Phase inversion emulsification reclamation process
A method for reclaiming an out-of-spec emulsion material includes recovering the out-of-spec emulsion material from a scrap manufacturing batch; distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to about 45 wt % or more based on a total weight of the emulsion material; dissolving the distilled emulsion material in a solvent to form a first mixture; adding a base to the first mixture to neutralize acid groups present in the distilled emulsion material, forming a second mixture; emulsifying the second mixture by adding water to the second mixture; and forming particles having an average particle diameter (D50v) within a target range, wherein the out-of-spec emulsion material has an average particle diameter falling outside of the target range.
1. A method for reclaiming an out-of-spec emulsion material comprising:
recovering the out-of-spec emulsion material from a scrap manufacturing batch;
distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to about 45 wt % or more based on a total weight of the emulsion material;
dissolving the distilled emulsion material in a solvent to form a first mixture;
adding a base to the first mixture to neutralize acid groups present in the distilled emulsion material, forming a second mixture;
emulsifying the second mixture by adding water to the second mixture; and
forming particles having an average particle diameter (D50v) within a target range,
wherein the out-of-spec emulsion material has an average particle diameter falling outside of the target range.
2. The method of claim 1 , wherein the solids content of the out-of-spec emulsion material is increased to a range of from about 45 wt % to about 85 wt %.
3. The method of claim 1 , wherein the out-of-spec emulsion material is distilled for from about 3 to about 6 hours.
4. The method of claim 1 , wherein the out-of-spec emulsion material is distilled by heating the out-of-spec emulsion material to a temperature of from about 50° C. to about 65° C.
5. The method of claim 1 , wherein the out-of-spec emulsion material comprises a mixture of polyester resins.
6. The method of claim 5 , wherein the mixture of polyester resins comprises a low molecular weight amorphous polyester resin, a high molecular weight amorphous polyester resin, and a crystalline polyester resin,
wherein:
the low molecular weight amorphous polyester resin has a weight average molecular weight (Mw) of less than 50,000; and
the high molecular weight amorphous polyester resin has a weight average molecular weight (Mw) of equal to or greater than 50,000.
7. The method of claim 1 , wherein the D50v target range is from about 150 to about 300 nm.
8. The method of claim 1 , further comprising:
removing the solvent from the second mixture; and
collecting the solvent.
9. The method of claim 1 , wherein the water is preheated to a temperature of from about 30° C. to about 100° C. prior to being added to the second mixture.
10. The method of claim 1 , wherein the solvent is a mixture of methyl ethyl ketone (MEK) and isopropyl alcohol (IPA).
11. The method of claim 10 , wherein a weight ratio of the distilled emulsion material to the MEK to the IPA is from about 10:6.5:1.4 to about 10:7.5:1.4.
12. A method of making a toner composition comprising:
reclaiming an out-of-spec emulsion material comprising:
recovering the out-of-spec emulsion material from a scrap manufacturing batch;
distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to greater than about 45 wt % based on a total weight of the emulsion material;
dissolving the distilled emulsion material in a solvent to form a first mixture;
adding a base to the first mixture to neutralize acidic groups present in the distilled emulsion material, forming a second mixture;
emulsifying the second mixture by adding water to the second mixture; and
forming particles having an average particle diameter (D50v) within a target range; and
mixing the particles with an optional colorant, an optional wax, and other optional additives forming a mixture; and
preparing a toner composition from the mixture,
wherein the out-of-spec emulsion material has an average particle diameter outside of the target range.
13. The method of claim 12 , wherein the out-of-spec emulsion material comprises a mixture of polyester resins.
14. The method of claim 13 , wherein the mixture of polyester resins comprises a low molecular weight amorphous polyester resin, a high molecular weight amorphous polyester resin, and a crystalline polyester resin,
wherein:
the low molecular weight amorphous polyester resin has a weight average molecular weight (Mw) of less than 50,000; and
the high molecular weight amorphous polyester resin has a weight average molecular weight (Mw) of equal to or greater than 50,000.
15. The method of claim 12 , wherein the solids content of the out-of-spec emulsion material is increased to a range of from about 45 wt % to about 85 wt %.
16. The method of claim 12 , wherein the D50v target range is from about 150 to about 300 nm.
17. The method of claim 12 , wherein the solvent is a mixture of methyl ethyl ketone (MEK) and isopropyl alcohol (IPA).
18. The method of claim 17 , wherein a weight ratio of the distilled emulsion material to the MEK to the IPA is from about 10:6.5:1.4 to about 10:7.5:1.4.
19. A toner prepared from a method comprising:
reclaiming an out-of-spec emulsion material comprising:
recovering the out-of-spec emulsion material from a scrap manufacturing batch;
distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to greater than about 45 wt % based on a total weight of the emulsion material;
dissolving the distilled emulsion material in a solvent to form a first mixture;
adding a base to the first mixture to neutralize acidic groups present in the distilled emulsion material, forming a second mixture;
emulsifying the second mixture; and
forming particles having an average particle diameter (D50v) within a target range; and
mixing the particles with an optional colorant, an optional wax, and other optional additives forming a mixture; and
preparing a toner composition from the mixture,
wherein the out-of-spec emulsion material has an average particle diameter outside of the target range.
20. The toner of claim 19 , wherein the D50v target range is from about 150 to about 300 nm.