US20020150688A1 - Process for applying a topcoat to a porous basecoat - Google Patents
Process for applying a topcoat to a porous basecoat Download PDFInfo
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- US20020150688A1 US20020150688A1 US09/491,642 US49164200A US2002150688A1 US 20020150688 A1 US20020150688 A1 US 20020150688A1 US 49164200 A US49164200 A US 49164200A US 2002150688 A1 US2002150688 A1 US 2002150688A1
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- basecoat
- topcoat
- wet liquid
- coating
- binder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/502—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording characterised by structural details, e.g. multilayer materials
- B41M5/506—Intermediate layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5218—Macromolecular coatings characterised by inorganic additives, e.g. pigments, clays
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5227—Macromolecular coatings characterised by organic non-macromolecular additives, e.g. UV-absorbers, plasticisers, surfactants
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5236—Macromolecular coatings characterised by the use of natural gums, of proteins, e.g. gelatins, or of macromolecular carbohydrates, e.g. cellulose
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5254—Macromolecular coatings characterised by the use of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds, e.g. vinyl polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5263—Macromolecular coatings characterised by the use of polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- B41M5/5281—Polyurethanes or polyureas
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
Definitions
- the present invention relates generally to ink-jet printing, and, more particularly, to improving the properties of an ink-receiving layer applied to a non-absorbent substrate.
- Ink-jet receiving layers need to absorb the ink vehicle delivered during the printing process.
- the substrate provides no absorption capacity and as a result, the ink-receiving layer must be the sole absorbing material.
- an absorbent precoat has been described in the prior art that serves to increase the capacity of the coating, much as a substrate functions in paper-based ink-jet media.
- a topcoat is applied to control surface properties such as gloss, tackiness, surface energy, and durability, as well as to function in concert with the adsorbent precoat.
- the topcoat must be free of defects that would contribute to perceived irregularities or non-uniformities in the coating.
- U.S. Pat. No. 5,275,867 describes a two-layer coating and a coating process where a topcoat is laminated on the precoat.
- U.S. Pat. No. 5,605,750 describes a three-layer coating and a coating process where the topcoats are applied to the precoat by coating both fluids before drying in a multi-slot hopper or a slide hopper.
- U.S. Pat. No. 5,576,088 describes a two layer coating and a coating process where a topcoat is cast coated on a precoat. All these examples describe a process that involves specialized equipment and coatings engineered to be compatible with the processes. In addition, production efficiencies may be lower.
- the present inventors describe herein a process that allows the production of multi-layer coatings in which one or more topcoats can be applied to a porous basecoat to produce a uniform and defect-free coating layer.
- a process is provided in which a liquid is applied to the basecoat prior to topcoating such that the air in the basecoat is removed prior to topcoating.
- This process can occur in-line with a simple apparatus described herein.
- An added benefit of this method is that it also allows the possibility of adding functionality or performing chemistry to the coatings after the basecoat is dried and before the topcoat is applied in a single process.
- the wetting liquid may contain, but is not limited to, surfactants, pH modifiers, polymers, crosslinkers, pigments, and/or dye stabilizers.
- Advantages of the invention over what has been done before include the use of re-wetting process that allows a topocoat to be applied to a porous basecoat that is coated on a non-porous, or non-permeable, substrate such that bubbles are not formed in the topcoat. This allows the production of defect-free coatings. In addition, there is added flexibility of incorporating functionality or chemistry in the re-wetting process. Finally, the process of the present invention is simple to implement and is compatible with many general coating methods, such as slot-die coating, rod coating, blade coating, gravure coating, knife-over-roll coating, or the like.
- An additional benefit of the above technique is that chemicals may be added to a coating which would otherwise be incompatible in the coating solution itself or the dried coating.
- a still further benefit of the above technique is that two coating layers may be applied where incompatibilities may present difficulties in a wet-on-wet coating application technique.
- the basecoat and the topcoat each comprise one or more pigments and one or more binders, which are polymeric compounds soluble or dispersible in the solvent in which the basecoat and topcoat are applied to the substrate.
- pigments indude silica and alumina and its various hydrates, titania, carbonates (e.g., calcium carbonate, magnesium carbonate), glass beads, and organic pigments (e.g., plastic or polymer pigments such as cross-linked SBR latexes, micronized polyethylene or polypropylene wax, acrylic beads, and methacrylic beads).
- the pigment may be the same in both the basecoat and topcoat or different.
- the binder is a polymeric matrix which serves, among other things, to hold the pigment(s) in place.
- the binder can be water-soluble or water-dispersible.
- water-soluble binders include polyvinyl alcohol and its derivatives, polyvinyl pyrrolidone/polyvinyl acetate copolymer, cellulose derivatives, polyamides, and polyethylene oxide.
- water-dispersed binders include styrene-butadiene latexes, polyacrylics, polyurethanes, and the like.
- the binder may be the same in both the basecoat and topcoat or different.
- the basecoat and topcoat are separately applied in solution to the substrate and allowed to dry.
- the substrate comprises non-permeable (non-air permeable) material, such as a film-based material, e.g., Mylar, or a resin-coated papers (e.g., photobase paper).
- non-permeable (non-air permeable) material such as a film-based material, e.g., Mylar, or a resin-coated papers (e.g., photobase paper).
- pores in the basecoat are saturated, or nearly saturated, with a liquid, also called a re-wetting solution herein, before the topcoat solution is applied.
- a liquid also called a re-wetting solution herein
- the pores in the basecoat are saturated with liquid before the topcoat solution is applied.
- a solvent that is compatible with the solvent in the topcoating is believed to give the best adhesion between coating layers.
- the liquid may comprise one or more solvents.
- the liquid may be heated or chemically modified to increase the penetration rate in the precoat.
- the liquid is heated to any temperature below its boiling point (or the minimum boiling point if two or more solvents are used).
- chemically modified is meant the addition of one or more surfactants, adhesion promoters, pH modifiers, polymers, crosslinkers, pigments, and/or dye stabilizers to the liquid.
- the chemically modified re-wet solution thus serves to modify the properties of the basecoat, topcoat, the coating process, or the performance of the coatings as it relates to its use as a printing media.
- Any of the usual surfactants, pH modifiers, and/or crosslinkers may be used in the practice of the present invention.
- a suitable crosslinker added to the liquid is a borate glyoxyl. This process is especially useful for chemistries that are not compatible with the coating fluids or process.
- excess fluid on the surface of the basecoat be removed before topcoating. This can be accomplished by a nip, doctoring blade, or the like.
- the sole Figure shows apparatus 10 useful in the process of the present invention.
- the apparatus 10 which is a conventional coater, comprises a container 12 for containing a re-wetting solution 14 .
- a web 16 comprises the non-absorbent substrate and a porous basecoat thereon and the solution 14 is introduced onto the surface of the porous basecoat by means of an applicator roller 18 .
- a hold-down roller 20 urges the web 16 against the top of the applicator roller 18 .
- the applicator roller 18 applies the liquid 14 to the web 16 .
- the liquid 14 is metered onto the applicator roller 18 by a metering roller 22 , provided with a doctor 24 , or other suitable means.
- the excess re-wet solution may be doctored off of the web.
- the re-wet solution can be metered by a pump directly onto the moving web 16 , thus eliminating the need for doctoring.
- the uptake of the liquid 14 depends on the speed of the web 16 . It is desired to move the web 16 as fast as possible to maximize the coating efficiency.
- the dwell time of the re-wet fluid is defined as the time interval between application of the re-wet fluid and application of the coating.
- the dwell time thus determines the length of time available for the re-wet solution to penetrate into the basecoat.
- the dwell time can be modified by the web speed and web distance between the re-wet station and the coating station.
- the length of time required to obtain adequate saturation of the basecoat is determined by the design of the re-wet station, the basecoat properties, the topcoat properties, and the re-wet fluid properties. For this process to be effective, all of these parameters need to be accounted for when designing the coating process.
- the present invention provides a number of advantages. First, the invention permits applying a topcoat solution on porous basecoats formed on non-porous substrates. Second, the invention permits incorporation of materials for either the basecoat or the topcoat that would otherwise be incompatible with each other. Third, the invention allows incompatible liquids to be coated in multilayer systems.
- a coating was prepared on either a film-based substrate (Mylar) or a resin-coated paper substrate (photobase paper) that contained the following components: Chemical Manufacturer Grade Parts by weight Basecoat silica Grace Davison 0.2 ⁇ m porous 100 polyvinyl alcohol Air Products Airvol 350 26 acrylic Dow XUR 1540 2494-6 5 water (solids at 17 wt %) Topcoat alumina Condea Vista Dispal 14N4-25 100 polyvinyl pyrroli- BASF Luviquat FC370 2 done/polyvinyl acetate polyvinyl alcohol Nippon Gohesfeimer Z200 12 polyethylene Union Carbide Carbowax 8000 7 glycol (surfactant) water (solids at 22 wt %)
- the basecoat was mixed in water by adding the components to the water to a level of 17 wt %.
- the basecoat was then coated on a resin coated substrate with a mayer rod.
- the coating was dried at 100° C. for 5 minutes to yield a coating with 20 g/m 2 coatweight and 0.9 cm 3 /g porosity.
- the topcoat materials were also mixed together in water by adding the components to the water, this time to a level of 22 wt %.
- the topcoat was then de-aerated overnight to remove retained air, and then coated.
- topcoat was applied as above except that the topcoat was applied after the basecoat was wetted with excess water (the re-wetting solution) and then the surface was dried with a towel. In this instance, water alone was used; no chemical modifiers were used. The result after drying was a defect-free coating.
- Comparative Example 2 and Example 2 demonstrate the occurrence of gelling and the alleviation of gelling, respectively.
- topcoat and the basecoat had the following formulations, where DI-H 2 O means deionized water: Parts Chemicals Manufacturer Grade by Weight Topcoat: alumina Condea Vista Dispal 14N4-25 36 polyamide Georgia-Pacific Amres 8855 2.5 glycerol Aldrich 1.2 DI-H 2 O 120 Basecoat: silica Grace Davison 0.2 ⁇ m porous 100 polyvinyl alcohol Air Products Airvol 350 26 styrene-butadiene Dow XUR 1540 2494-6 5 latex
- the basecoat had a solids concentration of 14.2% and a pH of 8.5, while the topcoat had a solids concentration of 15% and a pH of 4.1.
- the topcoat and the basecoat had the same formulations as in Comparative Example 2 and were formulated as described therein.
- the basecoat was applied to the substrate and dried.
- the topcoat was applied as above except that the topcoat was applied after wetting the basecoat with water (the re-wetting solution). Excess re-wetting solution was removed with a metering device prior to applying the topcoat. This process enabled long coating runs without streaks. The result after drying was a defect-free coating.
- topcoat and basecoat had the same formulations as in Comparative Example 1 and were formulated as described therein.
- a chemically-modified re-wet solution comprising 1.52 parts by weight citric acid (Aldrich) in 100 parts deionized water was used to adjust the pH of the coatings in the re-wetting step. Waterfastness was measured by the following procedure (after the coatings were printed on an HP CP2500 printer using UV-pigmented inks):
- the ink-receiving coating was able to achieve good image waterfastness with pigment ink after 2 hours delay time, whereas significant color smearing was observed after testing the waterfastness of the coating prepared in Example 1.
- topcoat had the following formulations and were coated as in Examples 1 or 2.
- Parts Chemicals Manufacturer Grade by Weight Topcoat polyvinyl alcohol Aldrich Airvol 165 100 polyurethane Dainippon Ink & IJ-60 25
- Chemicals Re-wet solution DI-H 2 O 100 polyethyleneimine Aldrich MW 800 1
- Basecoat silica Grace Davison 0.2 ⁇ m porous 100 polyvinyl alcohol Air Products Airvol 350 26 styrene-butadiene Dow XUR 1540 2494-6 5 latex
- test method for measuring water resistance was identical to that described in Example 3 above, except that after Step 4 , the test was performed on an unimaged coating and there was an additional step as follows:
- samples were treated only with the basecoat and the topcoat solutions, using water as a re-wet fluid.
- the samples were also treated with the re-wet solution after application of the basecoat and before application of the topcoat.
- the polyethyleneimine was added directly to the basecoat solution or the topcoat solution.
- the measuring gloss number decreased from 63% at 20 degrees to 13% at 20 degrees.
- the reading was 52 to 55% at 20 degrees, indicating improved water resistance of the coating.
- the solutions gelled and were un-coatable.
- Example 4 The basecoat of Example 4 was applied to a clear mylar film (Melinex, DuPont). Pore saturation time was measured by applying a 20 ⁇ l drop to the basecoat and measuring the time until the basecoat became transparent and unchanging, which indicated full pore saturation. The following re-wet solutions were tested, with the saturation time as indicated: Re-Wet Solution Saturation Time, sec. Water 25 1% tetrahydrofuran (Aldrich) in water 15 1% polyvinylalcohol (Aldrich) in water 15
- the topcoating process of the present invention is expected to find use in providing ink-receiving coatings on non-absorbent substrates.
Abstract
Description
- The present invention relates generally to ink-jet printing, and, more particularly, to improving the properties of an ink-receiving layer applied to a non-absorbent substrate.
- Ink-jet receiving layers need to absorb the ink vehicle delivered during the printing process. When the ink-receiving layer is applied to non-absorbent substrate, the substrate provides no absorption capacity and as a result, the ink-receiving layer must be the sole absorbing material. To increase the absorbing capacity of the coating, an absorbent precoat has been described in the prior art that serves to increase the capacity of the coating, much as a substrate functions in paper-based ink-jet media.
- A topcoat is applied to control surface properties such as gloss, tackiness, surface energy, and durability, as well as to function in concert with the adsorbent precoat. In addition, the topcoat must be free of defects that would contribute to perceived irregularities or non-uniformities in the coating.
- U.S. Pat. No. 5,275,867 describes a two-layer coating and a coating process where a topcoat is laminated on the precoat. U.S. Pat. No. 5,605,750 describes a three-layer coating and a coating process where the topcoats are applied to the precoat by coating both fluids before drying in a multi-slot hopper or a slide hopper. U.S. Pat. No. 5,576,088 describes a two layer coating and a coating process where a topcoat is cast coated on a precoat. All these examples describe a process that involves specialized equipment and coatings engineered to be compatible with the processes. In addition, production efficiencies may be lower.
- An on-going problem in the application of a topcoat with basic coating equipment such as mayer rod and slot die coaters is the formation of bubbles in the topcoat when it is coated on a porous basecoat that has been applied to a non-porous substrate.
- These bubbles are formed when the air voids in the pores of the precoat are filled with fluid from the topcoat application process which results in the air being forced to surface of the precoat where they coalesce into bubbles in a still fluid topcoat. These bubbles can then form defects in the topcoat as that coating is dried. Another challenge when developing coating fluids and chemistries is avoiding problems associated with incompatible chemistries that result in solution gelling or phase separation in the dried coatings.
- Thus, what is needed is a process that avoids the problems of the prior art and provides a uniform and defect-free topcoat layer, and thus allows the incorporation of incompatible chemistries into the coating.
- The present inventors describe herein a process that allows the production of multi-layer coatings in which one or more topcoats can be applied to a porous basecoat to produce a uniform and defect-free coating layer. Specifically, a process is provided in which a liquid is applied to the basecoat prior to topcoating such that the air in the basecoat is removed prior to topcoating. This process can occur in-line with a simple apparatus described herein. An added benefit of this method is that it also allows the possibility of adding functionality or performing chemistry to the coatings after the basecoat is dried and before the topcoat is applied in a single process. For example, the wetting liquid may contain, but is not limited to, surfactants, pH modifiers, polymers, crosslinkers, pigments, and/or dye stabilizers.
- Advantages of the invention over what has been done before include the use of re-wetting process that allows a topocoat to be applied to a porous basecoat that is coated on a non-porous, or non-permeable, substrate such that bubbles are not formed in the topcoat. This allows the production of defect-free coatings. In addition, there is added flexibility of incorporating functionality or chemistry in the re-wetting process. Finally, the process of the present invention is simple to implement and is compatible with many general coating methods, such as slot-die coating, rod coating, blade coating, gravure coating, knife-over-roll coating, or the like.
- An additional benefit of the above technique is that chemicals may be added to a coating which would otherwise be incompatible in the coating solution itself or the dried coating.
- A still further benefit of the above technique is that two coating layers may be applied where incompatibilities may present difficulties in a wet-on-wet coating application technique.
- The sole Figure illustrates apparatus useful in the practice of the present invention.
- Reference is made now in detail to a specific embodiment of the present invention, which illustrates the best mode presently contemplated by the inventors for practicing the invention. Alternative embodiments are also briefly described as applicable.
- The basecoat and the topcoat each comprise one or more pigments and one or more binders, which are polymeric compounds soluble or dispersible in the solvent in which the basecoat and topcoat are applied to the substrate. Examples of pigments indude silica and alumina and its various hydrates, titania, carbonates (e.g., calcium carbonate, magnesium carbonate), glass beads, and organic pigments (e.g., plastic or polymer pigments such as cross-linked SBR latexes, micronized polyethylene or polypropylene wax, acrylic beads, and methacrylic beads). The pigment may be the same in both the basecoat and topcoat or different.
- The binder is a polymeric matrix which serves, among other things, to hold the pigment(s) in place. The binder can be water-soluble or water-dispersible. Examples of water-soluble binders include polyvinyl alcohol and its derivatives, polyvinyl pyrrolidone/polyvinyl acetate copolymer, cellulose derivatives, polyamides, and polyethylene oxide. Examples of water-dispersed binders include styrene-butadiene latexes, polyacrylics, polyurethanes, and the like. The binder may be the same in both the basecoat and topcoat or different.
- The basecoat and topcoat are separately applied in solution to the substrate and allowed to dry.
- The substrate comprises non-permeable (non-air permeable) material, such as a film-based material, e.g., Mylar, or a resin-coated papers (e.g., photobase paper).
- In accordance with the present invention, pores in the basecoat are saturated, or nearly saturated, with a liquid, also called a re-wetting solution herein, before the topcoat solution is applied. Preferably, the pores in the basecoat are saturated with liquid before the topcoat solution is applied. Also preferably, a solvent that is compatible with the solvent in the topcoating is believed to give the best adhesion between coating layers.
- The liquid may comprise one or more solvents. The liquid may be heated or chemically modified to increase the penetration rate in the precoat.
- If heated, the liquid is heated to any temperature below its boiling point (or the minimum boiling point if two or more solvents are used).
- By “chemically modified” is meant the addition of one or more surfactants, adhesion promoters, pH modifiers, polymers, crosslinkers, pigments, and/or dye stabilizers to the liquid. The chemically modified re-wet solution thus serves to modify the properties of the basecoat, topcoat, the coating process, or the performance of the coatings as it relates to its use as a printing media. Any of the usual surfactants, pH modifiers, and/or crosslinkers may be used in the practice of the present invention. For example, where the binder in the basecoat is polyvinyl alcohol, a suitable crosslinker added to the liquid is a borate glyoxyl. This process is especially useful for chemistries that are not compatible with the coating fluids or process.
- It is also preferred that excess fluid on the surface of the basecoat be removed before topcoating. This can be accomplished by a nip, doctoring blade, or the like.
- The sole Figure shows
apparatus 10 useful in the process of the present invention. Theapparatus 10, which is a conventional coater, comprises acontainer 12 for containing a re-wetting solution 14. Aweb 16 comprises the non-absorbent substrate and a porous basecoat thereon and the solution 14 is introduced onto the surface of the porous basecoat by means of anapplicator roller 18. A hold-down roller 20 urges theweb 16 against the top of theapplicator roller 18. Theapplicator roller 18 applies the liquid 14 to theweb 16. The liquid 14 is metered onto theapplicator roller 18 by ametering roller 22, provided with adoctor 24, or other suitable means. - In an alternate embodiment, the excess re-wet solution may be doctored off of the web.
- In another alternative embodiment, the re-wet solution can be metered by a pump directly onto the moving
web 16, thus eliminating the need for doctoring. - The uptake of the liquid14 depends on the speed of the
web 16. It is desired to move theweb 16 as fast as possible to maximize the coating efficiency. - The dwell time of the re-wet fluid is defined as the time interval between application of the re-wet fluid and application of the coating. The dwell time thus determines the length of time available for the re-wet solution to penetrate into the basecoat. The dwell time can be modified by the web speed and web distance between the re-wet station and the coating station. The length of time required to obtain adequate saturation of the basecoat is determined by the design of the re-wet station, the basecoat properties, the topcoat properties, and the re-wet fluid properties. For this process to be effective, all of these parameters need to be accounted for when designing the coating process.
- The present invention provides a number of advantages. First, the invention permits applying a topcoat solution on porous basecoats formed on non-porous substrates. Second, the invention permits incorporation of materials for either the basecoat or the topcoat that would otherwise be incompatible with each other. Third, the invention allows incompatible liquids to be coated in multilayer systems.
- A coating was prepared on either a film-based substrate (Mylar) or a resin-coated paper substrate (photobase paper) that contained the following components:
Chemical Manufacturer Grade Parts by weight Basecoat silica Grace Davison 0.2 μm porous 100 polyvinyl alcohol Air Products Airvol 350 26 acrylic Dow XUR 1540 2494-6 5 water (solids at 17 wt %) Topcoat alumina Condea Vista Dispal 14N4-25 100 polyvinyl pyrroli- BASF Luviquat FC370 2 done/polyvinyl acetate polyvinyl alcohol Nippon Gohesfeimer Z200 12 polyethylene Union Carbide Carbowax 8000 7 glycol (surfactant) water (solids at 22 wt %) - The basecoat was mixed in water by adding the components to the water to a level of 17 wt %. The basecoat was then coated on a resin coated substrate with a mayer rod. The coating was dried at 100° C. for 5 minutes to yield a coating with 20 g/m2 coatweight and 0.9 cm3/g porosity. The topcoat materials were also mixed together in water by adding the components to the water, this time to a level of 22 wt %. The topcoat was then de-aerated overnight to remove retained air, and then coated.
- After coating the topcoat, bubbles appeared almost immediately. After drying as above, these bubbles produce visible coating defects where craters had formed.
- The topcoat was applied as above except that the topcoat was applied after the basecoat was wetted with excess water (the re-wetting solution) and then the surface was dried with a towel. In this instance, water alone was used; no chemical modifiers were used. The result after drying was a defect-free coating.
- Comparative Example 2 and Example 2 demonstrate the occurrence of gelling and the alleviation of gelling, respectively.
- The topcoat and the basecoat had the following formulations, where DI-H2O means deionized water:
Parts Chemicals Manufacturer Grade by Weight Topcoat: alumina Condea Vista Dispal 14N4-25 36 polyamide Georgia-Pacific Amres 8855 2.5 glycerol Aldrich 1.2 DI-H2O 120 Basecoat: silica Grace Davison 0.2 μm porous 100 polyvinyl alcohol Air Products Airvol 350 26 styrene-butadiene Dow XUR 1540 2494-6 5 latex - In both instances, the non-water components were added to water. The basecoat had a solids concentration of 14.2% and a pH of 8.5, while the topcoat had a solids concentration of 15% and a pH of 4.1.
- Cascade coating was employed, with one wet coating placed on top of another wet coating. Here, it was found that the two solutions gelled on the die even before the fluids hit the web at low web speed. In order to minimize the contact time between the two incompatible fluids, the web speed was increased and the pump for the topcoat was started only after the base layer coating reached steady state. The pump settings for both fluids were adjusted so that a better coating was obtained.
- After time, so-called “ice cap” formation was observed on the die. This “ice cap” formed where the two incompatible fluids first came into contact. The “ice cap” built up with time, then it started to break down into pieces as time went on. The break-down of the ice cap led to streaks in the coating and was difficult to recover.
- The topcoat and the basecoat had the same formulations as in Comparative Example2 and were formulated as described therein. The basecoat was applied to the substrate and dried. In a subsequent process, the topcoat was applied as above except that the topcoat was applied after wetting the basecoat with water (the re-wetting solution). Excess re-wetting solution was removed with a metering device prior to applying the topcoat. This process enabled long coating runs without streaks. The result after drying was a defect-free coating.
- The following Examples 3-4 describe the use of the re-wet solution where incompatible chemistries are used with each other.
- The topcoat and basecoat had the same formulations as in Comparative Example 1 and were formulated as described therein. A chemically-modified re-wet solution comprising 1.52 parts by weight citric acid (Aldrich) in 100 parts deionized water was used to adjust the pH of the coatings in the re-wetting step. Waterfastness was measured by the following procedure (after the coatings were printed on an HP CP2500 printer using UV-pigmented inks):
- 1. Drop 250 μl of DI water on an ink-receiving coating by utilizing a micro pipette.
- 2. Use index finger to rub the coating area containing the 250 μl of DI water for 1 minute.
- 3. Wipe the excess water with a paper towel.
- 4. Use a heat gun to dry the wet area for 30 seconds.
- 5. Observe how much colorant smeared outside the colored area due to rubbing.
- Following the above procedure, the ink-receiving coating was able to achieve good image waterfastness with pigment ink after 2 hours delay time, whereas significant color smearing was observed after testing the waterfastness of the coating prepared in Example 1.
- If citric acid is added to either the basecoat or topcoat, the coating fluid gels into a non-flocculated gel.
- The topcoat, the re-wet solution, and the basecoat had the following formulations and were coated as in Examples 1 or 2.
Parts Chemicals Manufacturer Grade by Weight Topcoat: polyvinyl alcohol Aldrich Airvol 165 100 polyurethane Dainippon Ink & IJ-60 25 Chemicals Re-wet solution: DI-H2O 100 polyethyleneimine Aldrich MW 800 1 Basecoat: silica Grace Davison 0.2 μm porous 100 polyvinyl alcohol Air Products Airvol 350 26 styrene-butadiene Dow XUR 1540 2494-6 5 latex - The test method for measuring water resistance was identical to that described in Example 3 above, except that after Step4, the test was performed on an unimaged coating and there was an additional step as follows:
- 5.
Measure 20 degree gloss on both rubbed and unrubbed areas and compare the results. - In one series of experiments, samples were treated only with the basecoat and the topcoat solutions, using water as a re-wet fluid. In another series of experiments, the samples were also treated with the re-wet solution after application of the basecoat and before application of the topcoat.
- In still another series of experiments, the polyethyleneimine was added directly to the basecoat solution or the topcoat solution.
- For samples that were not treated with the re-wet solution, the measuring gloss number decreased from 63% at 20 degrees to 13% at 20 degrees. For samples that were treated with the chemically-modified re-wet solution in accordance with the present invention, the reading was 52 to 55% at 20 degrees, indicating improved water resistance of the coating. In the samples where the polyethyleneimine was added directly to the basecoat or topcoat solution, the solutions gelled and were un-coatable.
- The results show that the chemical property such as water resistance of the ink-receiving coating is significantly improved by employing the re-wet process of the present invention, incorporating appropriate chemicals in the re-wet solution.
- The basecoat of Example4 was applied to a clear mylar film (Melinex, DuPont). Pore saturation time was measured by applying a 20 μl drop to the basecoat and measuring the time until the basecoat became transparent and unchanging, which indicated full pore saturation. The following re-wet solutions were tested, with the saturation time as indicated:
Re-Wet Solution Saturation Time, sec. Water 25 1% tetrahydrofuran (Aldrich) in water 15 1% polyvinylalcohol (Aldrich) in water 15 - These examples demonstrate the increase in re-wet solution absorption rate upon modification of the re-wet solution.
- The topcoating process of the present invention is expected to find use in providing ink-receiving coatings on non-absorbent substrates.
- The foregoing description of the preferred embodiment of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form or to exemplary embodiments disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in this art. Similarly, any process steps described might be interchangeable with other steps in order to achieve the same result. The embodiment was chosen and described in order to best explain the principles of the invention and its best mode practical application, thereby to enable others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use or implementation contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
Claims (24)
Priority Applications (12)
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US09/491,642 US6475612B1 (en) | 2000-01-27 | 2000-01-27 | Process for applying a topcoat to a porous basecoat |
US09/545,934 US6451379B1 (en) | 2000-01-27 | 2000-04-10 | Increasing dot size on porous media printed with pigmented inks |
US09/693,676 US6423375B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet media |
US09/693,531 US6432523B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet inks and print media |
EP20010300347 EP1120280B1 (en) | 2000-01-27 | 2001-01-16 | Method for increasing dot size on porous media printed with pigmented inks |
EP20010300346 EP1120279B1 (en) | 2000-01-27 | 2001-01-16 | Method for improving light fastness of inkjet images by adding salts into inkjet inks and print media |
DE60113572T DE60113572T2 (en) | 2000-01-27 | 2001-01-16 | Method for applying a cover layer to a porous substrate |
DE2001611655 DE60111655T2 (en) | 2000-01-27 | 2001-01-16 | Method for increasing the dot size on a porous substrate printed with pigmented inks |
EP01300345A EP1120278B1 (en) | 2000-01-27 | 2001-01-16 | Process for applying a topcoat to a porous basecoat |
DE2001607300 DE60107300T2 (en) | 2000-01-27 | 2001-01-16 | Improvement of the light stability of ink-jet print images by adding salts in ink jet ink and printing medium |
JP2001019837A JP3973841B2 (en) | 2000-01-27 | 2001-01-29 | Method for providing ink receiving layer on non-porous substrate |
JP2001019853A JP3741958B2 (en) | 2000-01-27 | 2001-01-29 | Inkjet ink and print media selection method |
Applications Claiming Priority (1)
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US09/491,642 US6475612B1 (en) | 2000-01-27 | 2000-01-27 | Process for applying a topcoat to a porous basecoat |
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US09/693,531 Continuation-In-Part US6432523B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet inks and print media |
US09/693,676 Continuation-In-Part US6423375B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet media |
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US09/545,934 Expired - Fee Related US6451379B1 (en) | 2000-01-27 | 2000-04-10 | Increasing dot size on porous media printed with pigmented inks |
US09/693,531 Expired - Fee Related US6432523B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet inks and print media |
US09/693,676 Expired - Fee Related US6423375B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet media |
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US09/545,934 Expired - Fee Related US6451379B1 (en) | 2000-01-27 | 2000-04-10 | Increasing dot size on porous media printed with pigmented inks |
US09/693,531 Expired - Fee Related US6432523B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet inks and print media |
US09/693,676 Expired - Fee Related US6423375B1 (en) | 2000-01-27 | 2000-10-19 | Light fastness of inkjet images by adding salts into inkjet media |
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US20050142305A1 (en) * | 2003-11-06 | 2005-06-30 | Mitsuru Kobayashi | Ink jet recording sheet and method for producing thereof |
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JPH08300804A (en) | 1995-04-28 | 1996-11-19 | Mitsubishi Paper Mills Ltd | Production of ink jet cast coated paper |
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-
2000
- 2000-01-27 US US09/491,642 patent/US6475612B1/en not_active Expired - Fee Related
- 2000-04-10 US US09/545,934 patent/US6451379B1/en not_active Expired - Fee Related
- 2000-10-19 US US09/693,531 patent/US6432523B1/en not_active Expired - Fee Related
- 2000-10-19 US US09/693,676 patent/US6423375B1/en not_active Expired - Fee Related
-
2001
- 2001-01-16 EP EP01300345A patent/EP1120278B1/en not_active Expired - Lifetime
- 2001-01-16 DE DE60113572T patent/DE60113572T2/en not_active Expired - Lifetime
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US20050142305A1 (en) * | 2003-11-06 | 2005-06-30 | Mitsuru Kobayashi | Ink jet recording sheet and method for producing thereof |
US20080057190A1 (en) * | 2003-11-06 | 2008-03-06 | Oji Paper Co., Ltd. | Method for producing an ink jet recording sheet |
US20080297573A1 (en) * | 2004-02-12 | 2008-12-04 | Canon Kabushiki Kaisha | Liquid applying apparatus and ink jet printing apparatus |
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Also Published As
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EP1120278A2 (en) | 2001-08-01 |
US6432523B1 (en) | 2002-08-13 |
US6423375B1 (en) | 2002-07-23 |
EP1120278A3 (en) | 2001-09-05 |
US6475612B1 (en) | 2002-11-05 |
EP1120278B1 (en) | 2005-09-28 |
DE60113572T2 (en) | 2006-07-13 |
DE60113572D1 (en) | 2005-11-03 |
US6451379B1 (en) | 2002-09-17 |
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