Process for making particulate compositions

Abstract

There is described a process for producing a particulate composition comprising the steps of: (a) forming a first dispersion comprising first particles stabilized in a first fluid by first species; (b) optionally the step of forming a second dispersion comprising second particles stabilized in a second fluid, miscible with the first fluid, by second species; (c) after (or simultaneously with) the optional step of mixing the first and second dispersions together if the second dispersion was formed from step b); inducing association between the dispersed particles to form clusters; and (d) binding together the particles within the clusters; characterized in that the first and/or second particles comprise at least one polar functional group to facilitate the binding of the particles in step (d). Preferably the polar group is other than an acid group, more preferably comprises at least one hydroxy group, non-acidic polar group and/or non-basic polar group, most preferably comprises one or more hydroxy and/or ether groups (e.g. an optionally polymeric alkylene glycol alkyl ether). A preferred embodiment of the process comprises mixing together two aqueous dispersions of particles (e.g. pigment particles and particles of hydroxy functional latex polymer). The dispersions are stabilized with surfactants. Association of the particles into clusters is induced by known means (e.g. heating and stirring) and the clusters are grown by aggregation into loose matrices which are more fused together to form particles which can be used in electroreprographic toners.

1 . A process for producing a particulate composition comprising the steps of: 
 (a) forming a first dispersion comprising first particles stabilised in a first fluid;    (b) forming a second dispersion comprising second particles which comprise hydroxy groups directly bonded to the surface by forming part of a polymer from which the particles are formed which particles do not contain acidic or basic polar groups and are stabilised in a fluid, miscible with the first fluid;    (c) mixing the first and second dispersions together;    (d) inducing association between the dispersed particles to form clusters; and    (e) binding together the particles within the dusters by raising their temperature to effect fusion.    
     
     
         2 . A process as claimed in  claim 1  in which the first particles are pigmentary particles.  
     
     
         3 . A process as claimed in  claim 1  or  2  in which step (e) takes place whilst the particles are in dispersion in a fluid.  
     
     
         4 . A process for producing an electroreprographically effective toner and/or developer composition which process comprises a process as claimed in any preceding claim.  
     
     
         5 . An electroreprographically effective toner and/or developer composition produced by a process as claimed in  claim 4 .  
     
     
         6 . An electroreprographic toner composition comprising particles produced by a process as claimed in any one of  claims 1  to  4  in which 80% of the toner particles have a diameter in the range 2 to 20 micrometers.  
     
     
         7 . A developer composition comprising an electroreprographic toner composition as claimed in  claim 5 , and an electroreprographically effective, inert carrier and/or diluent.  
     
     
         8 . An electroreprographic device, a component for said device or a consumable useable with said device each of which comprises a composition as claimed in  claim 5 ,  6  or  7 .  
     
     
         9 . Use of a composition as claimed in  claim 5 ,  6  or  7  as a consumable in an electroreprographic device.  
     
     
         10 . A process for producing a coloured toner composition which comprises: 
 (a) forming an aqueous dispersion comprising pigmentary particles;    (b) forming a second aqueous dispersion comprising polymer particles, the polymer comprising hydroxy functional groups;    (c) mixing the first and second dispersions to obtain a substantially homogeneous mixture in the absence of substantial association;    (d) forming clusters by inducing the particles to associate;    (e) inducing growth of the clusters into dispersed matrices of loosely associated clusters;    (f) heating the mixture from step (e) at a temperature above the glass transition temperature of the constituent hydroxy functional polymer to fuse together the clustered particles to form internally coalesced particles of a coloured toner, and    (g) collecting the coloured particulate toner obtained in step (f) and producing optionally after washing, drying and/or blending with other suitable ingredients, a coloured toner composition.