can be made ferrite while maintaining the uneven shape on the surface, and predetermined magnetic properties can be imparted. In FIG. 3, the SEM photograph of the particle | grains after a 2nd baking process and the peak count map image by EDS analysis are each shown. FIG. 4 is a diagram showing XDR patterns of particles before firing and after firing when firing at a temperature of 1200 ° C. in a nitrogen atmosphere in the second firing step. As is clear from these figures, the fired product after the second firing step had spinel structure Mn ferrite particles with an uneven surface. The oxygen concentration in the reducing atmosphere is preferably 1% or less.

FIG. 5 shows the relationship between the firing temperature in the second firing step and the magnetization σ _1k (Am ² / kg) in a magnetic field of 1000 / (4π) kA / m (1 k Oersted). The firing time was unified at 6 hours. When Mn ferrite particles are used as a carrier for the developer, the magnetization σ _1k is desirably larger than 50 Am ² / kg from the viewpoint of preventing carrier scattering from the developing sleeve. Therefore, when Mn ferrite particles are used as a carrier for the developer, the firing temperature in the second firing step is preferably 1050 ° C. or higher. On the other hand, when the firing temperature is increased, the desired magnetic properties can be obtained, but the uneven shape on the surface disappears, so the upper limit of the firing temperature is preferably 1300 ° C. The firing time is preferably 0.5 hours or more.

And if necessary, the obtained fired product is pulverized. For example, the fired product is pulverized by a hammer mill or the like. The form of the granulation step may be either a continuous type or a batch type. Further, if necessary, classification may be performed in order to make the particle diameter in a predetermined range. As a classification method, a conventionally known method such as air classification or sieve classification can be used. In addition, after primary classification with an air classifier, the particle size may be aligned within a predetermined range with a vibration sieve or an ultrasonic sieve.

The Mn ferrite particles produced as described above can be used for various applications, for example, electrophotographic developing carriers and electromagnetic wave absorbing materials, electromagnetic shielding material powders, rubber, plastic fillers / reinforcing materials, paints, It can be used as a matting material, filler, reinforcing material, etc. for paints and adhesives. Among these, it is particularly preferably used as a carrier for electrophotographic development.

When the Mn ferrite particles of the present invention prepared as described above are used as a carrier for electrophotographic development, the ferrite particles can be used as they are as a carrier for electrophotographic development. However, from the viewpoint of chargeability, the ferrite particles It is preferable that the surface is coated with a resin.

As the resin for coating the surface of the ferrite particles, conventionally known resins can be used. For example, silicone resin, polyethylene, polypropylene, polyvinyl chloride, poly-4-methylpentene-1, polyvinylidene chloride, ABS (acrylonitrile-butadiene) -Styrene) resin, polystyrene, (meth) acrylic resin, polyvinyl alcohol resin, polyvinyl chloride, polyurethane, polyester, polyamide, polybutadiene, and other thermoplastic elastomers, fluorosilicone resins, etc. .

In order to coat the surface of the ferrite particles with a resin, a resin solution or dispersion may be applied to the ferrite particles. Solvents for coating solutions include aromatic hydrocarbon solvents such as toluene and xylene; ketone solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; cyclic ether solvents such as tetrahydrofuran and dioxane; ethanol, propanol, and butanol 1 type, or 2 or more types, such as alcohol solvents such as ethyl cellosolve, cellosolve solvents such as butyl cellosolve; ester solvents such as ethyl acetate and butyl acetate; amide solvents such as dimethylformamide and dimethylacetamide can be used. . The concentration of the resin component in the coating solution is generally in the range of 0.001 to 30 wt%, particularly 0.001 to 2 wt%.

As a method for coating the resin on the ferrite particles, for example, a spray drying method, a fluidized bed method, a spray drying method using a fluidized bed, an immersion method, or the like can be used. Among these, the fluidized bed method is particularly preferable in that it can be efficiently applied with a small amount of resin. For example, in the case of the fluidized bed method, the resin coating amount can be adjusted by the amount of resin solution sprayed and the spraying time.

The particle diameter of the carrier is generally 10 to 110 μm, particularly 10 to 50 μm in terms of volume average particle diameter. The apparent density of the carrier, when mainly composed of a magnetic material, varies depending on the composition of the magnetic material, the surface structure, etc., but is generally preferably in the range of 1.0 to 2.5 g / cm ³ .

The electrophotographic developer is obtained by mixing the carrier prepared as described above and a toner. The mixing ratio of the carrier and the toner is not particularly limited, and may be determined as appropriate based on the developing conditions of the developing device to be used. In general, the toner concentration in the developer is preferably in the range of 1 wt% to 15 wt%. When the toner density is less than 1 wt%, the image density becomes too thin, and when the toner density exceeds 15 wt%, the toner scatters in the developing device, and the toner adheres to the background portion such as in-machine dirt or transfer paper. This is because there is a risk of occurrence. A more preferable toner concentration is in the range of 3 to 10 wt%.

The toner to be used can be produced by a method known per se such as a polymerization method, a pulverization classification method, a melt granulation method, a spray granulation method, and the like in a binder resin mainly composed of a thermoplastic resin. , A colorant, a release agent, a charge control agent, and the like.

As for the particle diameter of the toner, it is generally preferable that the volume average particle diameter measured by a Coulter counter is in the range of 5 to 15 μm, particularly 7 to 12 μm.

If necessary, a modifier can be added to the surface of the toner particles. Examples of the modifier include silica, aluminum oxide, zinc oxide, titanium oxide, magnesium oxide, calcium carbonate, polymethyl methacrylate, and the like. These 1 type (s) or 2 or more types can be used in combination.

A known mixing device can be used for mixing the carrier and the toner. For example, a Henschel mixer, a V-type mixer, a tumbler mixer, a hybridizer, or the like can be used.

EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these examples at all.

Example 1

Mn ferrite particles were produced by the following method. As starting materials, Fe ₂ O ₃ (average particle size 0.6 μm) 10.75 kg (67.3 mol), Mn ₃ O ₄ (average particle size: 2 μm) 4.25 kg (19.0 mol), water Dispersed in 5.0 kg, 90 g of ammonium polycarboxylate dispersant as dispersant, 45 g of carbon black as reducing agent, 30 g (0.25 mol) of colloidal silica (solid content concentration 50%) as SiO ₂ raw material added To make a mixture. The solid content concentration of this mixture was 75% by weight. This mixture was pulverized by a wet ball mill (media diameter 2 mm) to obtain a mixed slurry.

This mixed slurry was sprayed into hot air of about 130 ° C. with a spray dryer (disk rotation speed: 17500 rpm) to obtain a dry granulated product having a particle size of 10 to 200 μm. From this granulated product, coarse particles were separated using a sieve mesh having a mesh size of 54 μm, and fine particles were separated using a sieve mesh having a mesh size of 33 μm.

This granulated powder was put into an electric furnace in an air atmosphere and fired at 1150 ° C. for 3 hours. The magnetic properties, resistance properties, and circularity of the obtained precursor were measured by the methods shown below. Table 1 summarizes the measurement results.

Next, the obtained precursor was further put into an electric furnace in a nitrogen atmosphere and baked at 1050 ° C. for 6 hours. The fired product obtained was pulverized with a hammer mill and then classified using a vibration sieve to obtain ferrite particles having an average particle size of 35 μm.
The magnetic properties, resistance properties, apparent density, and circularity of the obtained ferrite particles were measured in the same manner as described above. Table 2 summarizes the measurement results. FIG. 6 shows an SEM photograph of the produced ferrite particles.

(Magnetic properties)

Using a vibration sample type magnetometer (VSM) dedicated to room temperature (“VSM-P7” manufactured by Toei Kogyo Co., Ltd.), one cycle continuously in the external magnetic field range of 0 to 10000 / (4π) kA / m (10000 Oersted) When applied, saturation magnetization σs (A · m ² / kg), residual magnetization σr (A · m ² / kg), coercive force Hc (A / m × 10 ³ / (4π)), magnetization σ _1k (Am ² / Kg) and magnetization σ ₅₀₀ (Am ² / kg).

(Resistance characteristics)

Two brass plates as electrodes having a thickness of 2 mm whose surfaces were electropolished were arranged to face each other with a distance of 2 mm. After inserting 200 mg of ferrite particles between the electrodes, a magnet having a cross-sectional area of 240 mm ² (ferrite magnet having a surface magnetic flux density of 1500 gauss) is arranged behind each electrode to form a bridge of ferrite particles between the electrodes. It was. Then, a DC voltage of 50 V was applied between the electrodes, the current value flowing through the ferrite particles was measured, and the resistance value of the ferrite particles was calculated.

(Apparent density)

The apparent density of the ferrite particles was measured according to JIS Z 2504.

(Roundness)

Carrier particles were cut using a cross-section polisher (SM-09019 (JEOL) voltage: 6 kV, time: 4 h), and the cross section was scanned with a scanning electron microscope (JSM-6510LA type acceleration voltage: 5 kV, spot size: 45, magnification) : 1000 times), the image was analyzed with an image analyzer (LEXT-OLS3000 analSIS (OLYMPUS)), and the circularity of the ferrite particles was calculated from the following equation.
Circularity = (circumference of a circle having the same area as the projected area of the particle) ² / (length of the contour of the particle projection) ²

Example 2

A precursor and ferrite particles were produced in the same manner as in Example 1 except that the firing time in the first firing step was 1.5 hours, the firing temperature in the second firing step was 1100 ° C., and the firing time was 3 hours. Then, the magnetic properties, resistance properties, apparent density, and circularity of the obtained precursor and ferrite particles were measured in the same manner as in Example 1. Table 1 shows the measurement results of the precursor, and Table 2 shows the measurement results of the ferrite particles. FIG. 7 shows an SEM photograph of the produced ferrite particles.

Example 3

A precursor and ferrite particles were prepared in the same manner as in Example 1 except that the firing temperature in the second firing step was 1125 ° C. and the firing time was 1 hour. Then, the magnetic properties, resistance properties, apparent density, and circularity of the obtained precursor and ferrite particles were measured in the same manner as in Example 1. Table 1 shows the measurement results of the precursor, and Table 2 shows the measurement results of the ferrite particles. FIG. 8 shows an SEM photograph of the produced ferrite particles.

Example 4

A precursor and ferrite particles were produced in the same manner as in Example 1 except that the firing temperature in the second firing step was 1200 ° C. and the firing time was 0.5 hours. Then, the magnetic properties, resistance properties, apparent density, and circularity of the obtained precursor and ferrite particles were measured in the same manner as in Example 1. Table 1 shows the measurement results of the precursor, and Table 2 shows the measurement results of the ferrite particles. FIG. 9 shows an SEM photograph of the produced ferrite particles.

Example 5

A precursor and ferrite particles were produced in the same manner as in Example 1 except that the firing temperature in the first firing step was 1200 ° C., the firing temperature in the second firing step was 1150 ° C., and the firing time was 3 hours. Then, the magnetic properties, resistance properties, apparent density, and circularity of the obtained precursor and ferrite particles were measured in the same manner as in Example 1. Table 1 shows the measurement results of the precursor, and Table 2 shows the measurement results of the ferrite particles. FIG. 10 shows an SEM photograph of the produced ferrite particles.

Example 6

A precursor and ferrite particles were produced in the same manner as in Example 1 except that the firing temperature in the first firing step was 1275 ° C., the firing temperature in the second firing step was 1150 ° C., and the firing time was 3 hours. Then, the magnetic properties, resistance properties, apparent density, and circularity of the obtained precursor and ferrite particles were measured in the same manner as in Example 1. Table 1 shows the measurement results of the precursor, and Table 2 shows the measurement results of the ferrite particles. FIG. 11 shows an SEM photograph of the produced ferrite particles.

Comparative Example 1

The granulated powder produced in the same manner as in Example 1 was put into an electric furnace in a nitrogen atmosphere and fired at 1150 ° C. for 3 hours. The obtained fired product was pulverized with a hammer mill and then classified using a vibration sieve to obtain ferrite particles having an average particle size of 35 μm. Then, the magnetic properties, resistance properties, apparent density, and circularity of the obtained ferrite particles were measured in the same manner as in Example 1. The measurement results are shown in Table 2. FIG. 12 shows an SEM photograph of the produced ferrite particles.

As can be seen from Table 2, the Mn ferrite particles of Examples 1 to 6 prepared by the production method according to the present invention have a circularity of 0.58 or less, an uneven surface, and as a carrier for electrophotographic development. Even when it was used, it had magnetic properties that did not cause problems such as carrier scattering.

On the other hand, although the Mn ferrite particles of Comparative Example 1 fired only once in a reducing atmosphere had predetermined magnetic characteristics and resistance characteristics, as is apparent from FIG. 64 and the degree of unevenness was small.

According to the method for producing ferrite particles according to the present invention, the surface can be formed into an uneven shape, and predetermined magnetic characteristics and resistance characteristics can be imparted, which is useful.

Claims (5)

1. 
   A slurry in which an Fe component raw material and an Mn component raw material whose components have been adjusted so that ferrite particles having a composition represented by Mn _X Fe _3-X O ₄ (where 0 ≦ X ≦ 1) are generated are added to the medium liquid A step of obtaining a granulated product by spray drying the slurry, a first firing step of calcining the granulated product in an oxidizing atmosphere to obtain a precursor, and reducing the obtained precursor to a reducing atmosphere. And a second firing step of further firing at a firing temperature in the range of 1050 ° C. to 1300 ° C. to obtain a fired product.
2. 
   The method for producing ferrite particles according to claim 1, wherein the firing temperature in the first firing step is in the range of 1150 ° C to 1300 ° C.
3. 
   The method for producing ferrite particles according to claim 1 or 2, wherein the firing time in the first firing step is 1.5 hours or more.
4. 
   The method for producing ferrite particles according to any one of claims 1 to 3, wherein a firing time in the second firing step is 0.5 hours or more.
5. 
   The method for producing ferrite particles according to any one of claims 1 to 4, wherein the oxygen concentration in the second firing step is 1% or less.

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