Toner composition and method for manufacturing the toner composition

Abstract

A toner composition including toner particles, wherein the toner particles are prepared by a method in which toner constituents including at least a binder resin and a colorant are kneaded upon application of heat to prepare a toner constituent mixture; the toner constituent mixture is dissolved or swelled in an organic solvent capable of dissolving or swelling at least the binder resin to prepare an oil phase liquid; the oil phase liquid is emulsified in an aqueous liquid to prepare an emulsion; the emulsion is coagulated; and then the coagulated emulsion is dried to prepare the toner particles.

What is claimed as new and desired to be secured by Letters Patent of the United States is:  
     
         1 . A toner composition comprising toner particles, wherein the toner particles are prepared by a method selected from the group consisting of: 
 a first method comprising: 
 kneading toner constituents comprising at least a binder resin and a colorant upon application of heat to prepare a toner constituent mixture;  
 dissolving the toner constituent mixture in an organic solvent capable of dissolving at least the binder resin to prepare an oil phase liquid;  
 emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;  
 coagulating the emulsion; and  
 drying the coagulated emulsion to prepare the toner particles;  
   a second method comprising: 
 kneading toner constituents comprising at least a binder resin and a colorant upon application of heat to prepare a toner constituent mixture;  
 swelling the toner constituent mixture in an organic solvent capable of swelling at least the binder resin to prepare an oil phase liquid;  
 emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;  
 coagulating the emulsion; and  
 drying the coagulated emulsion to prepare the toner particles;  
   a third method comprising: 
 kneading at least a colorant and a binder resin to prepare a master batch colorant;  
 dispersing toner constituents comprising at least the master batch colorant and a resin in an organic solvent capable of dissolving the resin to prepare an oil phase liquid, wherein the resin is the same as the binder resin or different from the binder resin;  
 emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;  
 coagulating the emulsion; and  
 drying the coagulated emulsion to prepare the toner particles;  
   a fourth method comprising: 
 kneading at least a colorant and a binder resin to prepare a master batch colorant;  
 dispersing toner constituents comprising at least the master batch colorant and a resin in an organic solvent capable of swelling the resin to prepare an oil phase liquid, wherein the resin is the same as the binder resin or different from the binder resin;  
 emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;  
 coagulating the emulsion; and  
 drying the coagulated emulsion to prepare the toner particles; and  
   a fifth method comprising: 
 dispersing at least a colorant in a binder resin to prepare a master batch colorant;  
 kneading toner constituents comprising at least the master batch colorant and a resin upon application of heat to prepare a toner constituent mixture, wherein the resin is the same as or different from the binder resin;  
 dispersing the toner constituent mixture in an organic solvent capable of dissolving at least the binder resin and the resin to prepare an oil phase liquid, wherein the resin is the same as the binder resin or different from the binder resin;  
 emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;  
 removing the organic solvent from the emulsion; and  
 drying the emulsion to prepare the toner particles.  
   
     
     
         2 . The toner composition according to  claim 1 , wherein the binder resin comprises a polyester resin.  
     
     
         3 . The toner composition according to  claim 1 , wherein the binder resin comprises a polyol resin.  
     
     
         4 . The toner composition according to  claim 1 , wherein the binder resin comprises a styrene-acrylic copolymer.  
     
     
         5 . The toner composition according to  claim 1 , wherein the toner constituents further comprises a wax.  
     
     
         6 . The toner composition according to  claim 1 , wherein the emulsion is coagulated by adding a wax emulsion.  
     
     
         7 . The toner composition according to  claim 1 , wherein the emulsion is coagulated by adding a particulate resin.  
     
     
         8 . The toner composition according to  claim 1 , wherein the colorant is selected from the group consisting of yellow, magenta, cyan and black colorants.  
     
     
         9 . A method for manufacturing a toner composition comprising toner particles, comprising: 
 kneading toner constituents comprising at least a binder resin and a colorant upon application of heat to prepare a toner constituent mixture;    dissolving or swelling the toner constituent mixture in an organic solvent capable of dissolving or swelling at least the binder resin to prepare an oil phase liquid;    emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;    coagulating the emulsion; and    drying the coagulated emulsion to prepare the toner particles.    
     
     
         10 . The method according to  claim 9 , further comprising: 
 removing the organic solvent from the emulsion before the coagulation step.    
     
     
         11 . The method according to  claim 9 , further comprising: 
 removing the organic solvent from the emulsion after the coagulation step.    
     
     
         12 . The method according to  claim 9 , wherein the colorant is selected from the group consisting of yellow, magenta, cyan and black colorants.  
     
     
         13 . A method for manufacturing a toner composition comprising toner particles, comprising: 
 kneading at least a colorant and a binder resin to prepare a master batch colorant;    dispersing or swelling toner constituents comprising at least the master batch colorant and a resin in an organic solvent capable of dissolving or swelling at least the binder resin and the resin to prepare an oil phase liquid, wherein the resin is the same as the binder resin or different from the binder resin;    emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;    coagulating the emulsion; and    drying the coagulated emulsion to prepare the toner particles.    
     
     
         14 . The method according to  claim 13 , further comprising: 
 removing the organic solvent from the emulsion before the coagulation step.    
     
     
         15 . The method according to  claim 13 , further comprising: 
 removing the organic solvent from the emulsion after the coagulation step.    
     
     
         16 . The method according to  claim 13 , wherein the colorant is selected from the group consisting of yellow, magenta, cyan and black colorants.  
     
     
         17 . A method for manufacturing a toner composition comprising toner particles, comprising: 
 dispersing at least a colorant in a binder resin to prepare a master batch colorant;    kneading toner constituents comprising at least the master batch colorant and a resin upon application of heat to prepare a toner constituent mixture, wherein the resin is the same as or different from the binder resin;    dispersing the toner constituent mixture in an organic solvent capable of dissolving at least the binder resin and the resin to prepare an oil phase liquid, wherein the resin is the same as the binder resin or different from the binder resin;    emulsifying the oil phase liquid in an aqueous liquid to prepare an emulsion;    removing the organic solvent from the emulsion; and    drying the emulsion to prepare the toner particles.    
     
     
         18 . The method according to  claim 17 , further comprising: 
 removing the organic solvent from the emulsion before the coagulation step.    
     
     
         19 . The method according to  claim 17 , further comprising: 
 removing the organic solvent from the emulsion after the coagulation step.    
     
     
         20 . The method according to  claim 17 , wherein the colorant is selected from the group consisting of yellow, magenta, cyan and black colorants.  
     
     
         21 . An image forming apparatus comprising: 
 an image bearer comprising at least one image bearing member configured to bear an electrostatic latent image;    an image developer comprising at least one developing section containing a developer including a toner, wherein the at least one developing section is configured to develop the electrostatic latent image with the developer to form a toner image on the image bearing member; and    an image transfer device configured to transfer the toner image onto a receiving material,    wherein the toner is the toner composition according to  claim 1 .    
     
     
         22 . The image forming apparatus according to  claim 21 , wherein the image bearing member bears plural electrostatic latent images, wherein the image developer comprises plural developing sections each containing a different color developer including a different color toner, and develops the plural electrostatic latent images to form plural color toner images on the image bearing member, and wherein the image transfer device transfers the plural toner images onto a receiving material one by one to form a color image.  
     
     
         23 . The image forming apparatus according to  claim 21 , wherein the image bearer comprises plural image bearing members each bearing an electrostatic latent image, wherein the image developer comprises plural developing sections each containing a different color developer including a different color toner, and develops the plural electrostatic latent images to form plural color toner images on the plural image bearing members, and wherein the image transfer device transfers the plural toner images onto a receiving material one by one to form a color image.  
     
     
         24 . The image forming apparatus according to  claim 23 , wherein the image transfer device transfers the plural toner images on an intermediate transfer medium one by one to form a color image, and wherein the color image is transferred onto the receiving material.  
     
     
         25 . The image forming apparatus according to  claim 22 , wherein the image transfer device transfers the plural toner images on an intermediate transfer medium one by one to form a color image, and wherein the color image is transferred onto the receiving material.  
     
     
         26 . The image forming apparatus according to  claim 21 , wherein the developer is a two component developer including a carrier and the toner.  
     
     
         27 . The image forming apparatus according to  claim 21 , wherein the developer is a one component developer, wherein the at least one developing section further comprises a developing roller and a developing blade configured to form a layer of the one component developer on a surface of the developing roller, and wherein the developing roller is configured to develop the electrostatic latent image with the layer of the one component developer.