Microtoner formulations having blended copolymers of a first and second resin and method of producing same

Abstract

A microtoner (C) and method for producing same ( 10 ) is presented. The microtoner (C) includes a blend of at least one polymer (P 1 , P 2 , . . . and P N ) and at least one thermoplastic polymer (P 1 , P 2 , . . . and P N ). The method ( 10 ) of producing microtoner (C) includes blending ( 12 ) the at least one polymer with the at least one thermoplastic polymer and with one or more pigments to thereby form a dry mix toner formulation (T). The toner formulation (T) is pulverized ( 18 ) by mechanical means into an unclassified particulate microtoner (U). The unclassified particulate microtoner is then classified to produce the microtoner (C).

1 . A microtoner formulation, comprising: a polymer blend including at least one polymer and at least one thermoplastic polymer.  
     
     
         2 . The microtoner formulation of  claim 1 , wherein said polymer and said thermoplastic polymer are each individually selected from the group consisting essentially of polyesters, polyamides, polyolefins, acrylic polymers and copolymers, methacrylic polymers and copolymers, styrenic polymers and copolymers, vinyl polymers and copolymers, and polyurethanes.  
     
     
         3 . The microtoner formulation of  claim 1 , further comprising one or more pigments, said pigments comprising from approximately two to approximately thirty percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-eight to approximately seventy percent by weight of said microtoner formulation.  
     
     
         4 . The microtoner formulation of  claim 3 , wherein said one or more pigments comprise from approximately four to approximately twenty percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-six to approximately eighty percent by weight of said microtoner formulation.  
     
     
         5 . The microtoner formulation of  claim 3 , wherein said one or more pigments comprise from approximately six to approximately ten percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-four to approximately ninety percent by weight of said microtoner formulation.  
     
     
         6 . The microtoner formulation of  claim 3 , wherein said polymer blend comprises from approximately five to approximately ninety-five percent by weight of a first polymer, and from approximately ninety-five to approximately five percent by weight of a second polymer.  
     
     
         7 . The microtoner formulation of  claim 3 , wherein said polymer blend comprises from approximately twenty to approximately forty percent by weight of a first polymer, and from approximately eighty to approximately sixty percent by weight of a second polymer.  
     
     
         8 . The microtoner formulation of  claim 3 , wherein each of said at least one polymer and said at least one thermoplastic polymer comprise thermoplastic polymers.  
     
     
         9 . The microtoner formulation of  claim 8 , wherein said polymers are the same thermoplastic polymer but with different fracture properties.  
     
     
         10 . The microtoner formulation of  claim 8 , wherein said polymers are different thermoplastic polymers.  
     
     
         11 . A method of forming a particulate microtoner for use in the development of electrophotographic images, comprising: 
 blending at least one polymer with at least one thermoplastic polymer and with one or more pigments to thereby form a toner formulation;    pulverizing by mechanical means the toner formulation into an unclassified microtoner powder; and    classifying the unclassified microtoner formulation.    
     
     
         12 . The method of forming a particulate microtoner of  claim 11 , wherein said blending step comprises: 
 dry blending said at least one polymer with said at least one thermoplastic polymer and said one or more pigments to thereby form a dry mix;    melt mixing the dry mix; and    extruding the melt mix.    
     
     
         13 . The method of forming a particulate microtoner of  claim 11 , wherein said blending step comprises: 
 melt mixing one of said at least one polymer and said at least one thermoplastic polymer with said one or more pigments;    adding the other of said at least one polymer and said at least one thermoplastic polymer to said melt mix and further melt mixing; and    extruding the melt mix.    
     
     
         14 . The method of forming a particulate microtoner of  claim 11 , wherein said at least one polymer and said at least one thermoplastic polymer are each individually selected from the group consisting essentially of polyesters, polyamides, polyolefins, acrylic polymers and copolymers, methacrylic polymers and copolymers, styrenic polymers and copolymers, vinyl polymers and copolymers, and polyurethanes.  
     
     
         15 . The method of forming a particulate microtoner of  claim 11 , wherein said one or more pigments comprise from approximately two to approximately thirty percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-eight to approximately seventy percent by weight of said microtoner formulation.  
     
     
         16 . The method of forming a particulate microtoner of  claim 11 , wherein said one or more pigments comprise from approximately four to approximately twenty percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-six to approximately eighty percent by weight of said microtoner formulation.  
     
     
         17 . The method of forming a particulate microtoner of  claim 11 , wherein said one or more pigments comprise from approximately six to approximately ten percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-four to approximately ninety percent by weight of said microtoner formulation.  
     
     
         18 . The method of forming a particulate microtoner of  claim 11 , wherein said polymer blend comprises from approximately five to approximately ninety-five percent by weight of a first polymer, and from approximately ninety-five to approximately five percent by weight of a second polymer.  
     
     
         19 . The method of forming a particulate microtoner of  claim 11 , wherein said polymer blend comprises from approximately twenty to approximately forty percent by weight of a first polymer, and from approximately eighty to approximately sixty percent by weight of a second polymer.  
     
     
         20 . The method of forming a particulate microtoner of  claim 11 , wherein each of said at least one polymer and said at least one thermoplastic polymer comprise thermoplastic polymers.  
     
     
         21 . The method of forming a particulate microtoner of  claim 20 , wherein said polymers are the same thermoplastic polymer.  
     
     
         22 . The method of forming a particulate microtoner of  claim 20 , wherein said polymers are different thermoplastic polymers.  
     
     
         23 . The method of forming a particulate microtoner of  claim 11 , wherein said pulverizing process is carried out by a conventional method using conventional process parameters, and produces a particulate microtoner having a volume-median particle size of less than approximately 12 microns.  
     
     
         24 . The method of forming a particulate microtoner of  claim 23 , wherein said pulverizing process is carried out by a conventional method using conventional process parameters, and produces a particulate microtoner having a volume-median particle size of less than approximately 6 microns.  
     
     
         25 . The method of forming a particulate microtoner of  claim 24 , wherein said pulverizing process is carried out by a conventional method using conventional process parameters, and produces a particulate microtoner having a volume-median particle size of less than approximately 5 microns.  
     
     
         26 . The method of forming a particulate microtoner of  claim 25 , wherein said pulverizing process is carried out by a conventional method using conventional process parameters, and produces a particulate microtoner having a volume-median particle size of less than approximately 4 microns.  
     
     
         27 . The method of forming a particulate microtoner of  claim 23 , wherein said mechanical means of pulverizing comprises a jet mill pulverizer.  
     
     
         28 . A method for producing particulate microtoner having an improved unclassified particle size distribution relative to the unclassified particle size distribution of a particulate microtoner produced by conventional methods, comprising: 
 blending at least one polymer with at least one thermoplastic polymer and with one or more pigments to thereby form a toner formulation; and    pulverizing by mechanical means the toner formulation into an unclassified microtoner powder.    
     
     
         29 . The method of  claim 28 , wherein said blending step comprises: 
 dry blending said at least one polymer with said at least one thermoplastic polymer and said one or more pigments to thereby form a dry mix;    melt mixing the dry mix; and    extruding the melt mix.    
     
     
         30 . The method of  claim 28 , wherein said blending step comprises: 
 melt mixing one of said at least one polymer and said at least one thermoplastic polymer with said one or more pigments;    adding the other of said at least one polymer and said at least one thermoplastic polymer to said melt mix and further melt mixing; and    extruding the melt mix.    
     
     
         31 . The method of  claim 28 , wherein said at least one polymer and said at least one thermoplastic polymer are each individually selected from the group consisting essentially of polyesters, polyamides, polyolefins, acrylic polymers and copolymers, methacrylic polymers and copolymers, styrenic polymers and copolymers, vinyl polymers and copolymers, and polyurethanes.  
     
     
         32 . The method of  claim 28 , wherein said one or more pigments comprise from approximately two to approximately thirty percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-eight to approximately seventy percent by weight of said microtoner formulation.  
     
     
         33 . The method of  claim 28 , wherein said one or more pigments comprise from approximately four to approximately twenty percent by weight of said microtoner formulation, and said polymer blend comprises from approximately ninety-six to approximately eighty percent by weight of said microtoner formulation.  
     
     
         34 . The method of  claim 28 , wherein said mechanical means comprises a jet mill pulverizer.