Abstract: Porous resin particles of from about 3 ?m to about 25 ?m size made in an emulsion aggregation process where coalescence occurs under continuous conditions which enable, for example, more rapid coalescence, are described.

Abstract: A method for reclaiming an out-of-spec emulsion material includes recovering the out-of-spec emulsion material from a scrap manufacturing batch; distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to about 45 wt % or more based on a total weight of the emulsion material; dissolving the distilled emulsion material in a solvent to form a first mixture; adding a base to the first mixture to neutralize acid groups present in the distilled emulsion material, forming a second mixture; emulsifying the second mixture by adding water to the second mixture; and forming particles having an average particle diameter (D50v) within a target range, wherein the out-of-spec emulsion material has an average particle diameter falling outside of the target range.

Abstract: A phase inversion emulsification process includes dissolving a polyester resin in a mixture comprising (1) an organic solvent, (2) a first portion of a total amount of neutralizing agent, and (3) a first portion of water, neutralizing the dissolved polyester resin with a second portion of neutralizing agent, the second portion of neutralizing agent including the remaining amount of the total amount neutralizing agent, forming an emulsion by adding a second portion of water after the neutralizing step, and removing a portion of the organic solvent from the emulsion to provide a latex.

Abstract: A method for reclaiming an out-of-spec emulsion material includes recovering the out-of-spec emulsion material from a scrap manufacturing batch; distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to about 45 wt % or more based on a total weight of the emulsion material; dissolving the distilled emulsion material in a solvent to form a first mixture; adding a base to the first mixture to neutralize acid groups present in the distilled emulsion material, forming a second mixture; emulsifying the second mixture by adding water to the second mixture; and forming particles having an average particle diameter (D50v) within a target range, wherein the out-of-spec emulsion material has an average particle diameter falling outside of the target range.

Abstract: A process is disclosed for making a resin emulsion suitable for use in forming toner particles including using a wiped film evaporator for removing residual solvents.

Abstract: A toner including a resin; an optional wax; and a colorant; wherein the colorant has disposed thereon a reactive component having at least one cross-linkable carbon-carbon double bond and wherein the tribo electric charge of the toner is adjusted through surface treatment of the colorant with the reactive component. Also a colorant having disposed thereon a reactive component having at least one cross-linkable carbon-carbon double bond, wherein the reactive component disposed on the colorant is selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, stearyl methacrylate, acrylic acid, methacrylic acid, maleic acid, hydroxyethyl methacrylate, hydroxypropyl acrylate, glycidyl acrylate, alkoxymethylol acrylamide, styrene, vinyl toluene, methylstyrene, acrylonitrile, methacrylonitrile, bisphenol A glycerolate diacrylate, and mixtures and combinations thereof.

Abstract: The present embodiments relate to toner particles having an increased surface hardness, and toners comprising said toner particles. More specifically, the present embodiments relate to toner particles having an average surface hardness of from about 130 mPa to about 250 mPa, comprising a core surrounded by a shell, wherein the shell comprises a crystalline resin.

Abstract: Processes for continuously producing a wax dispersion are disclosed. A multi-screw extruder is used for the processes. A wax and a surfactant are fed into the extruder and melted together. Water is then added to form a dispersion. The wax particles are homogenized and exit the extruder to be passed through a quenching unit. The wax dispersion can be used to make toner compositions.

Abstract: Processes for continuously coalescing particles from an aggregated particle slurry are disclosed. The aggregated particle slurry is heated, then coalesced by raising the pH. The coalesced particles are homogenized and exit as a coalesced particle slurry. A multi-screw extruder is used for the coalescing. These processes are useful for providing coalesced particles such as toner compositions.

Abstract: Processes for continuously producing latex emulsions are disclosed. A multi-screw extruder is used for the production of the emulsion. A resin is fed into the extruder, heated, optionally dissolved in a solvent, mixed with a base to neutralize the resin and form particles, then mixed with a surfactant and water to form a phase inverted emulsion (PIE). The PIE may be sent to a distillation column to separate out the solvent, and the resulting latex emulsion is then sent to a receiving tank. These processes are useful for making precursors for toner compositions.

Abstract: A continuous process for making a pigment dispersion includes continuously feeding a pigment into a feed section of a screw extruder at a controlled rate, continuously feeding a surfactant into the feed section of the screw extruder at a controlled rate, continuously feeding water downstream of the feed section to emulsify the pigment and the surfactant, forming a water-in-pigment dispersion, continuously feeding additional water downstream of the previously fed water to cause a phase inversion of the water-in-pigment dispersion, forming a pigment-in-water dispersion, continuously homogenizing the pigment-in-water dispersion in the screw extruder to create a homogenous aqueous pigment dispersion and collecting the homogenous aqueous pigment dispersion from an exit section of the screw extruder.

Abstract: A process for making toner particles is provided. In embodiments, a suitable process includes adding a washing aid agent to toner particles at the time of washing the toner particles prior to their drying and recover. The washing aid agent assist in the removal of ionic species, including surfactants and ions that are part of the emulsion aggregation process, from the resulting toner particles. Utilization of the washing aid agent produces toner particles having improved charging characteristics.

Abstract: A process and system for making a resin emulsion suitable for use in forming toner particles including a silicone free anti-foam agent to control foam during formation of a polyester dispersion.

Abstract: Methods herein include mixing at least one polyester resin with at least one solvent to form a resin mixture, adding water to cause phase inversion and form a polyester latex, adding at least one buffering agent to the phase inverted mixture to stabilize the phase inverted mixture, and subsequent to the buffering agent addition, substantially removing the at least one solvent from the phase inverted mixture.

Abstract: The continuous process for manufacturing toners disclosed herein includes continuously feeding components of a toner composition into a feed section of a screw extruder at a controlled rate. The continuous process for manufacturing toners may include feeding the components of a toner composition into the feed section of a screw extruder without performing an external or secondary dispersion step. That is to say, the components of the toner composition may be fed directly into the extruder without using dispersions of individual components as used in batch processes. Rather, the toner components are added to the extruder in dry form, melt-mixed, and may be dispersed in aqueous form in the extruder. The process may produce micron-sized toner particles, thus no further size reduction may be necessary.

Abstract: Methods herein include mixing at least one polyester resin with at least one solvent to form a resin mixture, adding water to cause phase inversion and form a polyester latex, adding at least one buffering agent to the phase inverted mixture to stabilize the phase inverted mixture, and subsequent to the buffering agent addition, substantially removing the at least one solvent from the phase inverted mixture.

Abstract: The continuous process for manufacturing toners disclosed herein includes continuously feeding components of a toner composition into a feed section of a screw extruder at a controlled rate. The continuous process for manufacturing toners may include feeding the components of a toner composition into the feed section of a screw extruder without performing an external or secondary dispersion step. That is to say, the components of the toner composition may be fed directly into the extruder without using dispersions of individual components as used in batch processes. Rather, the toner components are added to the extruder in dry form, melt-mixed, and may be dispersed in aqueous form in the extruder. The process may produce micron-sized toner particles, thus no further size reduction may be necessary.

Abstract: A continuous process for forming fine toner using a twin screw extruder.

Abstract: A washing process using one or more ionic liquids (ILs) as a washing aid agent for toners, including toners produced using such ILs, such as, low melt toners, is provided. ILs are environmentally sound, green solvents that act to swell toner particle surfaces so that surface absorbed and adsorbed pollutants, such as, surfactants and other manufacturing reactants, can be effectively removed. The resulting toners have good charging, charge maintenance and RH sensitivity.

Abstract: A continuous process for forming fine toner using a twin screw extruder.