Claims
- 1. A process for forming non-spherical toner particles by limited coalescence, said process comprising:
forming an organic phase comprising a polymeric material, a pigment, a quaternary ammonium tetraphenylborate salt, and a water-immiscible liquid; dispersing said organic phase in an aqueous phase containing a solid colloidal stabilizer; forming a suspension of small droplets of said organic phase in said aqueous phase by high shear agitation; removing said water-immiscible liquid from said small droplets, thereby forming a suspension of small solid particles in said aqueous phase; and separating said solid particles from said aqueous phase and drying said particles, thereby forming toner particles having a non-spherical shape.
- 2. The process of claim 1 wherein said quaternary ammonium tetraphenylborate salt is selected from the group consisting of salts represented by the general formulas (I), (II), (III), and (IV), and mixtures thereof:
- 3. The process of claim 2 wherein, in general formula (I), R1 is selected from the group consisting of methyl, ethyl, n-propyl, n-butyl, n-hexyl, n-undecyl, n-heptadecyl, phenyl, 4-methylphenyl, and 4-t-butylphenyl; R2 is selected from the group consisting of ethylene, 1,3-propylene, 1,4-butylene, hexamethylene, and p-phenylene; R3, R4, and R5 are each independently selected from the group consisting of methyl, ethyl, propyl, octadecyl, and benzyl, and R3 and R4 taken together may be 1,4-butylene or 1,5-pentylene, and R6 is selected from the group consisting of hydrogen, methyl, ethyl, n-propyl, n-butyl, octadecyl, and benzyl.
- 4. The process of claim 3 wherein R1 is undecyl, R2 is 1,3-propylene, R3 and R4 are each methyl, R5 is benzyl, and R6 is hydrogen.
- 5. The process of claim 2 wherein, in general formula (II), R1 is selected from the group consisting of methyl, ethyl, n-propyl, n-butyl, n-hexyl, n-undecyl, n-heptadecyl, phenyl, 4-methylphenyl, and 4-t-butylphenyl; R2 is selected from the group consisting of ethylene, 1,3-propylene, 1,4-butylene, hexamethylene, and p-phenylene; R3, R4 and R5 are each independently selected from the group consisting of methyl, ethyl, propyl, octadecyl, and benzyl, and and R3 and R4 taken together may be 1,4-butylene or 1,5-pentylene.
- 6. The process of claim 5 wherein R1 is undecyl or phenyl, R2 is 1,3-propylene, R3 and R 4 are each methyl, and R5 is benzyl.
- 7. The process of claim 2 wherein, in general formula (III), R1, R2, R3 and R4 are each independently selected from the group consisting of methyl, ethyl, propyl, isopropyl, n-butyl, t-butyl, pentyl, hexyl, 2-ethylhexyl, heptyl, octyl, decyl, octadecyl, benzyl, and 2-naphthylmethyl, and R1 and R2 taken together may be 1,4-butylene or 1,5-pentylene.
- 8. The process of claim 7 wherein R1 and R2 are each methyl, R3 is octadecyl, R4 is 2-naphthylmethyl.
- 9. The process of claim 2 wherein, in general formula (IV), R1, R2, and R3 are each independently selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, iso-butyl, t-butyl, n-octyl, n-octadecyl, and benzyl.
- 10. The process of claim 9 wherein R1 is octadecyl, R2 and R3 are each methyl.
- 11. The process of claim 2 wherein, in general formula (IV), the value of m is from 0.01 to 100.
- 12. The process of claim 11 wherein m is about 10 and n is about 90.
- 13. The process of claim 2 wherein, in general formula (IV), Z is selected from the group consisting of isobutyl methacrylate, isobutyl acrylate, methyl methacrylate, methyl acrylate, styrene, 4-t-butylstyrene, methyl vinyl ether, acrylamide, methacrylamide, and mixtures thereof.
- 14. The process of claim 13 wherein Z is isobutyl methacrylate.
- 15. The process of claim 1 wherein said said quaternary ammonium tetraphenylborate salt is selected from the salts listed in Tables 1, 2, 3, and 4, and mixtures of salts listed in said Tables.
- 16. The process of claim 1 wherein said quaternary ammonium tetraphenylborate salt comprises about 0.1 to about 10 weight percent of total solids.
- 17. The process of claim 1 wherein said pigment comprises a dispersion.
- 18. The process of claim 1 wherein said water-immiscible liquid is selected from the group consisting of dichloromethane, ethyl acetate, methyl ethyl ketone, and mixtures thereof.
- 19. The process of claim 1 wherein said solid colloidal stabilizer comprises dioxide.
- 20. The process of claim 1 wherein said aqueous phase has a pH of about 2 to about 7.
- 21. The process of claim 20 wherein said aqueous phase has a pH buffered to about 4.
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is related to co-pending, commonly assigned application Ser. No. ______, filed ______ for METHOD FOR FORMING TONER PARTICLES HAVING CONTROLLED MORPHOLOGY AND CONTAINING A QUATERNARY AMMONIUM TETRAPHENYLBORATE AND A POLYMERIC PHOSPHONIUM SALT, the disclosure of which is incorporated herein by reference.