HK1079541B - Water resistant ink jet recordable substrate - Google Patents
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- HK1079541B HK1079541B HK05111673.6A HK05111673A HK1079541B HK 1079541 B HK1079541 B HK 1079541B HK 05111673 A HK05111673 A HK 05111673A HK 1079541 B HK1079541 B HK 1079541B
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Description
This patent application claims priority from provisional patent application 60/373,957, filed on 9/4/2002.
The present invention relates to an inkjet recordable substrate. The present invention relates to, inter alia, a water-resistant coating composition for ink-jet recordable substrates, a method of preparing the coating composition, and a method of applying the coating composition to prepare a water-resistant ink-jet recordable substrate.
Methods are known in the art for using various paper treatments to improve the quality of ink jet printing thereon. However, problems often arise when the imaged paper is in contact with water; the image will migrate through the paper to the other side. In some cases, the back side of the paper appears as an image with more ink than the front side. In addition, the paper processing method for improving the problem of pigment loss in the color ink-jet image can improve the accuracy of image display.
It is also known in the art to size cellulose-based papers with a sizing component for the purpose of reducing the penetration of liquids into the substrate. "internal sizing" includes the introduction of material into the pulp during the papermaking operation. "surface sizing" includes coating a preformed sheet with a dispersion of a film-forming material such as modified starches, gums, and modified polymers. When printing with an ink jet printer containing mainly water-based ink, internally and surface sized paper often results in an image forming paper that is rolled into a cylinder.
Thus, it is desirable to develop an ink jet recordable substrate that does not suffer from the above-mentioned problems.
US patent US5,709,976 discloses a process for coating a paper substrate with a hydrophobic barrier layer and an image receptive layer. US patent US6,140,412 discloses a method for coating paper with an aqueous cationic polyurethane resin solution.
In addition to paper printing substrates, polyolefin-based printing substrates in the form of microporous sheets have also been developed and are well known in the art. For example, U.S. Pat. Nos. 4,861,644 and 5,196,262 disclose a microporous sheet material comprising a linear ultrahigh molecular weight polyolefin matrix, a plurality of finely divided water-insoluble silicon fillers, and interconnected pores. However, inks used for ink jet printing tend to coalesce to the surface of the polyolefin-based printing substrate.
US patent US6,025,068 discloses a method for coating a microporous polyolefin substrate with a composition comprising a binder dissolved or dispersed in a volatile aqueous liquid medium. The adhesive comprises an organic film-forming polymer of a water-soluble poly (ethylene oxide) and a water-soluble or water-dispersible crosslinkable polyurethane-acrylate heteropolymer. However, ink jet recording on these coated substrates lacks the desired clarity and vividness.
Japanese Patent (JP)2001-184881 discloses a coating composition comprising a reaction product of a nonionic or anionic polyurethane and a monomeric secondary amine with epichlorohydrin. However, when subsequently contacted with water, the monomeric amine adduct may dissolve, resulting in blurring of the image.
Further, US patent US6,020,058 discloses an acrylic composition and US patent US6,025,068 discloses a polyurethane-acrylic copolymer. These patents are incorporated herein by reference.
Further, U.S. patent application Ser. No. 60/309,348, filed on 8/1/2001, discloses a two-component water-resistant coating composition for microporous substrates; U.S. patent application serial No. 60/317,113, filed on 9/5/2001, discloses a method of treating a coated microporous substrate. Both of these patent applications are incorporated herein by reference.
Thus, there is a need in the art for an ink jet recordable substrate that is durable, water resistant, and capable of recording sharp images when ink jet printed thereon.
Disclosure of Invention
The present invention relates to a water resistant coating composition for ink jet recordable substrates. The water-resistant coating composition comprises:
(a) an aqueous polyurethane dispersion;
(b) an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound; and
(c) acrylic polymers, such as cationic acrylic polymers,
wherein the coating composition has a pH of 7 or less.
The invention also relates to a method of coating an inkjet recordable substrate, wherein an inkjet recordable substrate is provided and a coating composition as defined above is applied to the substrate.
The present invention still further relates to an ink jet recordable substrate comprising a substrate having at least one side, and a coating layer of the above coating composition applied on at least one side of the substrate.
Detailed Description
Unless otherwise indicated, all numbers and expressions referring to amounts of components, reaction conditions, etc., used herein are to be understood as modified in all instances by the term "about".
Unless otherwise indicated, all references to (meth) acrylic, (meth) acrylate and (meth) acrylamide monomers are meant to include both methacrylic and acrylic types.
Any polyurethane that can be dispersed in water is suitable for use in the coating composition of the present invention. Such polyurethanes include anionic, cationic and nonionic polyurethanes. Mixtures of anionic and cationic polymers often result in polymeric salts that are generally insoluble in water and other solvents. In the present invention, it has been found that anionic polyurethane dispersions in combination with cationic nitrogen-containing polymers can form stable aqueous dispersions that are very useful as coating compositions for ink jet recordable substrates.
An aqueous polyurethane resin dispersion containing polyurethane polymer particles dispersed in an aqueous medium can be used in the present invention.
The polyurethanes used in the present invention can be prepared by a variety of methods known in the art. For example, a polyisocyanate may be reacted with a polyol to form a prepolymer, such as an isocyanate-terminated prepolymer. As used herein and in the claims, the term "polyisocyanate" refers to a compound having more than one isocyanate group, such as a diisocyanate. Non-limiting examples of suitable diisocyanates for use in the present invention include toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexylmethane diisocyanate. Non-limiting examples of suitable tri-or polyfunctional isocyanates include the reaction products of diisocyanates with polyols such as trimethylolpropane, glycerol, and pentaerythritol. Suitable polyisocyanates for use in the present invention include, but are not limited to, Desmodur, which is commercially available from Bayer.
As used herein and in the claims, the term "polyol" refers to a compound having more than one hydroxyl group. Non-limiting examples of suitable polyols for use in the present invention include, for example, those polyols, polyester polyols, and polyether polyols from which polyisocyanates can be prepared.
The reaction of the polyisocyanate and the polyol may be carried out in the presence of an organic solvent. Suitable solvents may include, but are not limited to, n-methylpyrrolidone, tetrahydrofuran, or glycol ethers.
In one embodiment, the prepolymer can be reacted with a dihydroxy compound having one acid group, such as dimethylolpropionic acid, to produce a polyurethane having at least one pendant acid group. The acid group may comprise a carboxylic acid group or a sulfonic acid group. The polyurethane having pendant acid groups can then be reacted with a base to produce an anionic polyurethane. The anionic polyurethane dispersions of the present invention may generally be dispersed in a base capable of ionizing the polymer acid functional groups and stabilizing the dispersion. The base may be selected from inorganic bases, ammonia, amines and mixtures thereof.
Non-limiting examples of suitable anionic polyurethanes for use in the present invention may include anionic polyurethanes based on aromatic polyether polyurethanes, aliphatic polyether polyurethanes, aromatic polyester polyurethanes, aliphatic polyester polyurethanes, aromatic polycaprolactam polyurethanes, and/or aliphatic polycaprolactam polyurethanes. Examples of suitable anionic polyurethane dispersions that may be used in the present invention include those commercially available from Crompton Corporation, Greemwich, Connecticut under the WitcoBond trade name®But is not limited thereto.
The cationic polyurethane dispersions used in the present invention can be prepared by various methods known in the art. For example, U.S. Pat. No. 4, 3,470,310 discloses a process comprising the preparation of an aqueous polyurethane dispersion containing salt-type groups bonded to the polyurethane. US patent US3,873,484 discloses an aqueous polyurethane dispersion prepared from a quaternized polyurethane prepolymer. U.S. Pat. No. 4, 6,221,954 discloses a process for preparing polyurethane prepolymers in which tertiary N-monohydroxyalkyl amines are reacted with alkylene oxides in the presence of strong acids. The relevant portions of these patents are incorporated herein by reference.
In one embodiment, the prepolymer can be reacted with a dihydroxy compound containing an amine group, such as a secondary or tertiary amine, to produce a polyurethane having at least one pendant amine group. Non-limiting examples of dihydroxy compounds having amine groups may include polyamines such as ethylenediamine, isophoronediamine, and diethylenetriamine. The polyurethane having pendant amine groups can then be reacted with an acid to produce a cationic polyurethane.
Suitable cationic polyurethanes for use in the present invention include, but are not limited to, those commercially available from Crompton corporation, Greemwich, Connecticut, under the WitcoBond trade name (i.e., W213, W215, and X051).
In another embodiment of the invention, the prepolymer may be reacted with a diol having polyalkylene oxide chains to produce a polyurethane backbone having polyalkylene glycol pendant chains. Polyurethanes with pendant polyalkylene glycol chains can be reacted with water to produce non-anionic polyurethanes.
Suitable nonionic polyurethanes for use in the present invention may include, but are not limited to, those commercially available from Crompton corporation, Greemwich, Connecticut, under the WitcoBond (i.e., W320).
In one non-limiting embodiment, a vinyl or ethylenically unsaturated isocyanate prepolymer or a vinyl or ethylenically unsaturated polyurethane can be reacted with a vinyl or ethylenically unsaturated acid such as acrylic or methacrylic acid in a free radical synthesis reaction to form a carboxylic acid side-suspended polyurethane. The acid-side-hung polyurethane can be reacted with a base, such as the bases described above, to form an anionic polyurethane.
Further, the prepolymer may be dispersed in water in the presence of a base and chain extended by the addition of a polyamine. In one non-limiting embodiment, the prepolymer can be chain extended in an organic solvent solution and the resulting polyurethane polymer can be dispersed in water in the presence of a base.
In alternative non-limiting embodiments, the aqueous polyurethane dispersion may contain up to 70 wt.%, or up to 65 wt.%, or up to 60 wt.%, or up to 50 wt.% polyurethane. The aqueous polyurethane dispersion may comprise at least 1 wt%, or at least 5 wt%, or at least 10 wt%, or at least 20 wt% polyurethane. The amount of polyurethane in the aqueous polyurethane dispersion can vary widely. However, the amount should not be so high as to destabilize the dispersion itself or its mixture with the nitrogen-containing polymer; and should not be so low that the coating composition is unable to provide sufficient water and rub resistance, or the dispersion itself becomes unstable. The polyurethane may be present in the aqueous polyurethane dispersion in any range of values inclusive of the recited values.
In addition to the aqueous polyurethane dispersion, the coating composition of the present invention also includes an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound. In one non-limiting embodiment, the aqueous solution of cationic nitrogen-containing polymers suitable for use in the present invention may have a pH of 7 or less, or 6 or less, or 5 or less, to ensure that at least a portion of the nitrogen atoms carry an at least partial positive charge. In a further non-limiting embodiment, the coating composition of the present invention may also have a pH of 7 or less, or 6 or less, or 5 or less.
Any nitrogen-containing polymer having at least a portion of the nitrogen atoms with at least a partial positive charge in the above pH range may be used in the present invention. Non-limiting examples of suitable cationic nitrogen-containing polymers that can be used as dye fixatives include, but are not limited to, polymers containing one or more monomer residues derived from one or more of the following nitrogen-containing monomers:
wherein R is1Independently representing each occurrence of H or C1-C3An aliphatic compound; r2Independently represent a group selected from C2-C20Divalent linking groups for each occurrence of aliphatic hydrocarbons, polyethylene glycol, and polypropylene glycol; r3H, C representing each occurrence independently1-C22Aliphatic hydrocarbons or groups in which nitrogen reacts with epichlorohydrin; z is selected from-O-or-NR4Wherein R is4Represents H or CH3(ii) a X represents a halide or dimethyl sulfate.
Non-limiting examples of suitable cationic nitrogen-containing monomers for use in the present invention may include, but are not limited to, dimethylaminoethyl (meth) acrylate, (meth) acryloyloxyethyltrimethylammonium halide, (meth) acryloyloxyethyltrimethylammonium sulfate, dimethylaminopropyl (meth) acrylamide, (meth) acrylamidopropyltrimethylammonium halide, (meth) acrylamidopropyltrimethylammonium sulfate, diallylamine, methyldiallylamine, and diallyldimethylammonium halide.
In one non-limiting embodiment, the cationic nitrogen-containing polymer may contain one or more additional monomer residues. The additional monomer residue may be selected from any polymerizable ethylenically unsaturated monomer which, when copolymerized with the nitrogen-containing monomer, is capable of yielding a polymer that is at least partially soluble in water. As used herein and in the claims, the term "partially soluble" means that at least 0.1 gram of polymer can be dissolved in water when 10 grams of polymer are added to 1 liter of water and mixed for 24 hours.
Non-limiting examples of the monomer copolymerizable with the nitrogen-containing monomer include (meth) acrylamide, n-alkyl (meth) acrylamide, (meth) acrylic acid, alkyl (meth) acrylate, ethylene glycol (meth) acrylate, polyethylene glycol (meth) acrylate, hydroxyalkyl (meth) acrylate, itaconic acid alkyl ether, maleic acid mono-or di-alkyl ester, maleic anhydride, maleimide, aconitic acid alkyl ester, allyl alcohol, and allyl alcohol alkyl ether, but are not limited thereto.
In a further non-limiting embodiment, the nitrogen-containing polymer used in the present invention may be a homopolymer of a nitrogen-containing monomer or may be a copolymer of one or more nitrogen-containing monomers. The nitrogen-containing polymer may also be a copolymer of one or more polymerizable ethylenically unsaturated monomers, or one or more nitrogen-containing monomers, or mixtures thereof. In alternative non-limiting embodiments, when the nitrogen-containing polymer includes one or more other polymerizable ethylenically unsaturated comonomers, the nitrogen-containing polymer can include no more than 70 mol%, alternatively no more than 50 mol%, alternatively no more than 25 mol%, alternatively no more than 10 mol% of the nitrogen-containing monomer. The amount of nitrogen-containing monomer used depends on the polyurethane component used in the coating composition of the present invention. When the amount of the nitrogen-containing monomer in the nitrogen-containing polymer is too high, the resulting mixture of the nitrogen-containing polymer and the polyurethane dispersion may be unstable. Applying unstable mixtures to inkjet recordable substrates can be difficult.
When the nitrogen-containing polymer includes one or more other polymerizable ethylenically unsaturated comonomers, the nitrogen-containing polymer can include at least 0.1 mol%, alternatively at least 1.0 mol%, alternatively at least 2.5 mol%, alternatively at least 5.0 mol% of the nitrogen-containing monomer. When the amount of the nitrogen-containing monomer in the nitrogen-containing polymer is too low, the nitrogen-containing polymer will not provide sufficient dye-fixing properties, and the recorded image on the coated substrate may lack the desired water-and rubbing-resistant properties.
The nitrogen-containing monomer in the nitrogen-containing polymer can be present in any amount ranging including the above-mentioned values. One or more other polymerizable ethylenically unsaturated monomers may be present in an amount to make up the total percent to 100 mol%.
In one non-limiting embodiment of the invention, the nitrogen-containing polymer may comprise an aqueous solution. In this embodiment, the aqueous solution may comprise at least 5 wt%, or at least 10 wt%, or at least 15 wt% of the nitrogen-containing polymer and no more than 50 wt%, or no more than 45 wt%, or no more than 40 wt% of the nitrogen-containing polymer. When the percentage of nitrogen-containing polymer is too low, it may not be economical for commercial use and may be too dilute to provide an appropriate ratio to the polyurethane component. When the percentage of nitrogen-containing polymer is too high, the viscosity of the solution may rise and cause difficulties in handling in a commercial environment. In one non-limiting embodiment, the nitrogen-containing polymer may comprise a polyamide-amine solution reacted with epichlorohydrin, which is available under the trade name CinFIx from Stockhausen GmbH & Co.KG, Krefeld, Germany. Preferably, the cationic nitrogen-containing polymeric dye fixative compound comprises a polyamine and epichlorohydrin.
The coating composition of the present invention includes an acrylic polymer. In one non-limiting embodiment, the acrylic polymer may be selected from anionic, cationic, and nonionic acrylic polymers. In one non-limiting embodiment, the acrylic polymer may comprise a cationic acrylic polymer. Non-limiting examples of suitable cationic acrylic polymers include polyacrylates, polymethacrylates, polyacrylonitrile, and polymers having monomer types selected from the group consisting of acrylonitrile, acrylic acid, acrylamide, and mixtures thereof.
The cationic acrylic polymer can be prepared by various methods known in the art. In one non-limiting embodiment of the invention, the cationic acrylic polymer can be synthesized from monomeric butyl acrylate, methyl methacrylate, and 2- (tert-butylamino) ethyl methacrylate by free radical solution polymerization. The molar equivalent of butyl acrylate may be from 0.10 to 0.95, alternatively from 0.15 to 0.75; the molar equivalent of methyl methacrylate may be from 0.10 to 0.85, alternatively from 0.15 to 0.70; the molar equivalent of ethyl 2- (tert-butylamino) methacrylate may be 0.10 to 0.25, alternatively 0.12 to 0.20. The reaction mixture may be treated with an acid to bring the pH in the range of 4.0-7.0. The mixture may be diluted with water and stripped solvent. Non-limiting examples of suitable acids for use in this treatment step include any acid that can act as a dissolving or dispersing agent to obtain a stable cationic polymer dispersion. Non-limiting examples of suitable solvents for the stripping process include isopropanol and methyl isobutyl ketone (MIBK).
In one non-limiting embodiment of the invention, the molar equivalents of butyl acrylate, methyl methacrylate, and ethyl 2- (tert-butylamino) methacrylate may be 0.219 to 0.621 to 0.160, respectively.
In another non-limiting embodiment, the cationic acrylic polymer used in the present invention can have a number average molecular weight of 1500-.
The ink jet recordable substrate coating composition of the present invention comprises a mixture of an aqueous nitrogen-containing polymer solution, an aqueous polyurethane dispersion, and an acrylic polymer. In one non-limiting embodiment, the mixture can include from 20 wt% to 75 wt%, alternatively from 25 wt% to 70 wt%, alternatively from 30 wt% to 60 wt% of the aqueous polyurethane dispersion. The mixture may also include from 5 wt% to 75 wt%, alternatively from 15 wt% to 70 wt%, alternatively from 30 wt% to 65 wt% of an aqueous solution of the nitrogen-containing polymer. The mixture may also include from 1 wt% to 75 wt%, alternatively from 20 wt% to 60 wt%, alternatively from 25 wt% to 50 wt% of an acrylic polymer. The weight percentages are based on the total weight of the inkjet recordable base coating composition.
In one non-limiting embodiment of the invention, water may be added to the mixture of nitrogen-containing polymer, polyurethane and acrylic polymer. When water is added to the mixture, the resulting ink recordable base coating composition can have from 5 wt% to 35 wt%, alternatively from 5 wt% to 20 wt%, alternatively from 5 wt% to 15 wt%, of total resin solids, based on the total weight of the ink recordable base coating composition. Too high a total resin solids can cause the viscosity of the coating composition to increase such that the resulting coating composition will have less penetration into the substrate than desired. Too low a total resin solids can result in a decrease in the viscosity of the coating composition such that the resulting coating will have less penetration into the substrate than desired. In one non-limiting embodiment, the coating composition can have a viscosity of less than 500cps, or less than 400cps and at least 10cps, or at least 25cps, when measured with a Brookfield viscometer at 25 ℃.
In one non-limiting embodiment, the coating composition of the present invention may also include other additives typical known in the art. Non-limiting examples of suitable additives may include surfactants such as nonionic, cationic, anionic, amphoteric, and zwitterionic surfactants; rheology modifiers such as polyvinyl alcohol, polyvinyl pyrrolidone, polyethylene oxide, polyacrylamide, natural and synthetic gums; biocides such as mixtures of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, commercially available under the trade name Kathon from Rohm and Haas co, 2-hydroxypropyl methane thiosulfate, and dithiocarbamates; and coupling agents such as titanium pyrophosphate, silanes pyrophosphate, trisodium pyrophosphate.
The pH of the coating composition of the present invention may be less than 7, or less than 6, or less than 5. It is generally believed that when the pH is outside these ranges, the cationic polymeric dye anchoring compound will not be able to carry a sufficient positive charge to achieve its intended function. Furthermore, it is believed that when the pH is within the above range, the wetting action of the coating composition on certain substrates can be improved. In one non-limiting embodiment, the coating composition may have a pH greater than 2 for certain commercial uses.
The present invention also relates to a process for preparing the ink jet recordable substrate coating composition of the present invention. In one non-limiting embodiment, the method can include mixing together an aqueous solution of a nitrogen-containing polymer, an aqueous polyurethane dispersion, and an acrylic polymer. In one non-limiting embodiment, sufficient mixing can be maintained during the addition to obtain a homogeneous mixture.
The invention further relates to a method of coating an inkjet recordable substrate. In one non-limiting embodiment, the method comprises the steps of:
(a) providing an ink jet recordable substrate having at least one side;
(b) providing a coating composition as described above; and
(c) the coating composition is applied to at least one side of an inkjet recordable substrate.
Any ink jet recordable substrate known in the art can be used in the present invention. The substrate may be any cellulose-based paper as a non-limiting example. In another non-limiting embodiment, the ink jet recordable substrate can be a microporous substance substrate. One non-limiting example of the microporous substance substrate may have at least one surface and include:
(a) a substrate comprising a polyolefin;
(b) a particulate siliceous filler distributed in the medium; and
(c) a network of pores, wherein the pores may constitute at least 35% by volume of the microporous substance substrate.
Polyolefins suitable for use in the present invention may include various types well known in the art. In one non-limiting embodiment, the polyolefin may comprise polyethylene and/or polypropylene. In a further non-limiting embodiment, the polyethylene can be a linear high molecular weight polyethylene having an intrinsic viscosity of at least 10 liters/gram, and a linear high molecular weight polypropylene having an intrinsic viscosity of at least 5 liters/gram.
Intrinsic viscosity can be determined by various methods known to those skilled in the art. As used herein and in the claims, intrinsic viscosity can be determined by extrapolating the reduced viscosity or inherent viscosity of several polyolefin dilute solutions to zero concentration, where the solvent is freshly distilled decalin to which 0.2 wt% 3, 5-di-tert-butyl-4-hydroxyphenylpropionic acid, neopentyl tetrayl ester [ CAS Registry No.6683-19-8] is added. The reduced viscosity or inherent viscosity of the polyolefin can be determined from the relative viscosity measured at 135 ℃ with an Ubbelohde No.1 viscometer.
In alternative non-limiting embodiments, the pores constitute at least 35% of the volume of the microporous material, or constitute 60% of the volume of the microporous material, or constitute 35% to 80% of the volume of the microporous material, or constitute 60% to 75% of the volume of the microporous material, on an uncoated, non-printing ink, non-impregnating agent, and pre-bonded basis.
The particulate siliceous filler used in the present invention may be selected from various types known in the art. In one non-limiting embodiment, the particulate siliceous filler may be subdivided into substantially water-insoluble siliceous particles. The particles may be in the form of primary particles, agglomerates of primary particles, or a combination of both. In one non-limiting embodiment, at least 90 wt% of the siliceous particles used in preparing the microporous material have an approximate particle size in the range of about 5 to about 40 microns as determined using a Model TAII Coulter computer (Coulter Electronics, Inc.), but modified by use of a four-paddle 4.445 cm diameter propeller stirrer in an Isoton II electrolyte (Curtin Matheson Scientific, Inc.). In a further non-limiting embodiment, at least 90 weight percent of the siliceous particles used in making the microporous material have an approximate particle size in the range of about 10 to about 30 microns. It is expected that the size of the filler agglomerates will decrease during processing of the components to make the microporous mass.
Non-limiting examples of suitable siliceous particles include, but are not limited to, silica, mica, montmorillonite, kaolin, asbestos, talc, diatomaceous earth, vermiculite, natural and synthetic zeolites, cement, calcium silicate, aluminum silicate, sodium aluminum silicate, aluminum polysilicate, silica alumina gel, and glass particles, and mixtures thereof. In one non-limiting embodiment, silica and/or clay may be used in the present invention as siliceous particles. In a further non-limiting embodiment, precipitated silica, silica gel, or fumed silica may be used.
In alternative non-limiting embodiments, the finely divided particulate substantially water-insoluble siliceous filler may constitute from 50 wt% to 90 wt%, alternatively from 50 wt% to 85 wt%, alternatively from 60 wt% to 80 wt% of the microporous material substrate.
In one non-limiting embodiment, the ink jet recordable substrates used in the present invention can include non-siliceous filler particles. In a further non-limiting embodiment, finely divided, substantially water-insoluble, non-siliceous filler particles may be used. Non-limiting examples of suitable non-siliceous filler particles can include, but are not limited to, titanium dioxide, iron oxide, copper oxide, zinc oxide, antimony oxide, zirconium oxide, magnesium oxide, aluminum oxide, molybdenum disulfide, zinc sulfide, barium sulfate, strontium sulfate, calcium carbonate, magnesium hydroxide particles, and finely divided, substantially water-insoluble, flame retardant filler particles, such as ethylene bis (tetra-bromobenzenediamide), octabromodiphenyloxide, decabromodiphenyloxide, and ethylene bis-dibromonorbornanediamide particles.
Further description of suitable microporous materials for use in the present invention is provided in U.S. Pat. No. 4,861,644 to Young et al and U.S. Pat. No. 5,196,262 to Schwarz et al, the relevant portions of both of which are incorporated herein by reference.
The coating composition can be applied to the inkjet recordable substrate using a variety of suitable methods. The coating composition may generally be applied to a substrate using conventional techniques known in the art. Non-limiting examples of suitable methods include spraying, curtain coating, dipping, bar coating, knife coating, roll coating, size pressing, printing, brush coating, knife coating (drawing), slot die coating, and extrusion. In one non-limiting embodiment, a coating may be subsequently formed by removing the solvent from the applied coating composition. Removal of the solvent may be carried out by various conventional drying techniques known in the art. In one non-limiting embodiment, drying can be performed by exposing the coated substrate to forced air at a temperature in the range of from ambient temperature to 350F.
The coating composition may be applied one or more times. In one non-limiting embodiment, when the coating composition is applied multiple times, the applied coating may be partially or completely dried, typically between applications. In a further non-limiting embodiment, once the coating composition is applied to a substrate, the solvent can be substantially removed, typically by drying.
In one non-limiting embodiment, an air knife coating technique may be used, wherein the coating composition is applied to a substrate and the excess is "blown off" with a powerful air knife jet. In another embodiment, reverse roll coating may be used. In this process, the coating material is dosed onto the application roller via a predetermined gap between the upper regulating roller and the application roller lying therebelow. As the substrate passes over the bottom backup roll, the coating is "wiped" off the coating roll by the substrate.
In another embodiment of the present invention, the coating composition may be applied by a gravure coating method. In the gravure coating process, an etched roll is rotated in a coating bath so that the coating composition fills the etched dots or lines on the roll. Any excess coating on the roll may be scraped off with a doctor blade and the coating deposited on the substrate as it passes between the etching roll and the pressure roll. Reverse gravure coating methods may also be used. In this alternative process, the coating composition is metered through an etching roll prior to the wiping step of a conventional reverse roll coating process.
In a further non-limiting embodiment, a metering supply bar may be used to apply the coating composition. When a metering supply bar is used, excess coating material may be deposited on the substrate as it passes through the bath roller. A wire-wound metering supply rod, known as Meyer Bar, can achieve the desired amount of coating on the substrate. This amount may be determined by the diameter of the wire wound on the rod used.
The thickness of the substantially dry coating may vary widely. In an alternative non-limiting embodiment, the thickness of the coating may be in the range of 1 to 40 microns, or in the range of 5 to 25 microns, or in the range of 5 to 15 microns.
The invention also relates to coated microporous substance substrates. In one non-limiting embodiment, the coated microporous substrate may comprise a microporous substrate having at least one surface as described above and having a coating on at least one surface. The coating may be a dried coating composition of the present invention and may include an acrylic polymer, a polymeric nitrogen-containing dye fixing compound, and one or more polyurethanes, as described above.
The amount of substantially dry coating applied to a substrate, or coating weight, can be determined as coating weight/coating area. As used herein and in the claims, "substantially dry" means that the coating is dry to the touch. The amount of coating can vary widely. In alternative non-limiting embodiments, the amount of coating may be at least 0.001 grams per square meter, alternatively at least 0.01 grams per square meter, alternatively at least 0.1 grams per square meter. In alternative non-limiting embodiments, the amount of coating may be 50 grams per square meter or less, or 40 grams per square meter or less, or 35 grams per square meter or less. The amount of substantially dry coating applied to the substrate can vary between any of the specific amounts recited above.
The water resistant ink jet recordable substrate of the present invention can be polymer treated. In alternative non-limiting embodiments, the substrate may be laminated and/or shaped with a mold. Lamination can be performed by a variety of techniques known to those skilled in the art. In one non-limiting embodiment, the lamination layer can include bonding the ink jet recordable substrate to at least one layer of a substantially non-porous substance. The water resistant inkjet recordable substrate can be combined with a substantially non-porous substance, with or without an adhesive. As used herein, "substantially non-porous" materials are meant to refer to those materials that are not normally permeated by liquids, gases, and bacteria.
The substantially non-porous materials useful in the present invention can vary widely, including those materials that are commonly recognized and used for their known barrier properties. Non-limiting examples of such materials can include substantially non-porous thermoplastic polymers, substantially non-porous metallized thermoplastic polymers, substantially non-porous thermoset polymers, substantially non-porous elastomers, and substantially non-porous metals, and mixtures thereof. The substantially non-porous substance may be in the form of a sheet, film, or foil, or used in other shapes when desired, such as plates, rods, bars, tubes, and more complex forms. In one non-limiting embodiment, the substantially non-porous substance used in the present invention may be in the form of a sheet, film, or foil.
As used herein and in the claims, the term "thermoplastic polymer" means a polymer that can be softened by heating and recover its original properties by cooling. The term "thermoset polymer" as used herein and in the claims means a polymer that cures or sets by heating and is not remeltable.
Non-limiting examples of suitable thermoplastic polymer materials may include polyethylene, high density polyethylene, low density polyethylene, polypropylene, poly (vinyl chloride), vinylidene chloride, polystyrene, high impact polystyrene, nylon, polyesters such as poly (ethylene terephthalate), copolymers of ethylene and acrylic acid, copolymers of ethylene and methacrylic acid, and mixtures thereof. All or part of the carboxyl groups of the carboxyl group-containing copolymer may be neutralized with sodium, zinc, or the like, if necessary. One non-limiting example of a metallized thermoplastic polymer material may be aluminized poly (ethylene terephthalate).
Non-limiting examples of thermoset polymeric materials may include thermoset phenolic resins, thermoset melamine-formaldehyde resins, and mixtures thereof.
Non-limiting examples of elastomeric materials may include natural rubber, neoprene, styrene butadiene rubber, acrylonitrile butadiene styrene rubber, elastomeric polyurethane, and elastomeric copolymers of ethylene and propylene.
Non-limiting examples of metals may include iron, steel, red copper, brass, bronze, chromium, zinc, die metal, aluminum, and cadmium, but are not limited thereto.
In one non-limiting embodiment, a multilayer article incorporating the present invention can be constructed using a variety of known methods to bond at least one layer of an ink jet recordable substrate to at least one layer of a substantially non-porous material. In one non-limiting embodiment, at least one layer of a substantially water-resistant, at least partially coated inkjet recordable substrate can be melt bonded to at least one layer of a substantially non-porous material. Ink jet recordable substrates typically include opposing major surfaces that constitute features of the sheet, film, and plate. The resulting multilayer article can include one or more layers of an ink jet recordable substrate, and one or more layers of a substantially non-porous material. In one non-limiting embodiment, at least one outer layer can be an ink jet recordable substrate. In an alternative non-limiting embodiment, the inkjet recordable substrate can be a microporous substrate.
In one non-limiting embodiment, the multilayer articles of the present invention can be produced by melt bonding in the absence of an adhesive. Melt bonding can be accomplished by conventional techniques such as heat sealing by using heated rolls, heated rollers, heated plates, heated tapes, heated wires, flame tapes, Radio Frequency (RF) sealing, and ultrasonic sealing. Solvent bonding may also be used when the substantially nonporous substrate is at least partially soluble in the solvent used to render the surface tacky. The ink jet recordable substrate can be contacted with a tacky surface and the solvent removed to form a melt bond. In one non-limiting embodiment, the foamable composition is foamed in contact with an inkjet recordable substrate to form a melt bond between the foam and the substrate. A film-like or sheet-like nonporous substrate can be extruded and, while still hot and tacky, brought into contact with an inkjet recordable substrate to form a melt bond. The melt bonding may be permanent or peelable, depending on the known bonding technique and/or the nature of the substantially non-porous substrate used.
In one non-limiting embodiment, heat sealing can be used to melt bond an inkjet recordable substrate to a substantially non-porous material. Typically, heat sealing involves inserting the inkjet recordable substrate into standard heat sealing equipment known in the art. In one non-limiting embodiment, the ink jet recordable substrate can be intercalated with a substantially non-porous material, which can be a thermoplastic and/or thermoset polymer. Heat and/or pressure may be applied to the substrate/polymer structure for a period of time. The amount and length of time of the heat and/or pressure may vary widely. In general, the temperature, pressure, and time may be selected to at least partially join the substrate and polymer together to form a multilayer article. In one non-limiting embodiment, the temperature can be in the range of 100F to 400F. In another non-limiting embodiment, the pressure may be in the range of 5psi to 250 psi. In a further non-limiting embodiment, the time may be in the range of one (1) second to thirty (30) minutes. The multi-layer article may then be cooled under pressure for a conventional period of time, such as thirty (30) minutes. Although the strength of the bond formed between the substrate and the polymer can vary widely, in one non-limiting embodiment, the strength can be such that it generally exceeds the tensile properties of the substrate alone.
In one non-limiting embodiment, the substantially non-porous substrate may be polyvinyl chloride.
In another non-limiting embodiment, the ink jet recordable substrates used in the present invention can be at least partially attached to non-porous substrates such as polyethylene and polypropylene by heat sealing in the absence of an extraneous adhesive. The resulting melt bond can be sufficiently strong, which is surprising because it is difficult to laminate materials to polyolefins unless an adhesive is used.
In alternative non-limiting embodiments, the ink jet recordable substrate can be substantially continuously at least partially attached to the substantially non-porous substrate, or it can be discontinuously at least partially attached to the substantially non-porous substrate. Non-limiting examples of discontinuous bonds may include bond regions in the form of one or more dots, localized, elongated patches, stripes, chevrons, wavy stripes, zig-zag stripes, open-curved stripes (open-curved stripes), closed-curved stripes (close-curved stripes), irregular regions, and the like. In a further non-limiting embodiment, when reference is made to combinations, they may be random, repetitive, or a combination of the two.
In another non-limiting embodiment, an ink jet recordable substrate can be joined to a substantially non-porous material in the presence of an adhesive. The binder used in the present invention may be selected from various binders known in the art. Non-limiting examples of suitable adhesives include those having sufficient molecular weight and viscosity such that the adhesive does not substantially migrate or substantially penetrate into the ink jet recordable substrate. Migration or penetration of the adhesive into the substrate can reduce the bond strength of the adhesive. Non-limiting examples of suitable adhesives for use in the present invention include, but are not limited to, polyvinyl acetate, starch, gums, polyvinyl alcohol, animal glue, acrylics, epoxies, polyethylene-containing adhesives, and rubber-containing adhesives. In alternative non-limiting embodiments, the adhesive may be coated on the substrate, or on the substantially non-porous material, or on both the substrate and the substantially non-porous material. In a further non-limiting embodiment, the binder may be introduced by using a tie carrier coating (tiecrarrier coating).
The process of bonding a substrate to a substantially non-porous substance in the presence of an adhesive typically involves inserting the substrate/adhesive/material structure into standard processing equipment known in the art. Heat and/or pressure may be applied to the substrate/adhesive/material structure for a period of time. The amount and length of time of the heat and/or pressure may vary widely. In general, the temperature, pressure, and time may be selected to at least partially join the substrate and the substantially non-porous material together to form a multi-layer article. Typical temperatures are in the range of 100 to 400F. Typical pressures are in the range of 5psi to 250psi and typical times are in the range of one (1) second to thirty (30) minutes. The multi-layer article may then be cooled under pressure for a conventional period of time, such as 30 minutes. Although the strength of the bond formed between the ink jet recordable substrate and the substantially non-porous material can vary widely, the bond can be such that it generally exceeds the tensile properties of the substrate alone.
In one non-limiting embodiment of the invention, the inkjet recordable substrate can be molded using a variety of conventional molding techniques known in the art including, but not limited to, compression molding, rotational molding, injection molding, calendering, roll/roll lamination, thermoforming vacuum forming, extrusion coating, continuous tape lamination, and extrusion lamination.
In alternative non-limiting embodiments, the substrate may be molded in the presence or absence of a substantially non-porous material, such as a thermoplastic and/or thermoset polymer. Typically, the inkjet recordable substrate is inserted into standard molding equipment known in the art. In one non-limiting embodiment, a thermoplastic and/or thermoset polymer is introduced onto a substrate and the substrate/polymer structure is then inserted into a molding cavity. In another non-limiting embodiment, the substrate is placed in a molding chamber and then a thermoplastic and/or thermoset polymer is introduced onto the substrate. Heat and/or pressure may be applied to the substrate/polymer structure for a period of time. The amount and length of time of the heat and/or pressure may vary widely. In general, the temperature, pressure, and time may be selected to at least partially join the substrate and polymer together to form a multilayer article. Typical temperatures are in the range of 100 to 400F. In one non-limiting embodiment, where the polymer comprises a thermoplastic polymer, the substrate/polymer structure may be heated to a temperature equal to or greater than the melting temperature of the thermoplastic polymer. In one non-limiting embodiment, the thermoplastic polymer may be amorphous and the base polymer structure may be heated to a temperature equal to or greater than the vicat temperature. In an alternative non-limiting embodiment, the polymer comprises a thermoset polymer and the temperature may be below the curing or crosslinking temperature of the polymer. Typical pressures are in the range of 5psi to 250psi, and typical times are in the range of one (1) second to fifteen (15) minutes. The result of a typical molding process is the reshaping of the original article. Reshaping is generally defined by the pattern of the mold cavity. Thus, in a standard molding process, a two-dimensional planar sheet can be reshaped into a three-dimensional article.
In one non-limiting embodiment of the invention, the inkjet recordable substrate comprises Teslin from PPG Industries, Incorporated in Pittsburgh, Pa. The thickness of the ink jet recordable substrate of the present invention varies depending on its use. In one non-limiting embodiment, the inkjet recordable substrate can be 5-20 mils thick.
In one non-limiting embodiment, other tie coatings known in the art may also be used with the substrate and the substantially non-porous material.
As in one non-limiting embodiment of the present invention, a method of making a multilayer article is provided comprising the steps of:
a. providing an inkjet recordable substrate having a top surface and a bottom surface;
b. a substantially water-resistant coating composition is provided comprising a stable dispersion of:
(i) an aqueous polyurethane dispersion;
(ii) an aqueous solution of a cationic nitrogen-containing polymeric dye fixing material; and
(iii) an acrylic polymer which is a copolymer of a vinyl monomer and a vinyl monomer,
the coating composition has a pH of 7 or less;
c. at least partially applying the coating composition to at least one surface of the inkjet recordable substrate;
d. at least partially attaching the inkjet recordable substrate of (c) to a substantially non-porous material having a top surface and a bottom surface;
e. providing a friction reducing coating composition; and
at least partially coating the friction reducing coating composition on a surface of at least one of the inkjet recordable substrate and the substantially non-porous material.
In one non-limiting embodiment, the friction-reducing coating composition can be at least partially coated on at least one of an inkjet recordable substrate and a substantially non-porous material. In a further non-limiting embodiment, the friction reducing coating composition may contain at least one lubricant and at least one resin. Many of the various lubricants and resins that may be used herein are known to those skilled in the art. Non-limiting examples of suitable lubricants include natural and synthetic waxes, natural and synthetic oils, polypropylene waxes, polyethylene waxes, silicone oils and waxes, polyesters, polysiloxanes, hydrocarbon waxes, carnauba wax, microcrystalline waxes and fatty acids, and mixtures thereof. In one non-limiting embodiment, the lubricant used in the present invention may include a polysiloxane, such as a siloxane, but is not limited thereto.
Non-limiting examples of suitable resins include polyurethanes, polyesters, polyvinyl acetates, polyvinyl alcohols, epoxides, polyamides, polyamines, polyolefins, polypropylenes, polyethylenes, polyacrylic acids, polyacrylates, polyalkylene oxides, polyvinyl pyrrolidones, polyethers, polyketones, and copolymers and mixtures thereof. In one non-limiting embodiment, the resins useful in the present invention include styrene acrylic polymers such as styrene acrylic containing polyurethanes, polyepoxides, polyvinyl alcohols, polyesters, polyethers, and copolymers and mixtures thereof, but are not limited thereto.
In a further non-limiting embodiment, the friction-reducing coating composition used in the present invention comprises WikoffSCW 4890 and 2295 from Wikoff Industries, Incorporated as a multi-panel waterborne coating product.
Without wishing to be bound by any particular theory, it is believed that the resin component molecules of the friction-reducing coating are at least partially interconnected or inter-bonded with the inkjet recordable substrate and/or the substantially non-porous material such that the siloxane is necessarily immobilized to the surface of the substrate and/or the material. In one non-limiting embodiment, the molecules of the thermoplastic resin component are interconnected with the ink jet recordable substrate and/or the substantially non-porous material by fusing with the same. In another non-limiting embodiment, the molecules of the thermosetting resin component are bonded to each other by crosslinking with the inkjet recordable substrate and/or the substantially non-porous material.
In a further non-limiting embodiment, the friction-reducing coating composition can contain water and/or an organic solvent. Various organic solvents known to those skilled in the art may be used herein. Non-limiting examples of the suitable organic solvent may include N-methylpyrrolidone (NMP), Methyl Ethyl Ketone (MEK), acetone, diethyl ether, xylene, Dowanol PM, Butyl Cellosolve, and a mixture thereof, but are not limited thereto. In one non-limiting embodiment, the friction-reducing coating composition can contain water and an organic solvent, wherein the organic solvent is at least partially miscible with water.
In one non-limiting embodiment, the friction-reducing coating composition can be at least partially coated on at least one of the ink jet recordable substrate and the substantially non-porous material of the present invention. The friction-reducing coating composition may be applied to the substrate and/or the material using various techniques known in the art. In an alternative non-limiting embodiment, the techniques for applying a substantially water-resistant coating to an inkjet recordable substrate, as previously described herein, can also be used to apply a friction-reducing coating composition to an inkjet recordable substrate and/or a substantially non-porous material.
The amount of substantially dry friction reducing coating, or "coat weight", applied to the substrate/non-porous material is typically measured as coat weight/coated area. The amount of coating can vary widely. In alternative non-limiting embodiments, the weight of the substantially dry friction reducing coating may be at least 0.1 grams per square meter, alternatively from greater than 0 to 50 grams per square meter, alternatively from 1 to 15 grams per square meter.
In a non-limiting embodiment, the multilayer article of the present invention may comprise a 10mil thick Teslin sheet containing a substantially water-resistant coating composition, a 10mil thick polyvinyl chloride sheet, and a 2mil thick polyvinyl chloride sheet containing a friction-reducing coating composition. In a further non-limiting embodiment, the friction reducing coating composition can contain a polysiloxane and a styrene acrylic polymer.
The multi-layer articles of the present invention have many diverse uses including gaskets, cushioning devices, signs, cards, printed substrates, substrates for pens and ink pictures, maps (particularly nautical charts), book covers, pages, wall coverings, and seams, joints, and seals for breathable wraps.
The multilayer articles of the present invention may be used for decorative or identification purposes of substantially non-porous materials, or to impart unique substrate surface properties to substantially non-porous materials. Inkjet recordable substrates can be decorated by a variety of methods including: offset/lithographic printing, flexographic printing, lacquering, gravure printing, ink jet printing, electrophotographic printing, sublimation printing, thermal transfer printing, and screen printing. Decorating may also include applying one or more layers of the coating to the inkjet recordable substrate by conventional application methods known in the art. In general, unique properties that an inkjet recordable substrate can impart to a substantially non-porous material include one or more of the following: improved surface energy, increased porosity, decreased porosity, increased post-coating bond strength, and modification of polymer surface structure or pattern, but are not limited thereto.
Polymer processing techniques are disclosed in US4,892,779, which is incorporated herein by reference.
The present invention is more particularly described in the following examples, which are intended as illustrations only, and numerous modifications and variations therein will be apparent to those skilled in the art. All parts and percentages are by weight unless otherwise indicated, and all references to water refer to deionized water.
In the following examples, the term "Teslin" refers to Teslin TS1000, unless otherwise indicated.
Examples
Example 1
In preparing the coating composition of the present invention, 31% polydimethyldiallylammonium chloride sold under the trade name CinFix RDF from Stockhausen GmbH & Co.KG, Krefeld, Germany is diluted to 10% with deionized water at moderate temperature and with agitation in a stainless steel or polyethylene mixing vessel. Mild agitation is defined as a three-bladed, equally spaced, system having a ratio of agitator head to mixing vessel of 1 to 3, and the agitator head rotating at 600 and 1000rpm and being suitably mounted. A 29% aqueous cationic acrylic acid solution from PPG Industries, inc under the trade name WC-71-2143 was diluted to 10% with deionized water in a separate mixing vessel and added to the main mixing vessel containing pre-diluted cifix RDF. A30% aqueous cationic polyurethane dispersion sold under the trade name Witcobond W240 from Crompton Corporation was diluted to 10% with deionized water in a separate mixing vessel and added to the main mixing vessel containing the CinFix RDF and PPG WC-71-2143 mixture. The resulting coating composition was stirred for 15 minutes. The pH of the product was 5.5. + -. 0.5. The total solids content of the composition was 10% and the viscosity was 56cps as measured using a Brookfield viscometer, RVT, spindle No.1 at 50rpm and 25 ℃.
Other coating compositions were prepared with alternative CinFix additives and polyurethane dispersions with or without WC-71-2143, compared to 8181-67-09.
| Components | Solid content% | 8181-67-01 | -02 | -03 | -04 | -05 | -06 | -07 | -08 | -09 |
| CinFix NFCinFix 167CinFix RDFWitcobond W-234Witcobond X-051Witcobond W-240WC-71-2143 | 51101031101010 | 18.5--4 9.6--- | -100--150-- | -100--75-75 | -100---150- | -100---7575 | --100-150-- | --100-75-75 | --100--150- | --100--7575 |
All values are in parts by weight (pbw).
The components are as follows:
CinFix NF-50-60% aqueous solution of a reactive poly (quaternary amine) polymer (CAS No.68583-79-9) from Stockhausen GmbH & Co. KG, Krefeld, Germany.
CinFix 167-50-60% aqueous solution of activated poly (quaternary amine) (composition-trade secret) from Stockhausen GmbH & co.
CinFix RDF-30-35% aqueous solution of active poly (quaternary amine) polymer (CAS No.26062-79-3) from Stockhausen GmbH & Co. KG, Krefeld, Germany.
WitcoBond W-234-an aqueous dispersion of anionic aliphatic urethane at 30-35% solids from Uniroyal Chemical of Middlebury, CT.
WitcoBond X-051-A30-35% solids cationic aqueous urethane dispersion from Uniroyal Chemical of Middlebury, CT.
WitcoBond W-240-30-35% solids aqueous self-crosslinking anionic polyurethane dispersion from Uniroyal Chemical of Middlebury, CT.
WC-71-2143-an aqueous cationic acrylic polymer dispersion from PPG Industries of Pittsburgh, Pa.at 25-30% solids.
PPG formulation number WC-71-2143 is a waterborne acrylic polymer containing secondary amine and hydroxyl functional groups prepared by solution polymerization. Also described as aqueous dispersions of cationic acrylic polymers. WC-71-2143 was prepared as follows.
TABLE 1
Weight of the components, g
Starting material
Isopropanol 130.0
Charging 1
Isopropanol 113.0
N-butyl acrylate 69.2
Methyl methacrylate 153.0
2- (tert-butylamine) Ethyl methacrylate (CAS 3775-90-4) 73.0
Styrene 69.2
VAZO ® 67 initiator1 18.2
Charging 2
Glacial acetic acid 17.7
Charging 3
Deionized water 1085.0
12, 2' -azobis (2-methylbutyronitrile) initiator from e.i. du Pont de Nemours and Company, Wilmington, Delaware
The starting material was heated to reflux temperature (80 ℃) in the reactor with stirring. Charge 1 was added in a continuous manner over a period of 3 hours. After addition of 1 was complete, the reaction mixture was held at reflux for 3 hours. The resultant acrylic polymer solution had a total solid content of 61.7% (determined by the difference in weight between before and after heating the sample at 110 ℃ for 1 hour), and the number average molecular weight of the polymer was 4792 determined by gel permeation chromatography using polystyrene as a standard. Thereafter, charge 2 was added with stirring at room temperature over a period of 5 minutes. After addition 2 was complete, addition 3 was added over a period of 30 minutes while heating the reaction mixture to azeotropically distill the isopropanol. When the distillation temperature reached 99 ℃, distillation was continued for about 1 more hours, and then the reaction mixture was cooled to room temperature. The total distillate collected was 550.6 grams. The cationic acrylic polymer aqueous solution product had a solid content of 32.6% by weight (determined by the difference in weight between samples heated at 110 ℃ for 1 hour) and a pH of 5.25.
Note: all percent values of solids content are in weight percent.
Applying a coating to the blank 81/2". times.11" Teslin ® TS1000 chip. The weight of the coating was determined by weight difference using an electronic balance.
The blank pieces were weighed.
The coating was applied to the front of the sheet using a #9 wound rod.
The tablets were baked in a textile oven (Model LTF from Werner Mathis AG, Zurich, Switzerland) at 95 ℃ for 2 minutes.
The sheet was removed from the oven and a #9 wound rod was used to apply the coating to the back of the sheet.
The sheet was baked in a textile oven at 95 ℃ for 2 minutes.
The sheet was removed, cooled to allow access and reweighed.
The coating weight in milligrams per square inch was determined by dividing the difference in weight in milligrams by the area of the coating.
The dynamic viscosity of the mixed paint was measured using a #2 San cup and the static viscosity was measured using a Brookfield model DV-1+ viscometer using a #2 spindle at 100 rpm.
| Coating material | Coating weight | #2 Zan's cup | Brookfield viscosity |
| 8181-67--01-02-03-04-05-06-07-08-09 | mg/inch22.50.40.91.50.30.40.90.61.1 | (second) 16.523.617.715.521.121.716.116.315.4 | (centipoise @22 ℃ C.) 51.6236.465.64085.6125.240.848.841.2 |
Test prints from coated Teslin sheetsWas generated on an HP960C printer set to a general default print mode. Using X-Rite model 418®Measuring optical density value with densitometer by Macbeth®The black/white standard plate was adjusted. Test prints were also made using uncoated TeslinTS1000 for comparison. The optical density values are listed in the following table.
| Coating layer | CMY | C | M | Y | K |
| Without coating | 0.76 | 1.02 | 0.81 | 0.55 | 0.76 |
| 8181-67-01 | 1.30 | 1.05 | 1.32 | 1.04 | 1.13 |
| -02 | 1.01 | 0.84 | 1.05 | 0.84 | 1.03 |
| -03 | 1.08 | 0.83 | 1.03 | 0.83 | 1.08 |
| -04 | 1.05 | 0.95 | 1.23 | 0.96 | 1.04 |
| -05 | 1.15 | 0.87 | 1.07 | 0.87 | 1.15 |
| -06 | 1.25 | 1.11 | 1.26 | 0.97 | 1.28 |
| -07 | 1.23 | 1.27 | 1.21 | 1.01 | 1.39 |
| -08 | 1.27 | 1.07 | 1.28 | 1.00 | 1.16 |
| -09 | 1.30 | 1.24 | 1.41 | 1.13 | 1.29 |
Coatings 8181-67-09 are clearly the best of all the examples' optical density properties. The use of WC-71-2143 in the formulation resulted in an improved optical density over the polyurethane dispersion formulation alone.
Applying coatings 8181-67-09 to 81/2". times.11" Teslin ® TS1000 and SP1000 sheets and cured as described previously. The test prints obtained from the coated Teslin sheets were produced on an HP960C printer set to a general default print mode. Using X-Rite model 418®Measuring optical density value with densitometer by Macbeth®The black/white standard plate was adjusted. The optical density values are listed in the following table.
| Teslin | CMY | C | M | Y | K |
| TS1000 | 1.08 | 1.20 | 1.23 | 0.99 | 1.16 |
| SP1000 | 1.09 | 1.22 | 1.22 | 1.02 | 1.16 |
Example 2
The coating composition was prepared as in example 1 and applied to a roll of 500ft, 10.5mil Teslin TS1000 microporous substrate by either an offset or photographic printing process. In this coating method, a production line is used which comprises two coating stations, each with a forced air drying oven. Each coating station contains a paint supply tank, anilox roll and rubber applicator roll. The paint in the paint supply tank is supplied from a paint storage tank and a pump. The continuous web advancing linearly through the apparatusWhich is coated on both sides in a single pass. The apparatus was equipped with a 7BCM (billion cubic microns) roll and a 5BCM anilox roll. Are arranged to make successive passes so that both surfaces are wetted by each anilox roll contacting the rubber roll at least once. The complete coating sequence is described below: #1 by coating (7 bcm-obverse/5 bcm-reverse) + #2 by coating (7 bcm-obverse/5 bcm-reverse) + #3 by coating (5 bcm-obverse/7 bcm-reverse). The line speed was 240fpm, the oven temperature was 105 ℃ (220 ° f), and each roll was passed 3 times, in other words each surface was passed 3 times. The coating composition was applied at a rate of about 0.73g/m2(sum of front and back) coating weight. Converting the resulting coil into 81/2". times.11" sheet, with the grain running lengthwise. Test prints were produced on an HP960C printer set to a general default print mode. Both sides of the substrate are printed. Using X-Rite model 418®Measuring optical density value with densitometer by Macbeth®The black/white standard plate was adjusted. The optical density values are listed in the following table.
Optical density value
| Paper surface | CMY | C | M | Y | K |
| A side | 1.39 | 1.06 | 1.10 | 0.77 | 1.44 |
| Side B | 1.36 | 1.04 | 1.10 | 0.75 | 1.50 |
In addition to optical density, the printing has good overall aesthetics, sharp images and quality.
Example 3
Two rolls of 6600ft, 10.5mil Teslin TS1000 were sized with the coating composition described in example 1in the same manner as described in example 2. Volume to be producedConversion of paper to 81/2". times.11" sheet, with the grain running lengthwise. Test prints were produced on an HP960C printer set to a general default print mode and an optimal inkjet photo-level matte finish. Both sides of the substrate are printed. Using X-Rite model 418®Measuring optical density value with densitometer by Macbeth®The black/white standard plate was adjusted. The optical density values are listed in the following table.
Optical density value
| Paper surface | Print settings | CMY | C | M | Y | K |
| A side | General defaults | 1.47 | 1.07 | 1.26 | 0.86 | 1.65 |
| Side B | General defaults | 1.54 | 1.09 | 1.30 | 0.88 | 1.65 |
| A side | Optimal inkjet photo level matting modification | 1.32 | 1.12 | 1.27 | 0.86 | 1.20 |
| Side B | Optimal inkjet photo level matting modification | 1.29 | 1.11 | 1.25 | 0.89 | 1.16 |
In addition to optical density values, the use of the best mode produces a print with better image quality than a normal mode print. These same images printed using the best mode have very good pigment ink adhesion as tested by the coin rub test. The printed surface was rubbed with a coin until the substrate began to fatigue and fail. The printed surface maintains acceptable image definition with very little ink being wiped off.
Example 4
The treated sheet (sample a) resulting from the substrate prepared in the previous example was printed with a test print mode; an HP960c model printer set to the best mode, inkjet photo-grade matte finish was used. The assay represents five basic color/ink types: the optical density of the color columns compounding black, cyan, magenta, yellow and pigment black. The printed color bar was immersed in deionized water for 24 hours and the resulting optical density was measured. This procedure was repeated after a total of 96 hours of continuous soaking. The test was repeated on two additional samples (B & C) printed from the same set of substrates and all in the same manner. The optical density values are given in the following table.
Retained optical Density (sample A)
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.37 | 1.32 | 1.22 | 0.90 | 1.36 |
| 24 hours | 1.31 | 1.31 | 1.23 | 0.90 | 1.35 |
| 96 hours | 1.35 | 1.31 | 1.26 | 0.89 | 1.34 |
Retained optical Density (sample B)
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.33 | 1.25 | 1.27 | 0.92 | 1.32 |
| 24 hours | 1.25 | 1.31 | 1.35 | 0.98 | 1.22 |
| 96 hours | 1.25 | 1.30 | 1.37 | 0.99 | 1.20 |
Retained optical Density (sample C)
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.39 | 1.33 | 1.22 | 0.91 | 1.37 |
| 24 hours | 1.39 | 1.35 | 1.29 | 0.92 | 1.37 |
| 96 hours | 1.39 | 1.32 | 1.31 | 0.92 | 1.36 |
All color bars remained solid after 96 hours of soaking. Only some slight discoloration was seen from the composite and pigment black color bars. The thick 10 font of part of the test print remains clear.
Example 5
A few rolls of 6600ft, 10.5mil Teslin TS1000 were sized according to the technique described in example 2 using the coating composition described in example 1. Converting the resulting coil into 81/2". times.11" sheet, with the grain running lengthwise. Test prints were produced on an HP960C printer set for optimal inkjet photo-level matte finish. Both sides of the substrate are printed. The assay represents five basic color/ink types: the optical density of the color columns compounding black, cyan, magenta, yellow and pigment black. The printed color bar was immersed in tap water for 15 minutes and the resulting optical density was measured. This operation was repeated after a total of 24 hours of continuous immersion. The optical density values are given in the following table.
The retained optical density is that of the-a plane,
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.31 | 1.13 | 1.26 | 0.88 | 1.30 |
| 15 minutes | 1.31 | 1.14 | 1.25 | 0.90 | 1.30 |
| 24 hours | 1.32 | 1.12 | 1.24 | 0.89 | 1.29 |
Retained optical Density-B face, 2 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.31 | 1.14 | 1.27 | 0.89 | 1.30 |
| 15 minutes | 1.33 | 1.14 | 1.23 | 0.91 | 1.30 |
| 24 hours | 1.29 | 1.10 | 1.23 | 0.90 | 1.29 |
All color bars remained solid after 24 hours of immersion in tap water. No fading was seen for any color bar. The thick 10 font printed with composite black of some of the test print samples maintained good legibility.
Example 6
The sample collected after two coating passes in the operation described in the previous example was converted to 81/2". times.11" sheet, with the grain running lengthwise and tested. Test prints were produced on an HP960C printer set for optimal inkjet photo-level matte finish. Both sides of the substrate are printed. The assay represents five basic color/ink types: the optical density of the color columns compounding black, cyan, magenta, yellow and pigment black. The printed color bar was immersed in tap water for 15 minutes and the resulting optical density was measured. This operation was repeated after a total of 24 hours of continuous immersion. The optical density values are given in the following table.
Retained optical Density-A face, 2 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.31 | 1.16 | 1.27 | 0.87 | 1.30 |
| 15 minutes | 1.36 | 1.22 | 1.33 | 0.95 | 1.21 |
| 24 hours | 1.26 | 1.09 | 1.16 | 0.84 | 1.25 |
Retained optical Density-B face, 2 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.28 | 1.14 | 1.17 | 0.83 | 1.27 |
| 15 minutes | 1.32 | 1.20 | 1.20 | 0.89 | 1.30 |
| 24 hours | 1.25 | 1.06 | 1.13 | 0.77 | 1.22 |
In addition to the optical density retention results, slight discoloration was seen for both the composite and pigment black inks after 24 hours immersion in water. The 24 hour soaked samples had very few granular samples and all printed text remained well optically clear.
Example 7
Substrate samples were prepared according to the procedure set forth briefly in example 2, except that the coating sequence and the coating were adjusted to an active solids content of from 10% to 7%. Samples were collected after 2, 3 and 4 passes of coating. The subsequent coating sequence for the 2 passes of the coated sample was: #1 by coating (7 bcm-obverse/5 bcm-reverse) + #2 by coating (5 bcm-obverse/7 bcm-reverse). The subsequent coating sequence for coating the sample in 3 passes was: #1 by coating (7 bcm-obverse/5 bcm-reverse) + #2 by coating (7 bcm-obverse/5 bcm-reverse) + #3 by coating (5 bcm-obverse/7 bcm-reverse). The subsequent coating sequence for the 4 passes of the coated sample was: #1 by coating (7 bcm-obverse/5 bcm-reverse) + #2 by coating (7 bcm-obverse/5 bcm-reverse) + #3 by coating (5 bcm-obverse/7 bcm-reverse) + #4 by coating (5 bcm-obverse/7 bcm-reverse). Samples collected after 2, 3 and 4 passes of coating were converted to 81/2". times.11" sheet, with the grain running lengthwise and tested. Test prints were produced on an HP960C printer set for optimal inkjet photo-level matte finish. Both sides of the substrate are printed. The assay represents five basic color/ink types: the optical density of the color columns compounding black, cyan, magenta, yellow and pigment black. The printed color bar was immersed in tap water for 15 minutes and the resulting optical density was measured. This operation was repeated after a total of 24 hours of continuous immersion. The optical density values are given in the following table.
Retained optical density-side A, 7% solids, 2 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.26 | 1.12 | 1.13 | 0.80 | 1.21 |
| 15 minutes | 1.18 | 1.11 | 1.05 | 0.82 | 1.20 |
| 24 hours | 1.19 | 1.03 | 1.00 | 0.73 | 1.18 |
Retained optical Density-side B, 7% solids, 2 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.23 | 1.13 | 1.08 | 0.77 | 1.22 |
| 15 minutes | 1.17 | 1.10 | 0.97 | 0.71 | 1.15 |
| 24 hours | 1.15 | 0.98 | 0.92 | 0.65 | 1.14 |
Retained optical density-side A, 7% solids, 3 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.29 | 1.14 | 1.18 | 0.85 | 1.28 |
| 15 minutes | 1.26 | 1.12 | 1.11 | 0.84 | 1.25 |
| 24 hours | 1.23 | 1.05 | 1.11 | 0.79 | 1.24 |
Retained optical density-side B, 7% solids, 3 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.31 | 1.16 | 1.19 | 0.85 | 1.29 |
| 15 minutes | 1.30 | 1.20 | 1.14 | 0.87 | 1.28 |
| 24 hours | 1.26 | 1.07 | 1.16 | 0.80 | 1.27 |
Retained optical density-side A, 7% solids, 4 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.33 | 1.16 | 1.25 | 0.87 | 1.33 |
| 15 minutes | 1.34 | 1.18 | 1.23 | 0.92 | 1.33 |
| 24 hours | 1.32 | 1.11 | 1.13 | 0.91 | 1.31 |
Retained optical density-side B, 7% solids, 4 passes
24 hours tap water
| Time of immersion in water | CMY | Cyan color | Magenta color | Yellow colour | Pigment black |
| At the beginning | 1.31 | 1.15 | 1.21 | 0.85 | 1.30 |
| 15 minutes | 1.30 | 1.15 | 1.16 | 0.90 | 1.31 |
| 24 hours | 1.27 | 1.09 | 1.15 | 0.87 | 1.29 |
In addition to the retained optical density, differences in print quality were observed after 24 hours of immersion in tap water. The 2 and 3 pass coated samples became fine grained after 24 hours of immersion in water. The fine grained appearance of the 2 pass coated samples was more pronounced than the 3 pass coated samples. Some fading was observed with the composite and pigment black color bars. As the number of coating passes increases, the fade resistance is improved. The thick 10 font printed with composite black for some of the test printed samples maintained good optical clarity for all three sample types.
Example 8
Two rolls of 6600ft, 10.5mil Teslin TS1000 were sized with the coating composition described in example 1 to form an active solids content of 12.5% according to the operating setting described in example 2. Converting the resulting coil into 81/2". times.11" sheet, with the grain running lengthwise. Test prints were produced on an HP960C printer set for optimal inkjet photo-level matte finish. Both sides of the substrate are printed. Using X-Rite model 418®Measuring optical density value with densitometer by Macbeth®The black/white standard plate was adjusted. The optical density values are listed in the following table.
Optical density value
| Paper surface | Print settings | CMY | C | M | Y | K |
| A side | Optimal inkjet photo level matting modification | 1.38 | 1.19 | 1.34 | 0.93 | 1.26 |
| Side B | Optimal inkjet photo level matting modification | 1.36 | 1.18 | 1.33 | 0.91 | 1.24 |
The printing has excellent overall aesthetics, sharp image and quality in addition to optical density.
Example 9
A coating composition was prepared as in example 1, except that the resulting solids content was 12.5% instead of 10%. The coating composition was applied to a roll of 6600ft, 10.5mil Teslin SP1000 microporous substrate using the offset or photographic printing process described in example 2. The obtained coil is converted into 81/2". times.11" sheet, with the grain running lengthwise. Test prints were produced on an HP960C printer set for optimal inkjet photo-level matte finish. Both sides of the substrate are printed. Using X-Rite model 418®Measuring optical density value with densitometer by Macbeth®The black/white standard plate was adjusted. The optical density values are listed in the following table.
Optical density value
| Paper surface | CMY | C | M | Y | K |
| A side | 1.41 | 1.32 | 1.25 | 0.89 | 1.37 |
| Side B | 1.38 | 1.33 | 1.22 | 0.88 | 1.40 |
The printing has excellent overall aesthetics, sharp image and quality in addition to optical density. Composite paper and card manufacturing process
EXAMPLE 10 Hydraulic plate lamination (one-ply composite paper)
A26 inch by 38inch, 10.5mil thick sheet of the treated Teslin TS1000 substrate was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire Plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. (Note: this release liner was not an integral part of the final composite sheet as the laminate was removed from the composite sheet.) this structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire structure was placed on a 200 ton Wabash laminator preheated to 220 deg.F. The composite structure was laminated at a temperature of 220 deg.F, a pressure of 200psi for 8 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 22 minutes. After removal from the laminator, the resulting composite sheet is removed from the laminate structure. The finished composite sheet had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from the resulting 26inch by 38inch by 30.5mil composite sheet. The finished card had good integrity and good lat flat. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 11 Hydraulic plate Stack (four-layer composite sheet/book)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated two more times so that four pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 220 deg.F. The composite structure was laminated at a temperature of 220 deg.F, a pressure of 200psi for 8 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 22 minutes. After removal from the laminator, all four composite sheets were removed from the booklet. All four finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
EXAMPLE 12 Hydraulic plate Stack (10-layer composite sheet/book)
A paper of treated Teslin base, 26inch by 38inch, 10.5mils thick, was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated eight more times so that ten pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 220 deg.F. The composite structure was laminated at a temperature of 220 deg.F, a pressure of 200psi for 8 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 22 minutes. After removal from the laminator, all ten composite sheets were removed from the booklet. All ten finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 13 (10-layer composite sheet/booklet, other processing conditions)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated eight more times so that ten pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 200F. The composite structure was laminated at a temperature of 200 ° f and a pressure of 180psi for 6 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 18 minutes. After removal from the laminator, all ten composite sheets were removed from the booklet. All ten finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 14 (10-layer composite sheet/booklet, other processing conditions)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated eight more times so that ten pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 300F. The composite structure was laminated at a temperature of 300 ° f and a pressure of 250psi for 10 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 25 minutes. After removal from the laminator, all ten composite sheets were removed from the booklet. All ten finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 15 (7-layer composite sheet/booklet, other processing conditions)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated six more times so that seven pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 220 deg.F. The composite structure was laminated at 220 deg.F and 220psi pressure for 7 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 22 minutes. After removal from the laminator, all seven composite sheets were removed from the booklet. All seven finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 16 (7-layer composite sheet/booklet, other processing conditions)
A paper of treated Teslin base, 26inch by 38inch, 10.5mils thick, was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A piece of coated Teslin paper was placed on top of a 26inch x 38inch, 0.21inch piece of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated six more times so that seven pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 200F. The composite structure was laminated at a temperature of 200 ° f, a pressure of 250psi, for 7 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 22 minutes. After removal from the laminator, all seven composite sheets were removed from the booklet. All seven finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 16A (7-layer composite sheet/booklet, other processing conditions)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated six more times so that seven pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 300F. The composite structure was laminated at a temperature of 300 ° f for 7 minutes at a pressure of 90 psi. The laminate was cooled to less than 100 ° f under pressure and the process took about 26 minutes. After removal from the laminator, all seven composite sheets were removed from the booklet. All seven finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 17 (7-layer composite sheet/booklet, other processing conditions)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated six more times so that seven pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 300F. The composite structure was laminated at 300 ° f for 7 minutes at 250psi pressure. The laminate was cooled to less than 100 ° f under pressure and the process took about 26 minutes. After removal from the laminator, all seven composite sheets were removed from the booklet. All seven finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 26inch by 38inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 18 (7-layer composite sheet/booklet, failure of other process conditions)
A sheet of treated Teslin substrate 26inch by 38inch, 10.5mils thick was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a sheet of 26inch x 38inch, 0.21inch polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. A27 inch by 39inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 27 "39" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel plate of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated six more times so that seven pre-pressed multi-ply glues were present in the laminate. The resulting laminate was then placed between two 27 "39" 125mil unpolished noncorrosive metal plates. The entire construct, the construct referred to as a book, was placed in a 200 ton Wabash laminator preheated to 200F. The composite structure was laminated at a temperature of 200 ° f for 7 minutes at a pressure of 90 psi. The laminate was cooled to less than 100 ° f under pressure and the process took about 20 minutes. After removal from the laminator, all seven composite sheets were removed from the booklet. The Teslin/PVC structure was peeled off, indicating a lack of bond strength. No attempt was made to make ISO7910ID-1 cards.
Example 19 (12-layer composite sheet/booklet, other processing conditions)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a 20inch by 25inch, 0.1inch sheet of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut in the short direction according to the grain. Below the 10mil PVC glue with the grain in the short direction is a 20inch by 25inch by 2mil PVC sheet with the grain in the length direction. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel panels of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The cushion pad is a combination of polyamide fiber and mechanical rubber, manufactured and supplied by Yamauchi corporation, and is designed to have a more uniform temperature and pressure distribution during the thermal lamination process. The resulting laminate plus the bumper pad was then placed on two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 300F. The composite structure was laminated at a temperature of 300 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 19 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. All twelve of the finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 20inch by 25inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
The above example was also tested using Teslin SP1000 and gave the same results as Teslin TS 1000.
Example 20 (12-layer composite sheet/booklet, other processing conditions)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A piece of coated Teslin paper was placed on top of a 20inch by 25inch, 0.1inch piece of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut in the short direction according to the grain. Below the 10mil PVC glue with the grain in the short direction is a 20inch by 25inch by 2mil PVC sheet with the grain cut lengthwise. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel panels of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The resulting laminate plus a cushion pad was then placed between two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 250F. The composite structure was laminated at a temperature of 250 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 17 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. The PVC obtained from all twelve finished composite sheets was glued and peeled apart. None of the Teslin glues were peeled from the adjacent PVC sheets, indicating a good adhesion and seamless bond between Teslin and PVC. No attempt was made to make ISO7910ID-1 cards, since PVC gluing was not laminated.
Example 21 (12-layer composite sheet/booklet, other lamination modes and Process conditions)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the short direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a 20inch by 25inch, 0.1inch sheet of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut in the short direction according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut lengthwise according to the grain. Below the 10mil PVC glue with the grain in the short direction is a 20inch by 25inch by 2mil PVC sheet with the grain in the length direction. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel panels of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten more times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The resulting laminate plus a cushion pad was then placed between two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 300F. The composite structure was laminated at a temperature of 300 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 19 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. All twelve of the finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 20inch by 25inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 22 (12-layer composite sheet/booklet, other lamination patterns and Process conditions-failure)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the short direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a 20inch by 25inch, 0.1inch sheet of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut in the short direction according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut lengthwise according to the grain. Below the 10mil PVC glue with the grain in the short direction is a 20inch by 25inch by 2mil PVC sheet with the grain in the length direction. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC laminate was placed on top of the stainless steel panels of the existing construction. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The resulting laminate plus a cushion pad was then placed between two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 250F. The composite structure was laminated at a temperature of 250 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 17 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. The PVC obtained from all twelve finished composite sheets was glued and peeled apart. None of the Teslin glues were peeled from the adjacent PVC sheets, indicating a good adhesion and seamless bond between Teslin and PVC. No attempt was made to make ISO7910ID-1 cards, since PVC gluing was not laminated.
Example 23 (12-layer composite sheet/booklet, magnetic strip version)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a 20inch by 25inch, 0.1inch sheet of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut in the short direction according to the grain. Below the 10mil PVC glue with the grain in the short direction is a 20inch x 25inch x 2mil PVC magnetic strip master sheet made with the strip parallel to the short (20 ") direction of the sheet. The magnetic strip is 3-layer, 2750-force. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC/magnetic strip master sheet laminate structure was placed on top of the stainless steel plate of the existing structure. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten more times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The resulting laminate plus a cushion pad was then placed between two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 300F. The composite structure was laminated at a temperature of 300 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 19 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. All twelve of the finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 20inch by 25inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 24 (12-layer composite sheet/booklet, magnetic strip version)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the short direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a 20inch by 25inch, 0.1inch sheet of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut in the short direction according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut lengthwise according to the grain. Below the 10mil PVC glue with grain in the short direction is a 20inch x 25inch x 2mil PVC magnetic strip master sheet made with the strip parallel to the short (20 ") direction of the sheet. The magnetic strip is 3-layer, 2750-force. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC/magnetic strip master sheet laminate structure was placed on top of the stainless steel plate of the existing structure. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten more times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The resulting laminate plus the bumper pad was then placed on two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 300F. The composite structure was laminated at a temperature of 300 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 19 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. All twelve of the finished composite sheets had good integrity and any attempt to separate the sheets would destroy the Teslin layer, demonstrating good adhesion and a seamless bond between Teslin and PVC. ISO7910ID-1 cards were die cut from each 20inch by 25inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC.
Example 25 (12-layer composite sheet/booklet, magnetic stripe version failed)
A20 inch by 25inch, 10.5mil thick sheet of the treated Teslin substrate was cut from the master roll in the lengthwise direction according to the texture. Teslin was applied in 3 passes (3 x 3) on each side using the same coating composition described in example 1 and using the same offset printing application technique described in example 2. A sheet of coated Teslin was placed on top of a 20inch by 25inch, 0.1inch sheet of polyvinyl chloride (PVC) supplied by Empire plastics. The PVC sheet is cut lengthwise according to the grain. Below the PVC glue is a second 20inch by 25inch by 10mil PVC glue cut in the short direction according to the grain. Below the 10mil pvc glue with the grain in the short direction is a 20inch x 25inch x 2mil pvc magnetic strip master sheet made with the magnetic strip parallel to the short (20 ") direction of the sheet. The magnetic strip is 3-layer, 2750-force. A21 inch 26inch, 2mil sheet of clear polyester was placed on a Teslin sheet as a release liner. This structure was placed between two 21 "26" 30mil polished stainless steel metal plates. The same polyester/treated Teslin sheet/PVC/magnetic strip master sheet laminate structure was placed on top of the stainless steel plate of the existing structure. The polished metal plate was placed on the exposed polyester release liner. This pattern was repeated ten more times so that twelve precompressed multi-ply glues were present in the laminate. The resulting laminate is then placed between cushioning pads. The resulting laminate plus the bumper pad was then placed on two slightly larger 125mil unpolished non-corroding metal plates. The entire construct, the construct referred to as a book, was placed in a TMP laminator preheated to 250F. The composite structure was laminated at a temperature of 250 ° f and a pressure of 203psi for 18 minutes. The laminate was cooled to less than 100 ° f under pressure and the process took about 17 minutes. After removal from the laminator, all twelve composite sheets were removed from the booklet. The PVC obtained from all twelve finished composite sheets was glued and peeled apart. None of the Teslin glues were peeled from the adjacent PVC sheets, indicating a good adhesion and seamless bond between Teslin and PVC. No attempt was made to make ISO7910ID-1 cards, since PVC gluing was not laminated.
Example 26 (adjustment of card/composite sheet)
Cards made according to example 19 were each immersed in deionized water for 15 minutes and then allowed to air dry for 24 hours. The resulting conditioned card proved to be easier to separate from the laminate and to have slip characteristics than the unconditioned version.
Example 27 (adjustment of card/composite sheet)
The cards made according to example 19 were each conditioned at 75% relative humidity and 25 ℃ for 16 hours. The resulting conditioned card showed easier separation from the laminate and had slip characteristics compared to the unconditioned version.
Example 28 (adjustment of card/composite sheet)
Cards made according to example 19 were conditioned in a laminate at 75% relative humidity and 25 ℃ for 16 hours. The resulting conditioned card did not demonstrate easier separation from the laminate and slip characteristics than the unconditioned version.
Example 29 (adjustment of card/composite sheet)
Composite sheets made according to example 19 were each immersed in deionized water for 15 minutes and then allowed to air dry for 24 hours. ISO7910ID-1 cards were die cut from each 20inch by 25inch by 30.5mil composite sheet. The finished cards obtained from each composite sheet had good integrity and good ralte flatness. Any attempt to separate the card would destroy the Teslin layer, which demonstrates a good adhesion and seamless bond between Teslin and PVC. The resulting conditioned card proved to be easier to separate from the laminate and to have slip characteristics than the unconditioned version.
The table below compares the newly provided (8181-67-09 formulation) optical density retention performance to a standard IJ1000WP (two-component formulation). The test prints used in this study were produced on an HP970 color inkjet printer set to the best quality and photo-grade inkjet glossy paper.
Optical density after soaking in deionized water
| Soaking time (hours) | Composite black | Cyan color | Magenta color | Yellow colour | Pigment black | |
| Standard TesliniJ1000WP | 0 | 1.26 | 1.2 | 1.18 | 0.86 | 1.25 |
| 24 | 1.21 | 1.13 | 1.03 | 0.74 | 1.19 | |
| 96 | 1.18 | 1.08 | 1.03 | 0.71 | 1.17 | |
| New TesliniJ1000WP (8181-67-09) | 0 | 1.39 | 1.33 | 1.22 | 0.91 | 1.37 |
| 24 | 1.39 | 1.35 | 1.29 | 0.92 | 1.37 | |
| 96 | 1.39 | 1.32 | 1.31 | 0.92 | 1.36 |
The invention has been described with reference to specific embodiments. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the invention or the equivalents thereof.
Claims (63)
1. A substantially water resistant inkjet recordable base coating composition comprising:
a. an aqueous polyurethane dispersion;
b. an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound; and
c. an acrylic polymer which is a copolymer of a vinyl monomer and a vinyl monomer,
wherein the coating composition has a pH of 7 or less.
2. The coating composition of claim 1, wherein the polyurethane dispersion is selected from the group consisting of anionic polymers, cationic and nonionic polyurethanes that are dispersible in water.
3. The coating composition of claim 1, wherein the polyurethane dispersion is made from a polyisocyanate and a polyol.
4. The coating composition of claim 1, wherein the polyurethane dispersion contains 1 wt% to less than 70 wt% polyurethane.
5. The coating composition of claim 1 wherein the aqueous solution of the cationic nitrogen-containing polymeric dye fixative compound has a pH of 7 or less.
6. The coating composition of claim 1 wherein the cationic nitrogen-containing polymeric dye fixative compound comprises an aqueous mixture comprising from 5 wt% to 50 wt% or less of a nitrogen-containing polymer.
7. The coating composition of claim 1 wherein the cationic nitrogen-containing polymeric dye fixative compound comprises a polyamine and epichlorohydrin.
8. The coating composition of claim 1, wherein the acrylic polymer comprises a cationic acrylic polymer.
9. The coating composition of claim 8, wherein the cationic acrylic polymer is selected from the group consisting of polyacrylates, polymethacrylates, polyacrylonitrile, and non-polyacrylonitrile polymers having a monomer type selected from the group consisting of acrylonitrile, acrylic acid, acrylamide, and mixtures thereof.
10. The coating composition of claim 8, wherein the cationic acrylic polymer has a number average molecular weight of 1500-.
11. The coating composition of claim 10 wherein the cationic acrylic polymer has a number average molecular weight of 2900-.
12. The coating composition of claim 1, wherein the composition comprises 20 wt% to 75 wt% of the aqueous polyurethane dispersion, 5 wt% to 75 wt% of the aqueous solution of the cationic nitrogen-containing polymeric dye fixing compound, and 1 wt% to 75 wt% of the acrylic polymer, based on the total weight of the coating composition.
13. A method of preparing a substantially water resistant inkjet recordable substrate coating composition of claim 1 comprising the step of mixing an aqueous solution of a nitrogen-containing polymeric dye fixing compound with an aqueous polyurethane dispersion and an acrylic polymer to produce a substantially homogeneous mixture having a pH of 7 or less.
14. The method of claim 13, wherein the polyurethane dispersion is selected from the group consisting of anionic polymers, cationic and nonionic polyurethanes that are dispersible in water.
15. The method of claim 13, wherein the polyurethane dispersion is made from a polyisocyanate and a polyol.
16. The method of claim 13, wherein the polyurethane dispersion contains 1 wt% to less than 70 wt% polyurethane.
17. The method of claim 13 wherein the aqueous solution of the cationic nitrogen-containing polymeric dye fixative compound has a pH of 7 or less.
18. The method of claim 13 wherein the cationic nitrogen-containing polymeric dye fixative compound comprises an aqueous mixture comprising from 5 wt% to 50 wt% or less of a nitrogen-containing polymer.
19. The method of claim 13, wherein the acrylic polymer comprises a cationic acrylic polymer.
20. The method of claim 19, wherein the cationic acrylic polymer is selected from the group consisting of polyacrylates, polymethacrylates, polyacrylonitrile, and non-polyacrylonitrile polymers having a monomer type selected from the group consisting of acrylonitrile, acrylic acid, acrylamide, and mixtures thereof.
21. The method of claim 19 wherein the cationic acrylic polymer has a number average molecular weight of 1500-.
22. The method as claimed in claim 21, wherein the cationic acrylic polymer has a number average molecular weight of 2900-.
23. The method of claim 13, wherein the composition comprises 20 wt% to 75 wt% of the aqueous polyurethane dispersion, 5 wt% to 75 wt% of the aqueous solution of the cationic nitrogen-containing polymeric dye fixing compound, and 1 wt% to 75 wt% of the acrylic polymer, based on the total weight of the coating composition.
24. A substantially water resistant inkjet recordable substrate at least partially coated with a coating composition comprising:
a. an aqueous polyurethane dispersion;
b. an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound; and
c. an acrylic polymer which is a copolymer of a vinyl monomer and a vinyl monomer,
wherein the coating composition has a pH of 7 or less.
25. The inkjet recordable substrate of claim 24 wherein the polyurethane dispersion is selected from anionic polymers, cationic and nonionic polyurethanes that are dispersible in water.
26. The inkjet recordable substrate of claim 24 wherein the acrylic polymer comprises a cationic acrylic polymer.
27. The inkjet recordable substrate of claim 26 wherein the cationic acrylic polymer is selected from the group consisting of polyacrylates, polymethacrylates, polyacrylonitrile, and non-polyacrylonitrile polymers having monomer types selected from acrylonitrile, acrylic acid, acrylamide, and mixtures thereof.
28. The inkjet recordable substrate of claim 24 wherein the composition comprises 20% to 75% by weight of the aqueous polyurethane dispersion, 5% to 75% by weight of the aqueous solution of the cationic nitrogen-containing polymeric dye fixing compound, and 1% to 75% by weight of the acrylic polymer, based on the total weight of the coating composition.
29. The inkjet recordable substrate of claim 24 wherein the substrate comprises a cellulose-based paper.
30. The inkjet recordable substrate of claim 24 wherein the substrate comprises a microporous material.
31. The inkjet recordable substrate of claim 24 wherein the substrate comprises a matrix comprising a polyolefin, a siliceous filler, and a porous structure.
32. The inkjet recordable substrate of claim 31 wherein the substrate has a porosity of at least 35% by volume of the substrate.
33. The inkjet recordable substrate of claim 31 wherein the polyolefin is selected from polyethylene, polypropylene and mixtures thereof.
34. The inkjet recordable substrate of claim 33 in which the polyethylene comprises a linear high molecular weight polyethylene having an intrinsic viscosity of at least 10 liters/gram and the polypropylene comprises a linear high molecular weight polypropylene having an intrinsic viscosity of at least 5 liters/gram.
35. The inkjet recordable substrate of claim 31 wherein the siliceous filler is selected from the group consisting of silica, mica, montmorillonite, kaolin, asbestos, talc, diatomaceous earth, vermiculite, natural and synthetic zeolites, cement, calcium silicates, aluminum silicates, sodium aluminum silicates, aluminum polysilicates, silica alumina gels, glass particles, and mixtures thereof.
36. The inkjet recordable substrate of claim 35 wherein the siliceous filler is selected from precipitated silica, silica gel, or fumed silica.
37. The inkjet recordable substrate of claim 24 wherein the coating composition is applied to the substrate such that the substrate has a coating thickness of 1-40 microns.
38. The inkjet recordable substrate of claim 24 further comprising bonding the substrate with at least one layer of a substantially non-porous material.
39. The inkjet recordable substrate of claim 38in which the substantially non-porous material is selected from substantially non-porous thermoplastic polymers, substantially non-porous thermoset polymers, substantially non-porous elastomers, and substantially non-porous metals, and mixtures thereof.
40. The inkjet recordable substrate of claim 39 wherein the substantially non-porous thermoplastic polymer is a substantially non-porous metallized thermoplastic polymer.
41. A method of making an at least partially coated substantially water resistant inkjet recordable substrate of claim 24 comprising the steps of:
a. providing an ink jet recordable substrate having at least one side;
b. providing a coating composition comprising an aqueous polyurethane dispersion, an aqueous solution of a cationic nitrogen-containing polymeric dye fixing compound, and an acrylic polymer, said coating composition having a pH of 7 or less; and
c. a coating composition is at least partially applied to at least one side of the inkjet recordable substrate.
42. The method of claim 41, wherein the polyurethane dispersion is selected from the group consisting of anionic polymers, cationic and nonionic polyurethanes that are dispersible in water.
43. The method of claim 41, wherein the acrylic polymer comprises a cationic acrylic polymer.
44. The method of claim 43, wherein the cationic acrylic polymer is selected from the group consisting of polyacrylates, polymethacrylates, polyacrylonitrile, and non-polyacrylonitrile polymers having a monomer type selected from the group consisting of acrylonitrile, acrylic acid, acrylamide, and mixtures thereof.
45. A method as set forth in claim 41 wherein the composition comprises from 20% to 75% by weight of the aqueous polyurethane dispersion, from 5% to 75% by weight of the aqueous solution of the cationic nitrogen-containing polymeric dye fixing compound, and from 1% to 75% by weight of the acrylic polymer, based on the total weight of the coating composition.
46. The method of claim 41, wherein the substrate comprises a cellulose-based paper.
47. The method of claim 41, wherein the substrate comprises a microporous material.
48. The method of claim 41, wherein the substrate comprises a matrix comprising a polyolefin, a siliceous filler, and a porous structure.
49. The method of claim 48, wherein the substrate has a porosity of at least 35% by volume of the substrate.
50. The method of claim 48, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, and mixtures thereof.
51. The method of claim 50 wherein the polyethylene comprises linear high molecular weight polyethylene having an intrinsic viscosity of at least 10 liters/gram and the polypropylene comprises linear high molecular weight polypropylene having an intrinsic viscosity of at least 5 liters/gram.
52. The method of claim 48, wherein the siliceous filler is selected from the group consisting of silica, mica, montmorillonite, kaolin, asbestos, talc, diatomaceous earth, vermiculite, natural and synthetic zeolites, cement, calcium silicate, aluminum silicate, sodium aluminum silicate, aluminum polysilicate, silica alumina gel, glass particles, and mixtures thereof.
53. The method of claim 52, wherein the siliceous filler is selected from precipitated silica, silica gel, or fumed silica.
54. The method of claim 41, wherein the coating composition is applied to the substrate such that the substrate has a coating thickness of 1-40 microns.
55. The method of claim 41, further comprising bonding the substrate with at least one layer of substantially non-porous material.
56. The method of claim 55, wherein the substantially non-porous material is selected from the group consisting of substantially non-porous thermoplastic polymers, substantially non-porous thermoset polymers, substantially non-porous elastomers, and substantially non-porous metals, and mixtures thereof.
57. The method of claim 56, wherein the substantially non-porous thermoplastic polymer is a substantially non-porous metallized thermoplastic polymer.
58. The method of claim 41 further comprising the step of drying the coated inkjet recordable substrate with a temperature in the range of ambient temperature to 350 ° F.
59. A coated microporous substrate comprising:
a. a microporous substrate having an upper surface and a lower surface, the substrate comprising:
(i) polyolefins
(ii) A siliceous filler;
(iii) a porosity that constitutes at least 35% of the pores by volume of the microporous substrate; and
b. a coating formed from a coating composition at least partially applied to at least one surface of the microporous substrate, the coating composition comprising:
(i) at least one polyurethane selected from the group consisting of anionic polyurethanes, cationic polyurethanes, nonionic polyurethanes, and mixtures thereof;
(ii) an aqueous solution of a polymeric nitrogen-containing dye fixing compound; and
(iii) an acrylic polymer which is a copolymer of a vinyl monomer and a vinyl monomer,
the coating composition has a pH of 7 or less.
60. A multi-layer article comprising an ink jet recordable substrate at least partially attached to a substantially non-porous material, said ink jet recordable substrate being at least partially coated with a substantially water resistant coating composition, wherein said substantially water resistant coating composition comprises:
a. an aqueous polyurethane dispersion;
b. an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound; and
c. an acrylic polymer which is a copolymer of a vinyl monomer and a vinyl monomer,
wherein the coating composition has a pH of 7 or less.
61. The multilayer article according to claim 59 further comprising a friction reducing coating composition, wherein at least one of said ink jet recordable substrate and substantially non-porous material is at least partially coated with said friction reducing coating composition.
62. A method of making a multilayer article comprising the steps of:
a. providing an inkjet recordable substrate having a top surface and a bottom surface;
b. a substantially water-resistant coating composition is provided comprising a stable dispersion of:
(i) an aqueous polyurethane dispersion;
(ii) an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound; and
(iii) an acrylic polymer which is a copolymer of a vinyl monomer and a vinyl monomer,
the coating composition has a pH of 7 or less;
c. at least partially applying the coating composition to at least one surface of the inkjet recordable substrate;
d. at least partially attaching the inkjet recordable substrate of (c) to a substantially non-porous material having a top surface and a bottom surface;
e. providing a friction reducing coating composition; and
f. at least partially coating the friction reducing coating composition on a surface of at least one of the inkjet recordable substrate and the substantially non-porous material.
63. A substantially water resistant inkjet recordable base coating composition comprising:
a. an aqueous polyurethane dispersion;
b. an aqueous solution of a cationic nitrogen-containing polymeric dye fixative compound; and
c. a cationic acrylic polymer which is a copolymer of a cationic acrylic polymer,
wherein the coating composition has a pH of 7 or less.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US37395702P | 2002-04-19 | 2002-04-19 | |
| US60/373,957 | 2002-04-19 | ||
| US10/411,311 | 2003-04-11 | ||
| US10/411,311 US20040002570A1 (en) | 2002-04-19 | 2003-04-11 | Water resistant ink jet recordable substrate |
| PCT/US2003/011964 WO2003089533A1 (en) | 2002-04-19 | 2003-04-16 | Water resistant ink jet recordable substrate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| HK1079541A1 HK1079541A1 (en) | 2006-04-07 |
| HK1079541B true HK1079541B (en) | 2008-07-11 |
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