Process for preparing novel composite charge control agents and novel composite charge control agents prepared by the process

1. A process for producing a composite charge control agent wherein a porous inorganic core particle of at least approximately 0.08 microns in diameter is impregnated with 2% to 50% by weight of one or more charge control chemicals and up to 50% by weight of one or more additional compounds selected from the group consisting of: a polymer, a wax, a dye, and combinations thereof.

2. A process according to claim 1 wherein the inorganic core particle is chosen from the group consisting of: amorphous silica, alumina, titania and calcium carbonate.

3. A process according to claim 1 wherein the inorganic core particle is treated with a chemical to adjust its pH and/or hydrophobicity either before or after the coating or impregnation operation.

4. A process according to claim 1 wherein an aqueous or organic solution or dispersion is formed from a solvent, at least one charge control chemical and one or more additional components selected from the group consisting of: a polymer, a wax, a dye, and combinations thereof and the solution or dispersion is sprayed onto the inorganic core particles, and optionally, the composite particles are dried.

5. A process according to claim 1 comprising the steps of:

forming an aqueous or organic solution or dispersion from at least one charge control chemical and one or more additional components selected from the group consisting of: a polymer, a wax, a dye, and combinations thereof;

adding the solution or dispersion to a quantity of inorganic core particles which adsorb the solution or dispersion so as to form composite particles; and

optionally, drying the composite particles.

6. A process according to claim 1 comprising the steps of:

forming a dispersion of a mixture of at least one charge control chemical and one or more additional component selected from the group consisting of: a polymer, a wax, a dye, and combinations thereof in a liquid that does not dissolve some or all of the wax or polymer at room temperature;

heating said dispersion to a temperature such that the polymer or wax dissolves;

adding the heated dispersion to a quantity of inorganic core particles which function to absorb the heated dispersion so as to form a composition thereof;

cooling the composition so as to precipitate the wax and/or polymer; and

optionally, evaporating residual liquid from the composition.

7. A composite charge control agent comprising: porous inorganic core particles of at least 0.08 microns in diameter impregnated with 2% to 50% by weight of one or more charge control chemicals and up to 50% by weight of one or more additional compounds selected from the group consisting of: a polymer, a wax, a dye, and combinations thereof.

8. The composite charge control agent of claim 7 , wherein said inorganic core particles are chosen from the group consisting of metal oxides, metal carbonates, and combinations thereof.

9. The composite charge control agent of claim 7 , comprising: 50 to 95% of said inorganic core particles.

10. The composite charge control agent of claim 7 , wherein said wax is an acid or amine functional wax.

11. The composite charge control agent of claim 7 , wherein said polymer is at least one acid or amine functional polymer.

12. The composite charge control agent of claim 7 , wherein the agent also includes an additional IR or UV visible dye or pigment.

13. A process according to claim 1 , wherein the porous inorganic core particle is impregnated throughout with 2% to 50% by weight of one or more charge control chemicals and up to 50% by weight of one or more additional compounds selected from the group consisting of: a polymer, a wax, a dye, and combinations thereof.

14. A process according to claim 1 , wherein the diameter of the porous inorganic core particle is from 0.08 microns to 5 microns.