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

1. A method for manufacturing particles comprising the steps of:

spraying a high-pressure gas over a viscous material while the viscous material is being discharged in a chamber; and

introducing cooling air in the chamber for solidification, wherein

the cooling air is introduced in the chamber through air inlets disposed on the chamber, wherein

the air inlets are open to an atmosphere surrounding the chamber, the air inlets to the chamber are positioned on top of the chamber and on the sidewall of the chamber, and

guide vanes are arranged to enable secondary air flow from the air inlets.

2. The method for manufacturing particles according to claim 1 , wherein the viscous material is any one of a resin-melted material and a resin-dissolved material.

3. The method for manufacturing particles according to claim 1 ,

wherein the viscous material is any one of a resin-melted material and a resin-dissolved material;

any one of the resin-melted material and the resin-dissolved material is melt mixed under pressure, or any one of the resin-melted material and the resin-dissolved material is injected with a supercritical fluid and melt mixed; and

the obtained melt-mixed substance is subsequently sprayed with a high-pressure gas for atomization while the melt-mixed substance is being discharged in the chamber.

4. The method for manufacturing particles according to claim 3 ,

wherein at least one air inlet comprises a gate configured to adjust the cross-sectional area of the at least one air inlet.

5. The method for manufacturing particles according to claim 3 ,

wherein the air inlets are covered with a sound insulating material.

6. The method for manufacturing particles according to claim 3 ,

wherein the melt mixing is performed while the melt mixing apparatus in which a supercritical fluid is injected and dispersed has an internal temperature which is in any one of the range of −10° C. to +100° C. from the melting point or the initial efflux temperature of the viscous material and the range of +30° C. to +150° C. from the glass transition temperature of the viscous material.

7. The method for manufacturing particles according to claim 1 ,

wherein the method for manufacturing particles comprises:

a spray granulation apparatus comprising a means of melt mixing a viscous material under pressure, and

the chamber comprising a high-pressure gas nozzle; and

the viscous material is melt mixed, or the viscous material is injected with a supercritical fluid and melt mixed under pressure, and the obtained melt-mixed substance is subsequently sprayed with a high-pressure gas from the high-pressure gas nozzle for atomization while the melt-mixed substance is being discharged in the chamber.

8. The method for manufacturing particles according to claim 1 , wherein the viscous material is a composite comprising a resin and particles.

9. The method for manufacturing particles according to claim 1 ,

wherein the granulation is performed with the condition wherein the static pressure P inside the chamber satisfies the following relation: −0.01 Mpa≦P≦0.01 MPa.

10. The method for manufacturing particles according to claim 1 ,

wherein the chamber comprises a jacket on the outer surface of the chamber which allows temperature regulation.

11. The method for manufacturing particles according to claim 1 ,

wherein the chamber comprises a heat insulating mechanism which is divided into multiple segments on the outer surface of the chamber.

12. The method for manufacturing particles according to claim 1 ,

wherein the chamber comprises a sound insulating mechanism on the outer surface of the chamber.

13. The method for manufacturing particles according to claim 1 , wherein an ultrasonic pulse of 10 kHz to 80 kHz is imparted to the high-pressure gas.

14. The method for manufacturing particles according claim 1 ,

wherein the air inlets comprise a plurality of holes disposed on a chamber top lid on top of the chamber.

15. The method for manufacturing particles according to claim 1 ,

wherein the air inlets comprise a plurality of holes disposed on a sidewall of the chamber.

16. The method for manufacturing particles according to claim 1 , wherein the guide vanes are disposed on a chamber top lid, which top lid is disposed on top of the chamber.

17. 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

(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;

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 air inlets disposed on the chamber, wherein

the air inlets are open to an atmosphere surrounding the chamber, the air inlets to the chamber are positioned on top of the chamber and on the sidewall of the chamber, and

guide vanes are arranged to enable secondary air flow from the air inlets.

18. The method for manufacturing a toner according to claim 17 ,

wherein at least one air inlet comprises a gate configured to adjust the cross-sectional area of the at least one air inlet.

19. The method for manufacturing a toner according to claim 17 ,

wherein the air inlets are covered with a sound insulating material.

20. The method for manufacturing a toner according to claim 17 ,

wherein the granulation is performed with the condition wherein the static pressure P inside the chamber satisfies the following relation: −0.01 MPa≦P≦0.01 MPa.

21. The method for manufacturing a toner according to claim 17 ,

wherein the chamber comprises a jacket on the outer surface of the chamber which allows temperature regulation.

22. The method for manufacturing a toner according to claim 17 ,

wherein the chamber comprises a heat insulating mechanism which is divided into multiple segments on the outer surface of the chamber.

23. The method for manufacturing a toner according to claim 17 ,

wherein the chamber comprises a sound insulating mechanism on the outer surface of the chamber.

24. The method for manufacturing a toner according to claim 17 ,

wherein the melt mixing is performed while the melt mixing apparatus in which a supercritical fluid is injected and dispersed has an internal temperature which is in any one of the range of −10° C. to +100° C. from the melting point or the initial efflux temperature of the toner and the range of +30° C. to +150° C. from the glass transition temperature of the toner.

25. The method for manufacturing a toner according to claim 17 ,

wherein an ultrasonic pulse of 10 kHz to 80 kHz is imparted to the high-pressure gas.

26. The method for manufacturing a toner according to claim 17 ,

wherein the air inlets comprise a plurality of holes disposed on a chamber top lid on top of the chamber.

27. The method for manufacturing a toner according to claim 17 ,

wherein the air inlets comprise a plurality of holes disposed on a sidewall of the chamber.

28. 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

(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,

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 the chamber; and

cooling air is introduced in the chamber through air inlets disposed on the chamber for granulation, wherein

the air inlets are open to an atmosphere surrounding the chamber, the air inlets to the chamber are positioned on top of the chamber and on the sidewall of the chamber, and

guide vanes are arranged to enable secondary air flow from the air inlets.

29. The method for manufacturing a toner according to claim 28 ,

wherein at least one air inlet comprises a gate configured to adjust the cross-sectional area of the at least one air inlet.

30. The method for manufacturing a toner according to claim 28 ,

wherein the air inlets are covered with a sound insulating material.

31. The method for manufacturing a toner according to claim 28 ,

wherein the granulation is performed with the condition wherein the static pressure P inside the chamber satisfies the following relation: −0.01 MPa≦P≦0.01 MPa.

32. The method for manufacturing a toner according to claim 28 ,

wherein the chamber comprises a jacket on the outer surface of the chamber which allows temperature regulation.

33. The method for manufacturing a toner according to claim 28 ,

wherein the chamber comprises a heat insulating mechanism which is divided into multiple segments on the outer surface of the chamber.

34. The method for manufacturing a toner according to claim 28 ,

wherein the chamber comprises a sound insulating mechanism on the outer surface of the chamber.

35. The method for manufacturing a toner according to claim 28 ,

wherein the melt mixing is performed while the melt mixing apparatus in which a supercritical fluid is injected and dispersed has an internal temperature which is in any one of the range of −10° C. to +100° C. from the melting point or initial efflux temperature of the toner and the range of +30° C. to +150° C. from the glass transition temperature of the toner.

36. The method for manufacturing a toner according to claim 28 ,

wherein an ultrasonic pulse of 10 kHz to 80 kHz is imparted to the high-pressure gas.

37. The method for manufacturing a toner according to claim 28 ,

wherein the air inlets comprise a plurality of holes disposed on a chamber top lid on top of the chamber.

38. The method for manufacturing a toner according to claim 28 ,

wherein the air inlets comprise a plurality of holes disposed on a sidewall of the chamber.