Field of the Invention
[0001] This invention relates to certain electrostatographic toners and developers containing
ester-containing quaternary pyridinium salts which are useful as charge control agents
that also serve as adhesion promoters between toner and receiver sheets and as toner
fusing temperature reducers.
Description of the Prior Art
[0002] In the art of making and using toner powders, charge control agents are commonly
employed to adjust and regulate the triboelectric charging capacity and/or the electrical
conductivity characteristics thereof. Many different charge control agents are known
which have been incorporated into various binder polymers known for use in toner powders.
However, the need for new and improved toner powders that will perform in improved
copying equipment has resulted in continuing research and development efforts to discover
improved charge control agents.
[0003] Of potential interest are substances which not only serve as toner powder charge
control agents, but also function as agents that provide additional results or effects
such as promoting adhesion between toner and receiver sheets and as toner fusing temperature
reducers. Such multi-functionality offers the potential for achieving cost savings
in the manufacture and use of toner powders, developers and copier equipment.
[0004] It would, therefore, be desirable to provide dry, electrostatographic toners and
developers containing ester-containing quaternary pyridinium salts that could perform
the charge-controlling function well in dry, electrostatographic toners and developers
as well as promote the adhesion between toner and receiver sheets and, in addition
thereto, serve as toner fusing temperature reducers.
Summary of the Invention
[0005] This invention provides dry, particulate electrostatographic toners and developers
containing charge control agents comprising ester-containing quaternary pyridinium
salts having the structure:

wherein R₁ is alkyl or aryl, X is (̵CH₂)̵
n' Y is hydrogen, alkyl, alkoxy or halogen, Z
⊖ is an anion and n is an integer from 1 to 6.
[0006] The inventive toner powders comprise a polymeric matrix phase or polymeric binder
which has dispersed therein at least one quaternary pyridinium salt having incorporated
therein at least one ester-containing moiety that is bonded through an alkylene linking
group to the pyridinium nitrogen atom.
[0007] When incorporated into toner powders, such quaternary pyridinium salts not only function
as good charge control agents, but also serve as toner powder fusing temperature depressants
and paper adhesion promoters. These salts are preferably dispersed in the polymeric
binder matrix phase comprising the core or body portion of a toner particle.
[0008] Toner powders containing these salts can also be mixed with a carrier vehicle to
form electrostatographic developers.
[0009] Toner powders containing these salts incorporated into the polymeric binder thereof
can be used for producing developed toned images on a latently imaged photoconductor
element, for transfer of the toned image from the photoconductor element to a receiver
sheet and for heat fusion of the toned image on the receiver while employing processes
and processing conditions heretofore generally known to the art of electrophotography.
[0010] Various other advantages, aims, features, purposes, embodiments and the like associated
with the present invention will be apparent to those skilled in the art from the present
specification taken with the accompanying claims.
Description of the Preferred Embodiments
(A) Definitions
[0011] The term "particle size" as used herein, or the term "size", or "sized" as employed
herein in reference to the term "particles", means volume weighted diameter as measured
by conventional diameter measuring devices, such as a Coulter Multisizer, sold by
Coulter, Inc. Mean volume weighted diameter is the sum of the mass of each particle
times the diameter of a spherical particle of equal mass and density, divided by total
particle mass.
[0012] The term "glass transition temperature" or "Tg" as used herein means the temperature
at which a polymer changes from a glassy state to a rubbery state. This temperature
(Tg) can be measured by differential thermal analysis as disclosed in "Techniques
and Methods of Polymer Evaluation", Vol. 1, Marcel Dekker, Inc., N.Y., 1966.
[0013] The term "melting temperature" or "Tm" as used herein means the temperature at which
a polymer changes from a crystalline state to an amorphous state. This temperature
(Tm) can be measured by differential thermal analysis as disclosed in "Techniques
and Methods of Polymer Evaluation".
[0014] The term "adhesion index" as used herein is a measure of toner adhesion to paper
after the toner has been fused. The adhesion index test involves adhering a metal
block to a toner patch and measuring the energy required to cause interfacial failure
between the toner layer and its contacting substrate by collision of a pendulum with
the metal block. The range of adhesion index is from 0 units (no adhesion of the toner
to the substrate) to 100 units (excellent adhesion of the toner to the substrate).
(B) Ester-Containing Quaternary Pyridinium Salts
[0015] This invention is directed to dry particulate electrostatographic toners and developers
containing ester-containing quaternary pyridinium salts of the formula:

wherein R₁ is alkyl or aryl, X is (̵CH₂)̵
n' Y is hydrogen, alkyl, alkoxy or halogen, Z
⊖ is an anion and n is an integer from 1 to 6.
[0016] As used herein, the term "alkyl" includes straight and branched chain alkyl groups
and cycloalkyl groups.
[0017] As used herein, the term "anion" refers to negative ions such as m-nitrobenzenesulfonate,
tosylate, tetraphenylborate, dicyanamide, chloride and the like.
[0018] As used herein, the term "aryl" includes phenyl, naphthyl, anthryl and the like.
[0019] As used herein, the term "alkoxy" includes methoxy, ethoxy, propoxy, butoxy and the
like.
[0020] As used herein, the term "halogen" includes fluorine, chlorine, bromine and iodine.
[0021] Alkyl and aryl groups can be unsubstituted or substituted with a variety of substituents
such as alkoxy, halo or other groups.
[0022] Illustrative examples of ester-containing quaternary pyridinium salts useful in the
present invention include, for example,
N-(ethoxycarbonylmethyl)pyridinium m-nitrobenzenesulfonate;
N-(ethoxycarbonylmethyl)pyridinium tetraphenylborate;
N-(methoxycarbonylethyl)pyridinium m-nitrobenzenesulfonate;
N-(phenoxycarbonylmethyl)pyridinium m-nitrobenzenesulfonate;
N-(ethoxycarbonylmethyl)-4-methylpyridinium m-nitrobenzenesulfonate;
N-(2-naphthoxycarbonylmethyl)pyridinium tetraphenylborate;
N-(phenoxycarbonylmethyl)-3-chloropyridinium tetraphenylborate; and
N-(ethoxycarbonylmethyl)pyridinium bromide.
[0023] A presently preferred salt is an ester-containing quaternary pyridinium salt of the
invention wherein in the formula set forth above R₁ is ethyl, n is 1, Z
⊖ is tetraphenylborate and Y is hydrogen.
(C) Synthesis
[0024] The ester-containing pyridinium salts employed in the toners and developers of the
present invention can be prepared by any convenient route. One general route is to
quaternize a pyridine compound with a haloalkanoate ester. The quaternary pyridinium
halide can then be reacted with an alkali arylsulfonate or other acid salt through
ion exchange to give the desired N-(alkyloxycarbonyl- or aryloxycarbonylalkyl)-pyridinium
salt.
[0025] One convenient and presently preferred procedure for the preparation of the quaternary
pyridinium compound is to prepare the haloalkanoate ester and the pyridine compound
as solutes in the same highly polar solvent, acetonitrile being one presently particularly
preferred example. The mole ratio of pyridine compound to the haloquaternizing agent
is preferably about 1:1. Such a solution is then stirred at ambient temperature or
heated at reflux for a time in the range of from about 15 to about 25 hours. The reaction
mixture is then cooled or concentrated by solvent evaporation to yield an oil or a
crystalline solid. The product can be used without further purification for the next
step in the synthesis, or the product can be purified by recrystallization, for example,
from a ketone, such as 2-butanone, or the like, followed by washing and drying.
[0026] One convenient and presently preferred procedure for preparation of the quaternary
pyridinium organic salt from the intermediate halide is to dissolve the ion exchange
agent in water and add this solution to a second aqueous solution containing the quaternary
pyridinium salt intermediate. The mole ratio of such salt to such ion exchange agent
should be about 1:1. Typically, a precipitate is formed immediately. The resulting
product after drying, can be recrystallized from a suitable solvent such as acetonitrile
or ethyl acetate.
(D) Toners And Toner Preparation
[0027] To be utilized as a charge control agent in the electrostatographic toners of the
invention, the quaternary pyridinium salts are incorporated into toner particles.
For present purposes, toner particles can be regarded as being preferably comprised
on a 100 weight percent basis of:
(a) about 0.5 to about 10 weight percent of at least one quaternary pyridinium salt;
(b) about 75 to about 97.5 weight percent of a thermoplastic polymer; and
(c) about 2 to about 15 weight percent of a colorant.
[0028] The size of the toner particles is believed to be relatively unimportant from the
standpoint of the present invention; rather the exact size and size distribution is
influenced by the end use application intended. So far as now known, the toner particles
can be used in all known electrostatographic copying processes. Typically and illustratively,
toner particle sizes range from about 0.5 to about 100 microns, preferably from about
4 to about 35 microns.
[0029] The properties of the thermoplastic polymers employed as the toner matrix phase materials
in the present invention can vary widely. Typically, and preferably, amorphous toner
polymers having a glass transition temperature in the range of about 50 to about 120°C
or a blend of substantially amorphous polymers with substantially crystalline polymers
having a melting temperature in the range of about 65 to about 200°C are utilized
in the present invention. Preferably, such polymers, have a number average molecular
weight in the range of about 1,000 to about 500,000. The weight average molecular
weight can vary, but preferably is in the range of about 2 X 10³ to about 10⁶. Typical
examples of such polymers include polystyrene, polyacrylates, polyesters, polyamides,
polyolefins, polycarbonates, phenol formaldehyde condensates, alkyd resins, polyvinylidene
chlorides, epoxy resins, various copolymers of the monomers used to make these polymers,
such as polyesteramides, acrylonitrile copolymers with monomers, such as styrene,
acrylics, and the like.
[0030] Preferably, the thermoplastic polymers used in the practice of this invention are
substantially amorphous. However, as indicated above, mixtures of polymers can be
employed, if desired, such as mixtures of substantially amorphous polymers with substantially
crystalline polymers.
[0031] Presently preferred polymers for use in toner powders are styrene/n-butyl acrylate
copolymers. In general, preferred styrene/n-butyl acrylate copolymers have a glass
transition temperature (Tg) in the range of about 50 to about 100°C.
[0032] An optional but preferred starting material for inclusion in such a blend is a colorant
(pigment or dye). Suitable dyes and pigments are disclosed, for example, in U.S. Reissue
Patent No. 31,072, and in U.S. Patent Nos. 4,140,644; 4,416,965; 4,414,152; and 2,229,513.
One particularly useful colorant for the toners to be used in black and white electrophotographic
copying machines is carbon black. When employed, colorants are generally employed
in quantities in the range of about 1 to about 30 weight percent on a total toner
powder weight basis, and preferably in the range of about 2 to about 15 weight percent.
[0033] Toner compositions, if desired, can also contain other additives of the types which
have been heretofore employed in toner powders, including leveling agents, surfactants,
stabilizers, and the like. The total quantity of such additives can vary. A present
preference is to employ not more than about 10 weight percent of such additives on
a total toner powder composition weight basis.
[0034] Various procedures are known to the art for incorporating additives, such as the
quaternary pyridinium salts used in the present invention, colorants, or the like,
into a desired polymer or mixture of polymers. For example, a preformed mechanical
blend of particulate polymer particles, quaternary pyridinium salts, colorants, etc.,
can be roll milled or extruded at a temperature sufficient to melt blend the polymer,
or mixture of polymers, to achieve a uniformly blended composition. Thereafter, the
cooled composition can be ground and classified, if desired, to achieve a desired
toner powder size and size distribution.
[0035] Preferably, prior to melt blending, the toner components, which preferably are preliminarily
placed in a particulate form, are blended together mechanically. With a polymer having
a Tg in the range of from about 50 to about 120°C, or a Tm in the range of from about
65 to about 200°C, a melt blending temperature in the range of about 90 to about 240°C
is suitable using a roll mill or extruder. Melt blending times (that is, the exposure
period for melt blending at elevated temperatures) are in the range of about 1 to
about 60 minutes. After melt blending and cooling, the composition can be stored before
being ground. Grinding can be carried out by any convenient procedure. For example,
the solid composition can be crushed and then ground using, for example, a fluid energy
or jet mill, such as described in U.S. Patent No. 4,089,472. Classification, if employed,
can be conventionally accomplished using one or two steps.
[0036] In place of melt blending, the polymer can be dissolved in a solvent and the additives
dissolved and/or dispersed therein. Thereafter, the resulting solution or dispersion
can be spray dried to produce particulate toner powders.
[0037] Limited coalescence polymer suspension procedures are particularly useful for producing
small sized, uniform toner particles, such as tone particles under about 10 microns
in size.
[0038] The toner powders used in the present invention preferably have a fusing temperature
latitude in the range of about 275 to about 400°F, although toner powders with higher
and lower fusing temperatures can be prepared and used. The toner powders characteristically
display excellent paper adhesion characteristics. Typically, the toner powders have
a paper adhesion index value in the range of about 30 to about 100, although toner
powders with lower such values can be prepared and used. Paper adhesion index values
of such toner powders are characteristically higher than those of toner powders prepared
with the same polymer and additives but containing a quaternary ammonium salt not
of this invention and are comparable to a toner powder prepared with the same polymer
and additives but containing no charge agent.
[0039] To be utilized as toners in electrostatographic developers of the invention, toners
containing the aforedescribed salts can be mixed with a carrier vehicle. The carrier
vehicles which can be used to form such developer compositions can be selected from
a variety of materials. Such materials include carrier core particles and core particles
overcoated with a thin layer of film-forming resin.
[0040] The carrier core materials can comprise conductive, non-conductive, magnetic, or
non-magnetic materials. For example, carrier cores can comprise glass beads; crystals
of inorganic salts such as aluminum potassium chloride; other salts such as ammonium
chloride or sodium nitrate; granular zircon; granular silicon; silicon dioxide; hard
resin particles such as poly(methyl methacrylate); metallic materials such as iron,
steel, nickel, carborundum, cobalt, oxidized iron; or mixtures or alloys of any of
the foregoing. See, for example, U.S. Pat Nos. 3,850,663 and 3,970,571. Especially
useful in magnetic brush development schemes are iron particles such as porous iron
particles having oxidized surfaces, steel particles, and other "hard" or "soft" ferromagnetic
materials such as gamma ferric oxides or ferrites, such as ferrites of barium, strontium,
lead, magnesium, or aluminum. See, for example, U.S. Pat. Nos. 4,042,518; 4,478,925;
and 4,546,060.
[0041] As noted above, the carrier particles can be overcoated with a thin layer of a film-forming
resin for the purpose of establishing the correct triboelectric relationship and charge
level with the toner employed. Examples of suitable resins are the polymers described
in U.S. Pat. Nos. 3,547,822; 3,632,512; 3,795,618 and 3,898,170 and Belgian Patent
No. 797,132. Other useful resins are fluorocarbons such as polytetrafluoroethylene,
poly(vinylidene fluoride), mixtures of these, and copolymers of vinylidene fluoride
and tetrafluoroethylene. See, for example, U.S. Pat Nos. 4,545,060; 4,478,925; 4,076,857;
and 3,970,571. Such polymeric fluorohydrocarbon carrier coatings can serve a number
of known purposes. One such purpose can be to aid the developer to meet the electrostatic
force requirements mentioned above by shifting the carrier particles to a position
in the triboelectric series different from that of the uncoated carrier core material,
in order to adjust the degree of triboelectric charging of both the carrier and toner
particles. Another purpose can be to reduce the frictional characteristics of the
carrier particles in order to improve developer flow properties. Still another purpose
can be to reduce the surface hardness of the carrier particles so that they are less
likely to break apart during use and less likely to abrade surfaces (e.g., photoconductive
element surfaces) that they contact during use. Yet another purpose can be to reduce
the tendency of toner material or other developer additives to become undesirably
permanently adhered to carrier surfaces during developer use (often referred to as
scumming). A further purpose can be to alter the electrical resistance of the carrier
particles.
[0042] A typical developer composition containing the above-described toner and a carrier
vehicle generally comprises from about 1 to about 20 percent by weight of particulate
toner particles and from about 80 to about 99 percent by weight carrier particles.
Usually, the carrier particles are larger than the toner particles. Conventional carrier
particles have a particle size on the order of from about 20 to about 1200 microns,
preferably 30-300 microns.
[0043] Alternatively, the toners of the present invention can be used in a single component
developer, i.e., with no carrier particles.
[0044] The toner and developer compositions of this invention can be used in a variety of
ways to develop electrostatic charge patterns or latent images. Such developable charge
patterns can be prepared by a number of means and be carried for example, on a light
sensitive photoconductive element or a non-light-sensitive dielectric-surface element
such as an insulator-coated conductive sheet. One suitable development technique involves
cascading the developer composition across the electrostatic charge pattern, while
another technique involves applying toner particles from a magnetic brush. This latter
technique involves the use of a magnetically attractable carrier vehicle in forming
the developer composition. After imagewise deposition of the toner particles, the
image can be fixed, e.g., by heating the toner to cause it to fuse to the substrate
carrying the toner. If desired, the unfused image can be transferred to a receiver
such as a blank sheet of copy paper and then fused to form a permanent image.
[0045] The invention is further illustrated by the following Examples. In these Examples,
all melting points and boiling points are uncorrected. NMR (nuclear magnetic resonance)
spectra were obtained with a Varian Gemini-200 NMR spectrometer. All elemental analyses
were performed by combustion. Unless otherwise indicated, all starting chemicals were
commercially obtained.
Examples
Example 1: Preparation of N-(Ethoxycarbonylmethyl)-pyridinium Bromide
[0046] To a solution of 47.37 grams (0.599 mol) of pyridine in 300 milliters of acetonitrile
over a period of approximately 5 minutes there was added 100.0 grams (0.599 mol) of
ethyl bromoacetate. The mixture was then stirred for approximately 19.3 hours. Solid
crystallized and was collected, washed with ether and dried. The yield of product
was 113.3 grams (76.86% of theory); mp=133-134°C.
- Anal. Calcd. for C₉H₁₂BrNO₂:
- C, 43.92; H, 4.91; N, 5.69;
- Found:
- C, 43.87; H, 4.76; N, 5.68.
NMR agreed with the proposed structure.
Example 2: Preparation of N-(Ethoxycarbonylmethyl)-pyridinium Tetraphenylborate
[0047] To a solution of 24.61 grams (0.10 mol) of N-(ethoxycarbonylmethyl)pyridinium bromide
in 100 milliliters of water there was added a solution of 34.22 grams (0.10 mol) of
sodium tetraphenylborate in 150 milliliters of water. The mixture was diluted with
1 liter of water and filtered. The solid collected was dissolved in methylene chlorine,
the water layer was separated and the organic layer was dried over MgSO₄ and concentrated.
Recrystallization from ethyl acetate yielded 21.9 grams of product (45.11% of theory);
mp=150-152°C.
- Anal. Calcd. for C₃₃H₃₂BNO₂:
- C, 81.65; H, 6.64; B, 2.23; N, 2.89.
- Found:
- C, 81.33; H, 6.62; B, 2.22; N, 2.83.
NMR agreed with the proposed structure.
Example 3: Toner Powder Preparation (Dry Weight Basis)
[0048] A styrene/n-butyl acrylate copolymer was obtained by limited coalescence polymerization
and blended with the additive components identified in the following Table I in the
amounts set forth therein.

[0049] The carbon black was "Regal™ 300". Each blend was roll milled at 150°C for 20 minutes,
cooled, crushed and classified to produce a toner powder product having a size of
about 12 microns and a size distribution of about 2-30 microns. The charge control
agent identified in Table I above as N-octadecyl-N,N-dimethylbenzylammonium m-nitrobenzenesulfonate
was utilized for comparative purposes.
Example 4: Fusing And Adhesion Performance
[0050] Each of the styrene/n-butyl acrylate toner powder Blends A, B and C was evaluated
on a fusing breadboard consisting of a fusing roller coated with 100 mils of red rubber,
engaged at constant speed and pressure onto a backup roller coated with polytetrafluoroethylene
(available commercially as Silverstone™ from E.I. duPont de Nemours and Co.) Both
roller surfaces were coated by hand with a release oil (60,000 centistoke polydimethylsiloxane
oil available from Dow Corning Co.). The nip width between the two rollers was 0.215-0.240
inch and the fuser was operated at 12 inches/second. The fusing temperature was 350°F.
[0051] Six longitudinally extending stripes of toner were applied to the wire side of Kodak
alkaline DP paper, and the toned papers were run through the fusing breadboard. The
transmission density of the toned, fused stripes was between 1.2 and 1.5.
[0052] The adhesion index was determined for each stripe, and the results for each of the
various toner are presented in Table II below.
Table II
| Blend |
Charge-Control Agent |
Average Adhesion Index (AI) of Toner |
| A |
none |
69 |
| B |
N-(ethoxycarbonylmethyl pyridinium tetraphenylborate (formulation of Example 2) |
66 |
| C |
N-octadecyl-N,N-dimethylbenzyl-ammonium m-nitrobenzene-sulfonate |
37 |
[0053] The adhesion index values are the average of 8 measurements and the standard derivations
are less than 7 units for the measurements. The toner containing an ester-containing
quaternary pyridinium salt of the invention (Blend B) had a significantly higher adhesion
index than the toner containing the N-octadecyl-N,N-dimethylbenzylammonium m-nitrobenzenesulfonate
charge control agent, the comparative charge control agent outside the scope of the
invention, and had a comparable adhesion index to the toner without a charging agent.
[0054] This invention has been described in detail with particular reference to preferred
embodiments thereof, but it will be understood that variations and modifications can
be effected within the scope of the invention.