Xerox Corporation

Joo T Chung

Joseph L Leonardo

Chieh-Min Cheng

Scott M Silence

Santiago Faucher

Hui Chang

Brian J Andaya

Shigang S Qiu

Fumii Higuchi

Timothy L Lincoln

John J Ianni

Michael Steven Hawkins

Enno Eric Agur

Zhen Lai

J Stephen Kittelberger

Steven M Malachowski

James M Proper

Hadi K Mahabadi

Juan A Morales-Tirado

Gerald R Allison

Eric David Godshall

Eric Joseph Young

Yuhua Tong

T Brian McAneney

Allan K Chen

Bernard Grushkin

Edward J Gutman

William H Hollenbaugh, Jr

Sheau V Kao

James G Stenzel

Brian Joseph Marion

Michael G Hawkins

Yvonne M Kenney

Jennifer E Dewan

Edward Graham Zwartz

Rina Carlini

Samir Kumar

Eugene Frederick Young

John L Pawlak

Shigeng Li

Mark E Mang

Christopher M Wolfe

Kip L Jugle

James A Winters

Jay Lee Schneider

Yelena Shapiro

Brian E Moore

Brian S Giannetto

Kimberly Anne Stoll

Jeffrey H Sokol

Julia A Kohlmeier

Zhaoyi M Masucci

John S Walters

Randy Pheav Tin

Maria M Barden

Morris M DeYoung, Jr

Christine A Keenan

Christine L Demay

Robert Heim

Jeffrey L DeBarr

Derrick Black

Kristen L Ladue

Frank O Reitze

Jim Lee Pearson

Emine Irmak Serifoglu

Christine Louise DeMay

Linda A Flannery

Allison G Thomas

Eric J Young

Jay L Schneider

Randy P Tin

Kimberley A Stoll

Winters James A A

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.

Continuous coalescence processes

The present disclosure describes toner particles that have polyester resin and styrene/acrylate resin in the core.

Styrene/acrylate and polyester hybrid toner

A process for attaching additives onto toner particles using plasma is described.

Additive attachment on toner particles by plasma

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.

Continuous latex production processes

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.

Method of continuously forming an aqueous colorant dispersion using a screw extruder

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.

Continuous process for manufacturing toners

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

Continuous production of fine toner

A process for making a latex emulsion suitable for use in a toner composition includes contacting at least one amorphous polyester resin with a viscosity reducing additive in the absence of an organic solvent to form a resin mixture either via an extruder or batch process, and adding a surfactant, neutralizing agent, and deionized water to the resin mixture.

Processes for producing polyester latexes via solvent-free emulsification

A screw extruder is presented including a feed hopper for receiving materials and a body member having at least one supply port and at least one outlet port. The screw extruder also includes a screw positioned within the body member and movable along a channel defining a longitudinal axis. The screw extruder further includes a drive shaft for rotatably driving the screw along the channel. The screw extruder may be configured to mix the materials received via the feed hopper with a series of one or more forward, neutral, and reverse kneading elements.

Screw extruder for continuous and solvent-free resin emulsification

A process for making a self-emulsifying granule suitable for use in forming latex emulsions includes contacting a resin with a solid or highly concentrated surfactant, a solid neutralization agent and water in the absence of an organic solvent to form a mixture, melt mixing the mixture, and forming self-emulsifying granules of the melt mixed mixture. Self-emulsifying granules are also provided and configured to form a latex emulsion when added to water, which may then be utilized to form a toner.

Self emulsifying granules and process for the preparation of emulsions therefrom

Processes for continuously forming latex emulsions useful in preparing toners are provided which do not require the use of solvents.

Latex processes

A process for making a self-emulsifying composite suitable for use in forming latex emulsions includes contacting a resin with a solid or highly concentrated surfactant, a solid neutralizing agent in the absence of water and an organic solvent to form a mixture, melt mixing the mixture, and forming a self-emulsifying composite of the melt mixed mixture such as a granule. Self-emulsifying granules are also provided and configured to form a latex emulsion when added to water, which may then be utilized to form a toner.

Self emulsifying granules and solvent free process for the preparation of emulsions therefrom

A process for making a latex emulsion suitable for use in a toner composition includes contacting a resin with a solid neutralizing agent in the absence of an organic solvent to form a mixture either via a co-feeding process or a pre-blend mixture, and adding a solid or aqueous surfactant to the pre-blend mixture or prior to melt mixing the mixture.

Various solvent-assisted extrusion processes are disclosed that are suitable for forming high yield, low coarse content, polyester latexes that may be utilized in forming a toner.

Solvent-assisted continuous emulsification processes for producing polyester latexes

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Webster, NY, United States of America

Joo T Chung