Toner manufacturing method

• US 7,754,409 B2
• Filed: 01/18/2007
• Issued: 07/13/2010
• Est. Priority Date: 01/18/2007
• Status: Active Grant

• Current Assignee: Eastman Kodak Company
• Original Assignee: Eastman Kodak Company
• Inventors: Fees, Anita M., Lusignan, Charles P., Boris, David C., Nair, Mridula, Jones, Tamara K., Massa, Dennis J.
• Primary Examiner(s): Chapman; Mark A
• Application Number:
  US11/624,335
• Publication Number:
  US 20080176164A1
• Time in Patent Office: 1,272 Days
• Field of Search: 430/137.14, 430/137.15
• US Class Current: 430/137.14
• CPC Class Codes: G03G 9/0804 whereby the components are brought together in a liquid dispersing medium
• CPC Class Codes: G03G 9/08708 Copolymers of styrene
• CPC Class Codes: G03G 9/08722 Polyvinylalcohols; Polyallylalcohols; Polyvinylethers; Polyvinylaldehydes; Polyvinylketones; Polyvinylketals
• CPC Class Codes: G03G 9/08755 Polyesters

Abstract

The present invention is a method of manufacturing toner particles that includes providing a first emulsion of a first aqueous phase comprising a pore stabilizing hydrocolloid dispersed in an organic solution containing a polymer. The first emulsion is dispersed in a second aqueous phase to form a second emulsion that is sheared in the presence of a stabilizing agent to form droplets of the first emulsion in the second aqueous phase. The organic solution is evaporated from the droplets to form porous toner particles.

Claims

1. A method of manufacturing porous toner particles comprising:

providing a first emulsion of a first aqueous phase comprising a pore stabilizing hydrocolloid dispersed in an organic solution containing a polymer;

dispersing the first emulsion in a second aqueous phase;

shearing the second emulsion in the presence of a stabilizing agent to form droplets of the first emulsion in the second aqueous phase; and

evaporating the organic solution from the droplets to form porous toner particles of a controlled size and size distribution.

2. The method of claim 1 further comprising:

isolating the toner particles.

3. The method of claim 2 further comprising:

drying the toner particles.

4. The method of claim 1 wherein the polymer comprises a polymer formed from vinyl monomers, condensation monomers, condensation esters and mixtures thereof.

5. The toner particle of claim 1 wherein polymer is selected from the group consisting of polyesters, styrenes, vinyl ethers and vinyl ketones.

6. The method of claim 1 wherein the dispersing step and shearing step are done simultaneously.

7. The method of claim 1 wherein the organic solution further comprises colorants, waxes and charge control agents.

8. The method of claim 1 wherein the hydrocolloid is selected from the group consisting of carboxymethyl cellulose (CMC), gelatin, alkali-treated gelatin, acid treated gelatin, gelatin derivatives, proteins, protein derivatives, synthetic polymeric binders, water soluble microgels, polystyrene sulphonate, poly(2-acrylamido-2-methylpropanesulfonate) and polyphosphates.

9. The method of claim 1 wherein the first aqueous phase further comprises buffering salts.

10. The method of claim 1 wherein the stabilizer comprises colloidal silica.

11. The method of claim 1 wherein the organic solution comprises ethyl acetate, propyl acetate, chloromethane, dichloromethane, vinyl chloride, trichloromethane, carbon tetrachloride, ethylene chloride, trichloroethane, toluene, xylene, cyclohexanone and 2-nitropropane.

12. The method of claim 1 wherein prior to evaporating the organic solution, water is added to the second emulsion.

13. The method of claim 1 wherein the first emulsion further comprises a charge control agent.

14. A method of manufacturing porous polymer particles comprising:

providing a first emulsion of a first aqueous phase comprising a pore stabilizing hydrocolloid dispersed in an organic solution containing water-immiscible polymerizable monomers and a polymerization initiator;

dispersing the first emulsion in a second aqueous phase;

shearing the second emulsion in the presence of a stabilizing agent comprising colloidal silica to form droplets of the first emulsion in the second aqueous phase;

polymerizing the monomers to form droplets of polymer particles; and

evaporating the organic solution from the droplets of polymer particles to form porous polymer particles of a controlled size and size distribution.

15. The method of claim 14 wherein the first emulsion further comprises a colorant.

16. The method of claim 14 wherein the first emulsion further comprises a charge control agent.

17. The method of claim 14 further comprising:

isolating the polymer particles.

18. The method of claim 17 further comprising:

drying the polymer particles.

19. The method of claim 14 wherein the hydrocolloid is selected from the group consisting of carboxymethyl cellulose (CMC), gelatin, alkali-treated gelatin, acid treated gelatin, gelatin derivatives, proteins, protein derivatives, synthetic polymeric binders, water soluble microgels, polystyrene sulphonate, poly(2-acrylamido-2-methylpropanesulfonate) and polyphosphates.

20. A method of manufacturing porous polymer particles comprising:

providing a first emulsion of a first aqueous phase comprising a pore stabilizing hydrocolloid dispersed in a mixture of water-immiscible polymerizable monomers and a polymerization initiator;

dispersing the first emulsion in a second aqueous phase;

shearing the second emulsion in the presence of a stabilizing agent comprising colloidal silica to form droplets of the first emulsion in the second aqueous phase; and

polymerizing the monomers to form droplets of porous polymer particles.