Particles and manufacturing method thereof, toner and manufacturing method thereof, and developer, toner container, process cartridge, image forming method and image forming apparatus

A method for manufacturing a toner comprising the steps of:

• melt mixing any one mixture selected from (1) to (4) below under pressure or melt mixing any one mixture selected from (1) to (4) below with an injection of a supercritical fluid;
• spraying the obtained melt-mixed substance with a high-pressure gas for atomization while the melt-mixed substance is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

A method for manufacturing a toner comprising a spray granulation apparatus,

• wherein the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle,
• wherein the mixture is uniformly dispersed while the mixture is melt mixed or the mixture is injected with an injection of a supercritical fluid and melt mixed under pressure;
• the obtained dispersion is sprayed with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• cooling air is introduced in the chamber through an air inlet formed on the chamber for granulation:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

A toner manufactured by means of a method for manufacturing a toner,

• wherein the method for manufacturing a toner comprises the steps of:
• melt mixing any one mixture selected from (1) to (4) below under pressure or melt mixing any one mixture selected from (1) to (4) below with an injection of a supercritical fluid;
• spraying the obtained melt-mixed substance with a high-pressure gas for atomization while the melt-mixed substance is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

A toner manufactured by means of a method for manufacturing a toner,

• wherein the toner is manufactured with a spray granulation apparatus, and the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle,
• wherein the method for manufacturing a toner comprises the steps of:
• dispersing uniformly the mixture by melt mixing or by melt mixing under pressure with an injection of a supercritical fluid;
• spraying the obtained dispersion with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

A developer comprising a toner,

• wherein the toner is manufactured by a method for manufacturing a toner in a spray granulation apparatus,
• wherein the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle, and
• the method for manufacturing a toner comprises the steps of
• dispersing uniformly the mixture by melt mixing or by melt mixing under pressure with an injection of a supercritical fluid;
• spraying the obtained dispersion with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

A toner container filled with a toner,

• wherein the toner is manufactured by a method for manufacturing a toner in a spray granulation apparatus,
• wherein the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle, and
• the method for manufacturing a toner comprises the steps of
• dispersing uniformly the mixture by melt mixing or by melt mixing under pressure with an injection of a supercritical fluid;
• spraying the obtained dispersion with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

A process cartridge comprising:

• a latent electrostatic image bearing member, and
• a developing means which forms a visible image by developing a latent electrostatic image on the latent electrostatic image bearing member with a toner,
• wherein the toner is manufactured by a method for manufacturing a toner in a spray granulation apparatus,
• wherein the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle;
• and
• the method for manufacturing a toner comprises the steps of:
• dispersing uniformly the mixture by melt mixing or by melt mixing under pressure with an injection of a supercritical fluid;
• spraying the obtained dispersion with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

An image forming method comprising the steps of:

• forming a latent electrostatic image on a latent electrostatic image bearing member;
• developing the latent electrostatic image to form a visible image using a toner;
• transferring the visible image to a recording medium;
• and
• fixing a transfer image transferred on the recording medium;
• wherein the toner is manufactured by a method for manufacturing a toner in a spray granulation apparatus,
• wherein the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle;
• and
• the method for manufacturing a toner comprises the steps of:
• dispersing uniformly the mixture by melt mixing or by melt mixing under pressure with an injection of a supercritical fluid;
• spraying the obtained dispersion with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.

An image forming apparatus comprising:

• a latent electrostatic image bearing member;
• a latent electrostatic image forming means that forms a latent electrostatic image on the latent electrostatic image bearing member;
• a developing means that develops the latent electrostatic image using a toner;
• a transferring means that transfers the visible image on a recording medium;
• and
• a fixing means that fixes a transfer image transferred on the recording medium,
• wherein the toner is manufactured by a method for manufacturing a toner in a spray granulation apparatus;
• wherein the spray granulation apparatus comprises a means of melt mixing any one of the mixtures selected from (1) to (4) below and a chamber comprising a high-pressure gas nozzle;
• and
• the method for manufacturing a toner comprises the steps of:
• dispersing uniformly the mixture by melt mixing or by melt mixing under pressure with an injection of a supercritical fluid;
• spraying the obtained dispersion with a high-pressure gas for atomization while the dispersion is being discharged in a chamber;
• and
• granulating by introducing cooling air in the chamber through an air inlet formed on the chamber:
• (1) a mixture comprising a binding resin and a colorant;
• (2) a mixture comprising a binding resin, a colorant and a charge controller;
• (3) a mixture comprising a binding resin, a colorant, a charge controller and a wax;
• or
• (4) a mixture comprising a binding resin, a magnetizing agent, a charge controller, a wax and a magnetizing agent.