Toner aggregation processes

A process for the preparation of toner with controlled particle size comprising

• (i) preparing a pigment dispersion in water, which dispersion is comprised of a pigment and counterionic surfactant;
• (ii) shearing the pigment dispersion with a latex, which latex contains a resin content of from about 50 percent by weight to about 20 percent by weight, thereby causing a flocculation or heterocoagulation of the formed particles of pigment and resin;
• diluting with water to form a uniform dispersion of total solids from about 30 percent by weight to about 2 percent by weight;
• (iii) heating the above sheared blend at a temperature of from about 5.degree. C. to about 25.degree. C. about below the glass transition temperature (Tg) of the resin while continuously stirring to form toner sized electrostatically bound aggregates with a narrow size dispersity;
• (iv) heating the electrostatically bound aggregates at a temperature of from about 5.degree. C. to about 50.degree. C. about above the Tg of the resin to provide said toner composition comprised of polymeric resin, pigment and optionally a charge control agent;
• and optionally
• (v) separating said toner particles from the water;
• and
• (vi) drying said toner particles;
• wherein said latex comprises resin, anionic surfactant, nonionic surfactant and water, and said total solids components are comprised of resin and pigment.

A process for the preparation of toner compositions consisting essentially of

• (i) preparing a pigment dispersion in water, which dispersion is comprised of pigment, a counterionic surfactant with a charge polarity of opposite sign to the anionic surfactant of (ii) and optionally a charge control agent;
• (ii) shearing the pigment dispersion with a latex comprised of resin, anionic surfactant, nonionic surfactant, and water;
• and wherein the latex solids content, which solids are comprised of resin, is from about 50 weight percent to about 20 weight percent thereby causing a flocculation or heterocoagulation of the formed particles of pigment, resin and optional charge control agent;
• diluting with water to form a dispersion of total solids of from about 30 weight percent to 1 weight percent, which total solids are comprised of resin, pigment and optional charge control agent contained in a mixture of said nonionic, anionic and cationic surfactants;
• (iii) heating the above sheared blend at a temperature of from about 5.degree. to about 25.degree. C. below about the glass transition temperature (Tg) of the resin while continuously stirring to form toner sized electrostatically bound aggregates with a narrow size dispersity;
• and
• (iv) heating the electrostatically bound aggregates at a temperature of from about 5.degree. to about 50.degree. C. above about the Tg of the resin to provide a toner composition comprised of resin, pigment and optionally a charge control agent.