Title of Invention

WATER RESISTANT INK JET RECORDABLE SUBSTRATE.

Abstract A substantially water-resistant ink jet recordable substrate coating composition comprising: d. an aqueous polyurethane dispersion; e. a cationic nitrogen-containing polymeric dye fixative compound; and f. an acrylic polymer, wherein said coating composition has a pH of 7 or less.
Full Text WATER RESISTANT INK JET RECORDABLE SUBSTRATE
This patent applications claims priority to provisional patent application
having Serial Number 60/373,957 filed on April 19, 2002.
The present invention is directed to an ink jet recordable substrate. In
particular, the present invention relates to a water-resistant coating composition
for an ink jet recordable substrate, a method for preparing the coating
composition and a method of applying said coating composition to produce a
water-resistant ink jet recordable substrate.
It is known in the art to employ various paper treatment methods to
improve the quality of ink jet prints thereon. However, problems have been
experienced when the imaged-sheet comes into contact with water; the image
may migrate through the sheet to the other side. In some instances, the show-
through of the image on the back side of the paper has more ink than the front
side. Further, paper treatment methods which improve inter-color bleed
problems in color ink jet images may heighten the severity of show-through of
the image.
It is also known in the art to size cellulosic-based paper with sizing
components for the purpose of reducing the penetration of liquids into the
substrate. "Internal sizing" may include the introduction of a material into the pulp
during the paper making operation. "Surface sizing" may include the application
of dispersions of film-forming substances such as converted starches, gums, and
modified polymers to previously formed paper. When used to print with an ink jet
printer containing predominantly water based inks, internal and surface sized
papers often yield imaged papers which curl into tubes.
Thus, it would be desirable to develop an ink jet recordable substrate that
does not exhibit the aforementioned problems.
U.S. Patent No. 5,709,976 discloses a method for coating a paper
substrate with a hydrophobic barrier layer and an image- receiving layer. U.S.
Patent No. 6,140,412 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 a microporous material sheet were developed and are
known in the art. For example, U.S. Patents 4,861,644 and 5,196,262 disclose
microporous material sheets which include a matrix of linear ultrahigh molecular
weight polyolefin, a large proportion of finely divided water-insoluble siliceous
filler, and interconnecting pores. However, inks used for inkjet printing may
coalesce on the surface of the polyolefin based printing substrates.
U.S. Patent No. 6025,068 discloses a method for coating a microporous
polyolefin substrate with a composition including a binder dissolved or dispersed
in a volatile aqueous liquid medium. The binder includes a film-forming organic
polymer of a water-soluble poly(ethylene oxide) and a water-soluble or water-
dispersible crosslinkable urethane-acrylate hybrid polymer. However, ink jet
recordings on these coated substrates lack the sharpness and vibrancy which is
desired.
Japanese Patent (JP) 2001-184881 discloses a coating composition that
includes a nonionic or anionic polyurethane and the reaction product of a
monomeric secondary amine and epichlorohydrin. However, when subsequently
contacted with water, the monomeric amine adduct can solubilize, which may
result in a blurred image.
Further, United States Patent 6,020,058 discloses an acrylic composition
and United States Patent 6,025,068 discloses a urethane-acrylic co-polymer.
These patents are incorporated herein by reference.
Moreover, patent application having U.S. Serial No. 60/309,348 filed
August 1, 2001, discloses a two-component water-resistant coating composition
for use with a microporous substrate; and patent application having U.S. Serial
No. 60/317,113 filed September 5, 2001, discloses a method of processing 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 able to record share images when an ink jet printing
ink is applied thereto.
SUMMARY OF THE INVENTION
The present invention is directed to a water-resistant coating composition
for ink jet recordable substrates. The water-resistant coating composition
includes:
(a) an aqueous polyurethane dispersion;
(b) an aqueous solution of a cationic nitrogen-containing
polymeric dye fixative compound; and
(c) an acrylic polymer,
wherein the coating composition has a pH of 7 or less.
The present invention is also directed to a method of coating an ink jet
recordable substrate in which an ink jet recordable substrate is provided and the
above-defined coating composition is applied to the substrate.
The present invention is further directed to an ink jet recordable substrate
which includes a substrate having at least one side, and to at least one side of
the substrate is applied a coating layer of the above described coating
composition.
DETAILED DESCRIPTION OF THE INVENTION
Unless otherwise indicated, all numbers or expressions referring to
quantities of ingredients, 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 is meant to include both the methacrylic and
acrylic species.
Any polyurethane that may be dispersible in water is suitable for use in
the present coating composition. Such polyurethanes include anionic, cationic
and nonionic polyurethanes. The co-mixing of anionic polymers and cationic
polymers often produces a polysalt which is typically insoluble in water and other
solvents. In the present invention, it has been discovered that an anionic
polyurethane dispersion may be combined with a cationic nitrogen-containing
polymer to form a stable aqueous dispersion which can be useful as a coating
composition for an ink jet recordable substrate.
An aqueous dispersion of polyurethane resin comprising particles of a
polyurethane polymer dispersed in an aqueous medium can be used in the
present invention.
The poiyurethane for use in the present invention can be prepared by a
variety of methods known in the art. For example, a polyisocyanate can be
reacted with a polyol to form a prepofymer, such as an isocyanate-terminated
prepolymer. As used herein and the claims, the term "polyisocyanate" refers to a
compound with 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 dicyclohexyl methane diisocyanate. Non-limiting examples of
suitable three or more functional isocyanates include the reaction products of
diisocyanates with polyols such as trimethylol propane, glycerol and
pentaerythritol. A suitable polyisocyanate for use in the present invention can
include but is not limited to Desmodur which is commercially available from
Bayer.
As used herein and in the claims, the term "poiyol" refers to a compound
with more than one hydroxyl group. Non-limiting examples of suitable polyols for
use in the present invention include polyols such as those from which the
polyisocyanate can be prepared, polyester polyols and polyether polyols.
The reaction of the polyisocyanate and polyol can be carried out in the
presence of an organic solvent. Suitable solvents can include but are not limited
to n-methyl pyrrolidone, tetrahydrofuran or glycol ether.
In an embodiment, the prepolymer can be reacted with a di-hydroxyt
compound having an acid group, such as dimethylol propionic acid, to produce a
polyurethane with at least one pendant acid group. The acid group can include a
carboxylic acid group or a sulfonic acid group. The polyurethane having a
pendant acid group can then be reacted with a base to produce an anionic
polyurethane. The anionic poiyurethane dispersions of the present invention
generally can be dispersed in a base which ionizes the acidic groups of the
polymer and stabilizes the dispersion. The base can be selected from the group
consisting of an inorganic base, ammonia, amine and mixtures thereof.
Non-limiting examples of suitable anionic polyurethanes for use in the
present invention can 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 can be used in the present
invention can include but are not limited to those marketed under the trade name
WitcoBond® which are commercially available from Crompton Corporation,
Greenwich, Connecticut.
A cationic polyurethane dispersion for use in the present invention can be
prepared by a variety of methods known in the art. For example, United States
Patent 3,470,310 discloses a method which includes the preparation of water
dispersions of polyurethanes which contain salt-type groups bonded into the
polyurethane. United States Patent 3,873,484 discloses aqueous dispersions of
polyurethanes prepared from a quaternized polyurethane prepolymer. United
States Patent 6,221,954 discloses a method for preparing a polyurethane
prepolymer in which a N-monoalkanol tertiary amine is reacted with an alkylene
oxide in the presence of a strong acid. The relevant portions of these patents
are herein incorporated by reference.
In an embodiment, the prepolymer can be reacted with a di-hydroxyl
compound having an amine group, such as a secondary or tertiary amine, to
produce a polyurethane with at least one pendant amine group. Non-limiting
examples of a di-hydroxyl compound having an amine group can include
polyamines such as ethylene diamine, isophorone diamine and diethylene
triamine. The polyurethane having a pendant amine group can then be reacted
with an acid to produce a cationic polyurethane.
Suitable cationic polyurethanes for use in the present invention can
include but is not limited to those marketed under the trade name WitcoBond
(i.e., W213, W215 and X051) which are available from Crompton Corporation,
Greenwich, Connecticut.
In another embodiment of the present invention, the prepolymer can be
reacted with a diol having a polyalkylene oxide chain, to produce a polyurethane
backbone with a polyalkylene glycol pendant chain. The polyurethane having a
polyalkylene glycol pendant chain can be reduced with water to produce a
nonionic polyurethane.
Suitable nonionic polyurethanes for use in the present invention can
include but is not limited to those marketed under the trade name WitcoBond
(i.e., W320) which are available from Crompton Corporation, Greenwich,
Connecticut.
In a non-limiting embodiment, a vinyl or ethylenic unsaturated isocyanate
prepolymer or vinyl or ethylenic unsaturated polyurethane can be reacted with a
vinyl or ethylenic unsaturated acid species, such as acrylic acid or methacrylic
acid, in a free radical synthesis to form a carboxylic acid pendant polyurethane.
The acid pendant polyurethane can be reacted with a base, such as those
aforementioned, to form an anionic polyurethane.
Further, the prepolymer can be dispersed in water in the presence of a
base and then chain extended by adding a polyamine. In a 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 alternate non-limiting embodiments, the aqueous polyurethane
dispersion can contain up to 70 wt.%, or up to 65 wt.%, or up to 60 wt.%, or up to
50 wt.% of the polyurethane. The aqueous polyurethane dispersion can include
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
cause the dispersion itself or the mixture with the nitrogen-containing polymer to
be unstable; and the amount should not be so low that the coating composition
does not provide sufficient water and rub resistance or that the dispersion itself
becomes unstable. The polyurethane can be present in the aqueous
polyurethane dispersion in any range of values inclusive of those stated above.
In addition to an aqueous polyurethane dispersion, a coating composition
of the present invention, includes an aqueous solution of a cationic nitrogen-
containing polymeric dye fixative compound. In a non-limiting embodiment, the
aqueous solution of a cationic nitrogen-containing polymer suitable for use in the
present invention can have a pH of 7 or less, or a pH of 6 or less, or 5 or less, to
ensure that at least a portion of the nitrogen atoms carry at least a portion of a
cationic charge. In a further non-limiting embodiment, the coating composition of
the present invention can also have a pH 7 or less, or 6 or less, or 5 or less.
Any nitrogen-containing polymer in which at least a portion of the nitrogen
atoms carry at least a portion of a cationic charge at a pH within the
aforementioned range can be useful in the present invention. Non-limiting
examples of suitable cationic nitrogen-containing polymers for use as a dye
fixative include but are not limited to polymers that include one or more monomer
residues derived from one or more of the following nitrogen-containing
monomers:

where R1 represents independently for each occurrence H or C1 to C3 aliphatic;
R2 represents independently for each occurrence a divalent linking group
selected from C2 to C2o aliphatic hydrocarbon, polyethylene glycol and
polypropylene glycol; R3 represents independently for each occurrence H, C1 to
C22 aliphatic hydrocarbon or a residue from the reaction of the nitrogen with
epichlorohydrin; Z is selected from -O- or-NR4-, wherein R4 represents H or
CH3; and X represents a halide or methylsulfate.
Non-limiting examples of suitable cationic nitrogen-containing monomers
for use in the present invention can include but are not limited to dimethyl
aminoethyl (meth)acrylate, (meth)acryloyloxyethyl trimethyl ammonium halides,
(meth)acryloyloxyethyl trimethyl ammonium methylsulfate, dimethyl aminopropyl
(meth)acrylamide, (meth)acrylamidopropyl trimethyl ammonium
halides,(meth)acrylamidopropyl trimethyl ammonium methylsulfate, diallyl amine,
methyl diallyl amine, and diallyl dimethyl ammonium halides.
In a non-limiting embodiment, the cationic nitrogen-containing polymers
can contain one or more additional monomer residues. An additional monomer
residue can be selected from any polymerizable ethylenically unsaturated
monomer that when copolymerized with a nitrogen-containing monomer, can
result in a polymer that is at least partially soluble in water. As used herein and
in the claims, "partially soluble" means at least 0.1 gram of the polymer can be
dissolvable in water when 10 grams of the polymer is added to 1 liter of water
and mixed for 24 hours.
Non-limiting examples of monomers that can be copolymerized with the
nitrogen-containing monomers include but are not limited to (meth)acrylamide, n-
alkyl (meth)acrylamides, (meth)acrylic acid, alkyl esters of (meth)acrylate, glycol
esters of (meth)acrylic acid, polyethylene glycol esters of (meth)acrylic acid,
hdroxyalkyl (meth)acrylates, itaconic acid, alkyl ethers of itaconic acid, maleic
acid, mono- and di-alkyl esters of maleic acid, maleic anhydride, maleimide,
aconitic acid, alkyl esters of aconitic acid, allyl alcohol and alkyl ethers of allyl
alcohol.
In a further non-limiting embodiment, a nitrogen-containing polymer for
use in the present invention, can be a homopolymer of a nitrogen-containing
monomer or it can be a copolymer of one or more nitrogen-containing
monomers. A nitrogen-containing polymer can also be a copolymer of one or
more polymerizable ethylenically unsaturated monomers, or one or more
nitrogen-containing monomers, or mixtures thereof. In alternate non-limiting
embodiments, when a nitrogen-containing polymer includes one or more other
polymerizable ethylenically unsaturated comonomers, the nitrogen-containing
polymer can include not more than 70 mol%, or not more than 50 mol%, or not
more than 25 mol%, or not more than 10 mol% of the nitrogen-containing
monomer. The amount of nitrogen-containing monomer used can depend upon
the polyurethane component used in the present coating composition. 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
polyurethane dispersion can be unstable. The application of an unstable mixture
to an ink jet recordable substrate 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%, or at least 1.0 mol%, or at least 2.5
mol%, or at least 5.0 mol% of the nitrogen-containing monomer. When the
amount of nitrogen-containing monomer in the nitrogen-containing polymer is too
low, the nitrogen-containing polymer may not provide adequate dye fixative
properties and a recorded ink image on the coated substrate can lack the
desired water and rub fastness properties.
A nitrogen-containing monomer may be present in the nitrogen-containing
polymer in any range of values inclusive of those stated above. The one or more
other polymerizable ethylenically unsaturated monomers can be present in an
amount sufficient to bring the total percentage to 100 mol%.
In a non-limiting embodiment of the present invention, a nitrogen-
containing polymer can comprise an aqueous solution. In this embodiment, the
aqueous solution can include at least 5 wt.%, or at least 10 wt.%, or at least 15
wt.% of the nitrogen-containing polymer and not more than 50 wt.%, or not more
than 45 wt.%, or not more than 40 wt.% of the nitrogen-containing polymer.
When the concentration of the nitrogen-containing polymer is too low it may not
be economical for use in commercial applications and can be too dilute to
provide optimum ratios with the polyurethane component. When the
concentration is too high, the viscosity of the solution can increase and result in
handling difficulties in a commercial environment. In a non-limiting embodiment,
the nitrogen-containing polymer can include a solution of polyamide amines
reacted with epichlorohydrin, available under the trade name CinFix by
Stockhausen GmbH & Co. KG, Krefeld, Germany.
The coating composition of the present invention includes an acrylic
polymer. In a non-limiting embodiment, the acrylic polymer can be selected from
anionic, cationic and nonionic acrylic polymers. In a non-limiting embodiment,
the acrylic polymer can include a cationic acrylic polymer. Non-limiting examples
of suitable cationic acrylic polymers can include polyacrylates,
polymethacrylates, polyacrylonitriles 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 a variety of methods
known in the art. In a non-limiting embodiment of the present invention, a
cationic acrylic polymer can be synthesized via a free radical solution
polymerization from monomer types butyl acrylate, methyl methacrylate and 2-
(tert-butylamino)ethyl methoacrylate. The molar equivalent of butyl acrylate can
be from 0.10 to 0.95, or from 0.15 to 0.75; the molar equivalent of methyl
methacrylate can be from 0.10 to 0.85, or from 0.15 to 0.70; and the molar
equivalent of 2-(tert-butylamino)ethyl methyacrylate can be from 0.10 to 0.25, or
from 0.12 to 0.20. The reaction mixture can be treated with acid such that the pH
is within a range of from 4.0 to 7.0. The mixture then can be diluted with water
and solvent stripped. Non-limiting examples of suitable acids for use in the
treatment step can include any acid which can function as a solubilizing or
dispersing agent to produce a stable dispersion of a cationic polymer. Non-
limiting examples of suitable solvents for use in the stripping process can include
isopropanol and methyisobutyl ketone (MIBK).
In a non-limiting embodiment of the present invention, the molar
equivalent of the butyl acrylate, methyl methacrylate and 2-(tert-butylamino)ethyl
methacrylate, can be 0.219 to 0.621 to 0.160, respectively.
In another non-limiting embodiment, the cationic acrylic polymer for use in
the present invention can have a number average molecular weight of from 1500
to 8150, or from 2900 to 7125.
The ink jet recordable substrate coating composition of the present
invention includes a mixture of an aqueous solution of a nitrogen-containing
polymer, an aqueous polyurethane dispersion, and an acrylic polymer. In a non-
limiting embodiment, the mixture can include from 20 wt.% to 75 wt.%, or from
25 wt.% to 70 wt.%, or from 30 wt.% to 60 wt.% of the aqueous polyurethane
dispersion. The mixture can also include from 5 wt.% to 75 wt.%, or from 15
wt.% to 70 wt.%, or from 30 wt.% to 65 wt.% of an aqueous solution of the
nitrogen-containing polymer. The mixture can also include from 1 wt.% to 75
wt.%, or from 20 wt.% to 60 wt.%, or from 25 wt.% to 50 wt.% of an acrylic
polymer. The weight percentages are based on the total weight of the ink jet
recordable substrate coating composition
In a non-limiting embodiment of the present invention, water can be
added to the mixture of nitrogen-containing polymer, polyurethane and acrylic
polymer. When water is added to the mixture, the resulting ink recordable
substrate coating composition can have a total resin solids of from 5 wt.% to 35
wt.%, or from 5 wt.% to 20 wt.%, or from 5 wt.% to 15 wt.% based on the total
weight of the ink recordable substrate coating composition. A total resin solids
that is too high, can cause the viscosity of the coating composition to increase
such that the resulting penetration of the coating composition to the substrate
can be less than desired. A total resin solids that is too low, can cause the
viscosity of the coating composition to decrease such that the resulting
penetration of the coating to the substrate can be less than desired. In a non-
limiting embodiment, the viscosity of the coating composition can be less than
500 cps, or less than 400 cps and at least 10 cps, or at least 25 cps when
measured using a Brookfield viscometer at 25°C.
In a non-limiting embodiment, the coating composition of the present
invention can also include other additives typically known in the art. Non-limiting
examples of suitable additives can include surfactants, such as nonionic,
cationic, anionic, amphoteric and zwiterionic surfactants; rheology modifiers,
such as polyvinyl alcohols, polyvinyl pyrrolidones, polyethylene oxides,
polyacrylamides, natural and synthetic gums; biocides, such as a blend of 5-
chloro-2-methyl-4-isothiazoline-3-oneand 2-methyl-4-isothiazolin-3-one
available commercially by the trade name Kathon, from Rohm and Haas Co., 2-
hydroxypropylmethane thiosulfonate, and dithiocarbamates; and coupling
agents, such as titanium, silane-type, trisodium pyrophosphate.
The pH of the coating composition of the present invention can be less
than 7, or less than 6, or less than 5. It is believed that when the pH is outside of
these ranges, the cationic polymeric dye fixative compound may not carry a
sufficient cationic charge to perform its intended function. Further, it is believed
that on certain substrates, the wetting action of the coating composition can be
improved when the pH is within the aforementioned ranges. In a non-limiting
embodiment, for commercial applications, the coating composition can have pH
greater than 2.
The present invention is also directed to a method of preparing the ink jet
recordable substrate coating composition of the present invention. In a non-
limiting embodiment, the method can include combining an aqueous solution of a
nitrogen-containing polymer, an aqueous polyurethane dispersion, and an acrylic
polymer. In a non-limiting embodiment, sufficient mixing can be maintained
during the addition step to produce a homogeneous mixture.
The present invention is further directed to a method of coating an ink jet
recordable substrate. In a non-limiting embodiment, the method can include the
steps of:
(a) providing an ink recordable substrate having at least one side;
(b) providing the coating composition described above; and
(c) applying the coating composition to at least one side of the ink
recordable substrate.
Any ink jet recordable substrate known in the art can be used in the
present invention. As a non-limiting example, the substrate can be any cellulosic-
based paper. In another non-limiting embodiment, the ink recordable substrate
can be a microporous material substrate. A non-limiting example of such a
microporous substrate can be one having at least one surface and which
includes:
(a) a matrix comprising a polyolefin;
(b) particulate siliceous filler distributed throughout the matrix; and
(c) a network of pores, wherein the pores can constitute at least 35
percent by volume of the microporous material substrate.
Suitable polyolefins for use in the present invention can include a wide
variety known in the art. In a non-limiting embodiment, the polyolefin can
comprise a polyethylene and/or a 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 deciliters/gram and the
polypropylene can be a linear high molecular weight polypropylene having an
intrinsic viscosity of at least 5 deciliters/gram.
Intrinsic viscosity can be measured using a variety of methods known to
the skilled artisan. As used herein and in the claims, intrinsic viscosity can be
determined by extrapolating to zero concentration the reduced viscosities or the
inherent viscosities of several dilute solutions of the polyolefin wherein the
solvent is freshly distilled decahydronaphthalene to which 0.2 percent by weight,
3,5-di-tert-butyl-4-hydroxyhydrocinnamic acid, neopentanetetrayl ester [CAS
Registry No. 6683-19-8] has been added. The reduced viscosities or the inherent
viscosities of the polyolefin can be ascertained from relative viscosities obtained
atJ35°C using an Ubbelohde No. 1 viscometer.
In alternate non-limiting embodiments, on a coating-free, printing ink free,
impregnant-free, and pre-bonding basis, pores constitute at least 35 percent by
volume of the microporous material, or at least 60 percent by volume of the
microporous material, or from 35 percent to 80 percent by volume of the
microporous material, or from 60 percent to 75 percent by volume.
The particulate siliceous filler for use in the present invention can be
selected from a wide variety that are known in the art. In a non-limiting
embodiment, the particulate siliceous filler can be finely divided substantially
water-insoluble siliceous particles. These particles can be in the form of ultimate
particles, aggregates of ultimate particles, or a combination of both. In a non-
limiting embodiment, at least 90 percent by weight of the siliceous particles used
in preparing the microporous material can have gross particle sizes in the range
of from about 5 to about 40 micrometers as determined by use of a Model TAII
Coulter counter (Coulter Electronics, Inc.) but modified by stirring the filler for 10
minutes in Isoton II electrolyte (Curtin Matheson Scientific, Inc.) using a four-
blade, 4.445 centimeter diameter propeller stirrer. In a further non-limiting
embodiment, at least 90 percent by weight of the siliceous particles can have
gross particle sizes in the range of from about 10 to about 30 micrometers. It is
expected that the sizes of filler agglomerates can be reduced during processing
of the ingredients to prepare the microporous material.
Non-limiting examples of suitable siliceous particles include, but are not
limited to particles of silica, mica, montmorillonite, kaolinite, asbestos, talc,
diatomaceous earth, vermiculite, natural and synthetic zeolites, cement, calcium
silicate, aluminum silicate, sodium aluminum silicate, aluminum polysilicate,
alumina silica gels, and glass particles. In a non-limiting embodiment, silica
and/or the clay can be used as siliceous particles in the present invention. In a
further non-limiting embodiment, precipitated silica, silica gel, or fumed silica can
be used.
In alternate non-limiting embodiments, the finely divided particulate
substantially water-insoluble siliceous filler can constitute from 50 to 90 percent
by weight of the microporous material substrate, or from 50 to 85 percent by
weight, or from 60 percent to 80 percent by weight.
In a non-limiting embodiment, the ink jet recordable substrate for use 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 can be used. Non-limiting examples of suitable non-siliceous filler
particles can include but are not limited to particles of titanium oxide, iron oxide,
copper oxide, zinc oxide, antimony oxide, zirconia, magnesia, alumina,
molybdenum disulfide, zinc sulfide, barium sulfate, strontium sulfate, calcium
carbonate, magnesium carbonate, magnesium hydroxide, and finely divided
substantially water-insoluble flame retardant filler particles such as particles of
ethylenebis(tetra-bromophthalimide), octabromodiphenyl oxide,
decabromodiphenyl oxide, and ethylenebisdibromonorbornane dicarboximide.
A further description of suitable microporous materials for use in the
present invention is U.S. Patent Nos. 4,861,644 to Young et al. and 5,196,262 to
Schwarz et al., the relevant portions of both are incorporated herein by
reference.
A variety of suitable methods can be used to apply the coating
composition to the ink recordable substrate. The coating compositions generally
can be applied to the substrate using any conventional technique known in the
art. Non-limiting examples of suitable methods include spraying, curtain coating,
dipping, rod coating, blade coating, roller application, size press, printing,
brushing, drawing, slot-die coating, and extrusion. In a non-limiting embodiment,
the coating can be dried by exposing the coated substrate to forced air at a
temperature in the range of from ambient to 177°C.
The coating composition can be applied once or a multiplicity of
times. In a non-limiting embodiment, when the coating composition is applied a
multiplicity of times, the applied coating usually can be dried, either partially or
totally, between coating applications. In a further non-limiting embodiment, once
the coating composition has been applied to the substrate, the solvent can be
substantially removed, usually by drying.
In a non-limiting embodiment, an air knife coating technique wherein
the coating composition is applied to the substrate and the excess is 'blown off'
by a powerful jet from the air knife, can be used. In another embodiment, a
reverse.
roll coating can be used. In this procedure, the coating material can be
measured onto an applicator roller by precision setting of the gap between an
upper metering roller and the application roller below it. The coating can be
'wiped' off the application roller by the substrate as it passes around the support
roller at the bottom.
In another embodiment of the present invention, gravure coating coating can
be used to apply the coating composition. In the gravure coating method, an
engraved roller can run in a coating bath, which fills the engraved dots or lines of
the roller with the coating composition. Any excess coating on the roller can be
wiped off by a doctor blade and the coating can be deposited onto the substrate
as it passes between the engraved roller and a pressure roller, the coating
composition can be also be used. In this alternate method, the coating
composition can be metered by the engraving on a roller before being wiped off
as in a conventional reverse roll coating process.
In a further non-limiting embodiment, a metering rod can be used to apply the
coating composition. When a metering rod is used, an excess of the coating can
be deposited onto the substrate as it passes over a bath roller. The wirewound
metering rod, known as a Meyer Bar, allows the desire quantity of the coating to
remain on the substrate. The quantity can be determined by the diameter of the
wire used on the rod.
The thickness of the substantially dry coating can vary widely. In alternate non-
limiting embodiments, the thickness of the coating can be in the range of from 1
to 40 urn, or from 5 to 25 urn .
The present invention is also directed to a coated microporous material
substrate. In a non-living enbodiment, the coated microporous substrate can
include the micriporous material substrat having at least one surface described
above and which has a coating layer on at least one surface. The coating layer
can be the dried coating composition of the present invention and can include an
acrylic polymer, a polymeric nitrogen containing dye fixative compound and one
or more polyurethanes as described above.
The amount of the substantially dry coating applied to the substrate, or coat
weight, can be measured as coating weight per coated area. As used
herein and in the claims, "substantially dry" means that the coating layer feels
dry to the touch. The amount of coating can vary widely. In alternate non-
limiting embodiments, the amount of coating can be at least 0.001 gram per
square meter, or at least 0.01 gram per square meter, or at least 0.1 gram per
square meter. In alternate non-limiting embodiments, the amount of the coating
can be 50 gram per square meter or less, or 40 gram per square meter or less,
or 35 gram per square meter or less. The amount of the substantially dry
coating applied to the substrate can vary between any of the afore-specified
amounts.
The water-resistant ink jet recordable substrate of the present invention,
can be polymer processed. In alternate non-limiting embodiments, the substrate
can be laminated and/or molded. Lamination can be performed using a variety
of techniques known to one having ordinary skill in the art. In a non-limiting
embodiment, lamination can include bonding the ink jet recording substrate to at
least one layer of a substantially nonporous material. The water-resistant ink jet
recordable substrate can be bonded together with the substantially nonporous
material in the presence or the absence of an adhesive. As used herein,
"substantially nonporous" materials means those materials which are generally
impervious to the passage of liquids, gases, and bacteria.
Substantially nonporous materials for use in the present invention can
vary widely and can comprise those materials customarily recognized and
employed for their known barrier properties. Non-limiting examples of such
materials can include substantially nonporous thermoplastic polymers,
substantially nonporous metalized thermoplastic polymers, substantially
nonporous thermoset polymers, substantially nonporous elastomerics, and
substantially nonporous metals. The substantially nonporous material can be in
the form of a sheet, film, or foil, or other shapes can be used when desired, such
as for example, plates, bars, rods, tubes, and forms of more complex shape. In
one non-limiting embodiment, the substantially nonporous material for use in the
present invention can be in the form or a sheet, film or foil.
As used herein and the claims, the term "thermoplastic polymer" means a
polymer that can be softened by heat and then regain its original properties upon
cooling. The term "thermoset polymer" as used herein and the claims means a
polymer that solidifies or sets on heating and cannot be remelted.
Non-limiting examples of thermoplastic polymeric materials which are
suitable for use can include polyethylene, high density polyethylene, low density
polyethylene, polypropylene, poly(vinyl chloride), saran, polystyrene, high impact
polystyrene, nylons, polyesters such as polyethylene terephthalate), copolymers
of ethylene and acrylic acid, copolymers of ethylene and methacrylic acid, and
mixtures thereof. If desired, all or a portion of the carboxyl groups of carboxyl-
containing copolymers can be neutralized with sodium, zinc, or the like. A non-
limiting example of a metalized thermoplastic polymeric material can be
aluminized poly(ethylene terephthalate).
Non-limiting examples of thermoset polymeric materials can include
thermoset phenol-formaldehyde resin, thermoset melamine-formaldehyde resin,
and mixtures thereof.
Non-limiting examples of elastomeric materials can include natural rubber,
neoprene, styrene-butadiene rubber, acrylonitrile-butadiene-styrene rubber,
elastomeric polyurethanes, and elastomeric copolymers of ethylene and
propylene.
Non-limiting examples of metals can include but are not limited to iron,
steel, copper, brass, bronze, chromium, zinc, die metal, aluminum, and
cadmium.
In a non-limiting embodiment, a multilayer article comprising the present
invention can be constructed using a wide variety of known methods for
connecting at least one layer of an ink jet recordable substrate with at least one
layer of a substantially nonporous material. In one non-limiting embodiment, at
least one layer of a substantially water-resistant, at least partially coated ink jet
recordable substrate can be fusion bonded to at least one layer of a substantially
nonporous material. The ink jet recordable substrate generally comprises
opposed major surfaces which are characteristic of sheets, films, foils, and
plates. The resulting multilayer article can comprise one layer or more than one
layer of the ink jet recordable substrate and one layer or more than one layer of
the substantially nonporous material. In a non-limiting embodiment, at least one
exterior layer can be the ink jet recordable substrate. In an alternate non-limiting
embodiment, the ink jet recordable substrate can be a microporous substrate.
In one non-limiting embodiment, the multilayer article of the present
invention can be produced by fusion bonding in the absence of an adhesive.
Fusion bonding can be accomplished using conventional techniques such as
sealing through use of heated rollers, heated bars, heated plates, heated bands,
heated wires, flame bonding, radio frequency (RF) sealing, and ultrasonic
sealing. Solvent bonding can be used where the substantially nonporous
substrate is at least partially soluble in the applied solvent to the extent that the
substrate is at least partially soluble in the applied solvent to the extant that the
surface becomes tacky. The ink jet recordable substrate can be contacted with
the tacky surface, and the solvent then can be removed to form the fusion bond.
In a non-limiting embodiment, foamable compositions can be foamed in contact
with the ink jet recordable substrate to form a fusion bond between the foam
and the substrate. Films or sheets to form a fusion bond between the foam and
the substrate. The fusion bond can be permanent or peelable, depending upon
the known bonding technique and/or the nature of the substantially nonporous
substrate employed.
In one non-limiting embodiment, heat sealing can be used to fusion bond an
ink jet recordable substrate to a substantially nonporous material. In general,
heat sealing includes inserting the ink jet recordable substrate into standard heat
sealing equipment which is known in the art. In one non-limiting embodiment,
the ink jet recordable substrate can be inserted in conjunction with the
substantially nonporous material which can be a thermoplastic and/or thermoset
polymer. Heat and/or pressure can be applied to the substrate/polymer
construction for a period if time. The amount of heat and/or pressure and length
of time can vary widely. In general, the temperature, pressure and time can be
selected such that the substrate and polymer are at least partially connected
together to form a multiplayer article. In a non-limiting embodiment, the
temperature can be within the range of from 38°C-204°C. in another non-limiting
embodiment, the pressure can be within the range of from 0.34-1.7 X105 pas. In
a further non-limiting embodiment, the period of time can be in the range
of from one (1) second to thirty (30) minutes. The multilayer article can then be
cooled while under pressure for a typical period of time, such as thirty (30)
minutes. Although the strength of the bond formed between the substrate and
polymer can vary, in a 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 nonporous substrate
can be polyvinyl chloride.
In another non-limiting embodiment, the ink jet recordable substrate
employed in the present invention can be at least partially connected to a
nonporous substrate such as polyethylene and polypropylene by heat sealing In
the absence of an extrinsic adhesive. The resultant fusion bond can be
sufficiently strong which is surprising inasmuch as the lamination of materials to
polyolefins can be difficult unless adhesives are used.
In alternate non-limiting embodiments, the ink jet recordable substrate can
be substantially continuously at least partially connected to the substantially
nonporous substrate, or it can be discontinuously at least partially connected to
the substantially nonporous substrate. Non-limiting examples of discontinuous
bonds can include bonding areas in the form of one or more spots, patches,
strips, stripes, chevrons, undulating stripes, zigzag stripes, open-curved stripes,
closed-curved stripes, irregular areas, and the like. In a further non-limiting
embodiment, when patterns of bonds are involved, they can be random,
repetitive, or a combination of both.
In another non-limiting embodiment, an ink jet recordable substrate can
be connected to a substantially nonporous material in the presence of an
adhesive. The adhesive for use in the present invention can be selected from a
wide variety of adhesives known in the art. Non-limiting examples of suitable
adhesives include those having a sufficient molecular weight and viscosity such
that the adhesive will not substantially migrate into or substantially penetrate the
ink jet recordable substrate. Migration or penetration of the adhesive into the
substrate can reduce the tack and bond strength of the adhesive. Non-limiting
examples of suitable adhesives for use in the present invention can include but
are not limited to polyvinyl acetate, starches, gums, polyvinyl alcohol, animal
glues, acrylics, epoxies, polyethylene-containing adhesives, and rubber-
containing adhesives. In alternate non-limiting embodiments, the adhesive can
be applied to the substrate, or to the substantially nonporous material, or to both
the substrate and the substantially nonporous material. In a further non-limiting
embodiment, the adhesive can be introduced via the use of a tie carrier coating.
The process of bonding the substrate and substantially nonporous
material in the presence of an adhesive generally includes inserting inserting the
substrate/adhesive/material construction into standard processing equipment
which is known in the art. Heat and/or pressure can be applied to the
substrate/adhesive/material construction for a period of time. The amount of
heat and/or pressure and length of time can vary widely. In general, the
temperature, pressure and time are selected such that the substrate and
substantially nonporous material are at least partially connected together to form
a multi-layer article. A typical temperature can be within the range of from 38°C-
204°C. A typical pressure can be within the range of from one (1) second to
thirty (30) minutes. The multilayer article may then be cooled under pressure for
a typical time period, such as thirty (30) minutes. Although the strength of the
bond formed between the ink jet recordable substrate and the substantially
nonporous material can vary, the bond generally can be such that it typically
exceeds the tensile properties of the substrate alone.
In one non-limiting embodiment of the present invention, an ink jet
recordable substrate can be molded using a variety of conventional molding
techniques known in the art, which can include but are not limited to
compression molding, rotational molding, injection molding, calendaring, roll/nip
laminating, thermoforming vacuum forming, extrusion coating, continuous belt
laminating and extrusion laminating.
In alternate non-limiting embodiments, the substrate can be molded in the
presence or the absence of a substantially nonporous material, such as a
thermoplastic and/or thermoset polymer. In general, the ink jet recordable
substrate is inserted into standard molding equipment which is known in the art.
In one non-limiting embodiment, a thermoplastic and/or thermoset polymer is
introduced onto the substrate and then the substrate/polymer construction is
inserted into the mold cavity. In another one non-limiting embodiment, the
substrate is placed into the mold cavity and then the thermoplastic and/or
thermoset polymer is introduced onto the substrate. Heat and/or pressure can be
applied to the substrate/polymer construction for a period of time. The amount
of heat and/or pressure and time length of time can vary widely. In general, the
temperature, pressure and time are selected such that the substrate and polymer
are at least partially connected together to form a multi-layer article. A typical
temperature can be within the range of form a multi-layer article. A typical
temperature can be within the range of from 38°C-204°C. In a non-limiting
embodiment, wherein the polymer comprises a thermoplastic polymer, the
substrate/polymer construction can be heated to a temperature that equals or
exceeds the melt temperature of the thermoplastic polymer. In one non-limiting
embodiment, where the thermoplastic polymer can be amorphous, the substrate
polymer construction can be heated to a temperature that equals or exceeds the
Vicat temperature. In an alternative non-limiting embodiment, wherein the
polymer comprises a thermoset polymer, the temperature can be below the
curing or crosslinking temperature of the polymer. A typical pressure can be
within the range of from 0.34-1.7 X 105pas and a typical period of time can be in
the range of from one (1) second to fifteen (15) minutes. The result of a typical
molding process is a re-shaping is generally defined by the design of the mold
cavity. Thus, in a standard molding process,, a two-dimensional flat sheet can be
re-shaped into a three-dimensional article.
In one non-limiting embodiment of the present invention, the ink jet
recordable substrate comprises Teslin which is available from PPG industries,
Incorporated in Pittsburgh, PA. The thickness of the ink jet recordable substrate
of the present invention varies widely depending on the application for use. In
one non-limiting embodiment, the ink jet recordable substrate can be from 127-
508(µm thick. In one non-limiting embodiment, other tie coatings known in the
art can be used in conjunction with the substrate and the substantially
nonporous material.
In a non-limiting embodiment, a friction-reducing coating composition can
be at least partially applied to at least one of the ink jet recordable substrate and
the substantially nonporous material. In a further non-limiting embodiment, the
friction-reducing coating composition can comprise at least one lubricant and at
least one resin. There are a wide variety of lubricants and resins known to the
skilled artisan that could be useful herein. Non-limiting examples of such
suitable lubricants can include natural and synthetic waxes, natural and synthetic
oils, polypropylene waxes, polyethylene waxes, silicone oils and waxes,
polyesters, polysiloxanes, hydrocarbon waxes, carnauba waxes, microcrystalline
waxes and fatty acids, and mixtures thereof. In a non-limiting embodiment, the
lubricant for use in the present invention can include polysiloxanes, such as but
not limited to silicone.
Non-limiting examples of suitable resins can include polyurethanes,
polyesters, polyvinyl acetates, polyvinyl alcohols, epoxies, polyamides,
polyamines, polyalkylenes, polypropylenes, polyethylenes, polyacrylics,
polyacrylates, polyalkylene oxides, polyvinyl pyrrolidones, polyethers,
polyketones, and co-polymers and mixtures thereof. In a non-limiting
embodiment, the resin for use in the present invention can include styrene
acrylic polymers such as but not limited to styrene acrylic-comprising
polyurethanes, polyepoxies, polyvinyl alcohols, polyesters, polyethers, and co-
polymers and mixtures thereof.
In a further non-limiting embodiment, the friction-reducing coating
composition for use in the present invention can include Wikoff SCW 4890 and
2295 which are commercially available from Wikoff Industries, Incorporated, as
poly board aqua coat products.
Not intending to be bound by any particular theory, it is believed that the
molecules of the resin component of the friction-reducing coating can be at least
partially interconnected or interlinked with the ink jet recordable substrate and/or
the substantially nonporous material, such that the silicone can be essentially
fixed to the surface of said substrate and/or said material. In a non-limiting
embodiment, the molecules of a thermoplastic resin component can be
interconnected by fusion to the ink jet recordable substrate and/or the
substantially nonporous material. In another non-limiting embodiment, the
molecules of a thermoset resin component can be interlinked by crosslinking to
the ink jet recordable substrate and/or the substantially nonporous material.
In a further non-limiting embodiment, the friction-reducing coating
composition can comprise water and/or an organic solvent. A wide variety of
organic solvents known to the skilled artisan can be useful herein. Non-limiting
examples of such suitable organic solvents can include but are not limited to M-
methyl pyrrolidone (NMP), methyl ethyl ketone (MEK), acetone, diethyl ether,
toluene, Dowanol PM, Butyl Cellosolve, and mixtures thereof. In a non-limiting
embodiment, the friction-reducing coating composition can organic solvent,
wherein said organic solvent at least partially miscible with water.
In a non-limiting embodiment, the friction-reducing coating composition
can be at least partially applied to at least one of the ink jet recordable substrate
and the substantially nonporous material of the present invention. Application of
said friction-reducing coating composition to said substrate and/or said material
can employ a wide variety of known techniques. In alternate non-limiting
embodiments, the techniques described previously herein for applying the
substantially water-resistant coating to the ink jet recordable substrate can be
used for application of the friction-reducing coating composition to the ink jet
recordable substrate and/or the substantially nonporous material.
The amount of the substantially dry friction-reducing coating applied to
the substrate/material, or "coat weight", is typically measured as coating weight
per coated area. The coat weight can vary widely. In alternate non-limiting can
be at least 0.1 gram per square meter, or from greater than 0 to 50 grams per
square meter, or from 1 gram per square meter to 15 grams per square meter.
In a non-limiting embodiment, the multilayer article of the present
invention can include 254µm thick sheet of Teslin comprising a substantially
water-
resistant coating comprising, a 254µm sheet of polyvinylchloride, a 254µm thick
sheet of polyvinylchloride, and a 50.84m thick sheet polyvinylchloride
comprising a friction-reducing coating composition. In a further non-limiting
embodiment, the friction-reducing coating composition can comprise a
polysiloxane and a styrene acrylic polymer.
The multilayer article of the present invention has many and varied uses
including gaskets, cushion assemblies, signs, cards, printing substrates,
substrates for pen and ink drawings, maps (particularly maritime maps), book
covers, book pages, wall coverings, and seams, joints, and seals of breathable
packages.
The multilayer article of the present invention can be useful for the
purpose of decorating or identifying the substantially nonporous material, or
imparting to the substantially nonporous material unique properties of the
substrate surface. The ink jet recordable substrate can be decorated with a
variety of methods including: offset/lithographic printing, flexographic printing,
painting, gravure printing, inkjet printing, electrophotographic printing,
sublimation printing, thermal transfer printing, and screen printing. Decorating
can also include applying a single or multilayer coating to the ink jet recordable
substrate via normal coating methods known in the art. In general, the unique
properties that an ink jet recordable substrate can impart on a substantially
nonporous material include, but are not limited to one or more of: improved
surface energy, increased porosity, decreased porosity, increased bond strength
of post coat layer, and modification of the polymer's surface texture or pattern.
Polymer processing techniques are disclosed in U.S. Patent No.
4,892,779, which is incorporated herein by reference.
The present invention is more particularly described in the following
examples, which are intended to be illustrative only, since numerous
modifications and variations therein will be apparent to those skilled in the art.
Unless otherwise specified, all parts and percentages are by weight and all
references to water are meant to be deionized water.
In the following examples, the term "Teslin" refers to Teslin TS 1000,
unless otherwise stated.
EXAMPLES
Example 1
In preparing a coating composition of the present invention, a 31%
polydimethyldiallylammonium chloride sold under the trade name CinFix RDF
available from Stockhausen GmbH & Co. KG, Krefeld, Germany was diluted to
10% with deionized water in a stainless steel or polyethylene mix vessel under
mild agitation. Mild agitation defined by a medium pitch three lobed mixing head,
the system at a mix-head to mix vessel diameter ratio of 1 to 3 and the mix-head
spinning at 600 -1000 rpm and appropriately positioned: In a separate mix
container, a 29% aqueous cationic acrylic solution sold under the name WC-71-
2143 available from PPG Industries, Inc. is diluted with deionized water to 10%
and added to the main mix vessel containing pre diluted CinFix RDF. In a •
separate mix container, a 30% aqueous cationic polyurethane dispersion sold
under the trade name Witcobond W240 available from Crompton Corporation is
diluted with deionized water to 10% and added to the main mix vessel containing
the CinFix RDF and PPG WC-71-2143 mixture. The resultant coating
composition is stirred for 15 minutes. The resultant pH was 5.5 +/- 0.5. The
total solids of the composition was 10% and a viscosity of 56cps measured using
a Brookfield viscometer, RVT, spindle no. 1, at 50 rpm and 25°C.
For comparison with 8181-67-09, other coating compositions were
produced using alternate CinFix additives and polyurethane dispersions with or
without WC-71-2143.

All values are in parts by weight (pbw).
Ingredients:
CinFix NF - a 50-60% active aqueous solution of poly(quaternary amine)
polymer (CAS No. 68583-79-9) from Stockhausen GmbH & Co. KG, Krefeld,
Germany
CinFix 167 - a 50-60% active aqueous solution of poly(quaternary amine)
(Composition -Trade Secret) from Stockhausen GmbH & Co. KG, Krefeld,
Germany
CinFix RDF - a 30-35% active aqueous solution of poly(quaternary amine)
polymer (CAS No. 26062-79-3) from Stockhausen GmbH & Co. KG, Krefeld,
Germany
WitcoBond W-234 - a 30-35% solids water-based dispersion of an anionic
aliphatic urethane from Uniroyal Chemical of Middlebury, CT.
WitcoBond X-051 - a 30-35% solids water-based dispersion of a cationic
urethane from Uniroyal Chemical of Middlebury, CT
WitcoBond W-240 - a 30-35% solids water-based self-cross linking anionic
polyurethane dispersion from Uniroyal Chemical of Middlebury, CT
WC-71-2143 - a 25-30% solids aqueous dispersion of a cationic acrylic polymer
from PPG Industries of Pittsburgh, PA.
PPG formulation no. WC-71-2143 is as an aqueous secondary amine and
hydroxyl functional acrylic polymer prepared via solution polymerization. Also
described as a cationic acrylic polymer aqueous dispersion. WC-71-2143 was
prepared as follows.

% 2'-Azobis(2-methyibutanenitrile) initiator commercially available from E.I. du
Pont de Nemours and company, Wilmington, Delaware
The initial charge was heated in a rector with agitation to reflux temperature
(80°C). The Feed 1 was added in a continuous manner over a period of 3 hours.
At the completion of feed 1 addition, the reaction mixture was held at reflux for
3 hours. The resultant acrylic polymer solution had a total solids content of 61.7
percent (determined by weight difference of a sample before and after heating at
110°C. for one hour) and number average molecular weight of 4792 as
determined by gel permeation chromatography using polystyrene as the
standard. Thereafter, Feed 2 was added over five minutes at room temperature
with agitation. After the completion of the addition of freed 2, Feed 3 was added
over 30 minutes while the reaction mixture was heated for azeotropic distillation
of isopropanol. When the distillation collected was 550.6 grams. The product,
which was a cationic acrylic polymer aqueous solution, had a solids content of
32.6 percent by weight (determined by weight difference of a sample before and
after heating at 110°C. for one hour), and a pH of 5.25.
Note: All % solids values are % by weight.
Coatings were applied to bank 21.6 X 27.9 cm TS 1000 sheet. Coating weight is
measured by difference using an electronic balance.
• The blank sheet is weight.
• Coating is applied to the front side using a #9 wire-wrapped rod.
• The sheet is baked at 95° C in a textile oven (Model LTF from Werner Mathis
AG, Zurich, Switzerland) for 2 minutes.
• The sheet is removed from the oven and coating is applied to the backside
using a #9 wire-wrapped rod.
• The sheet is re-baked at 95° C in the textile oven for 2 minutes.
• The sheet is removed, allowed to cool to the touch and reweighed.
• Coating weight in milligrams/square-inch is determined by dividing weight
difference in milligrams by coated area.
The dynamic viscosity of the mixed coatings was measured using a #2 Zahn cup
and the static viscosity was measured using a Brookfield Model DV-1+
viscometer using a #2 spindle at 100 rpm.
Test prints from the coated Teslin sheets were generated off of an HP960C
printer, set to normal default print mode. Optical density values were measured
using an X-Rite® densitometer, model type 418, normalized against a Macbeth®
black/white plate.
Test prints were also generated using uncoated Teslin TS1000 for comparison.
Optical density values are listed in the following table.
Coating 8181-67-09 is clearly the best overall in optical density performance of
all the examples as is illustrated in the following graphic representation of the
previous Table. The use of WC-71-2143 in the formula provides improved
optical density over polyurethane dispersion-only formulas.
Coating 8181-67-09 was applied to 8½" x 11" sheets of Teslin® TS1000 and
SP 1000 and cured as described above. Test prints from the coated Teslin
sheets were generated off of an HP960C printer, set to normal default print
mode. Optical density values were measured using an X-Rite® densitometer,
model type 418, normalized against a Macbeth® black/white standard plate.
Optical density values are listed in the following table.
Example 2
Coating composition prepared as in example 1 and was applied to a 500ft
roll of 10.5mil Teslin TS1000 microporous substrate by a flexographic or gravure
coating method. In this coating method, a line consisting of two coating station,
each with a forced air drying oven was used. Each coating station consists of a
coating feed chamber, anilox roll and rubber application roll. The coating feed
chambers were supplied from a coating holding tank and pump. Continuous roll
stock was threaded through the equipment so that both side were coated during
a single pass. The apparatus was fitted with a 7BCM (billion cubic microns) roll
and a 5BCM anilox roll. Successive passes were arranged so that both sheet
surfaces contacted the rubber roll wet by each anilox roll type at least once. The
complete coating sequence is described as follows: Pass #1 (7bcm-face/5bcm-
back) + Pass #2 (7bcm-face/5bcm-back) + Pass #3 (5bcm-face/7bcm-back).
The line speed was 73m/um, oven temperature was 105°C (220°F) and 3 passes
per roll were made, which translates into 3 passes per surface. The coating
composition was applied with an approximate coat weight of 0.73g/m2 (total
front and back). The resultant roll was converted into 8.5" X 11" sheets, grain
long. Test prints were generated off an HP960C printer, set to normal default
print mode. Both sides of the substrate were printed. Optical density values were
measured using an X-Rite® densitometer, model type 418, normalized against a
Macbeth® black/white standerd plate. Optical densities values are listed in the
following table.

In addition to optical density the prints had good overall aesthetics, distinctness
of image and quality.

Example 3
Two 6,600ft rolls 287µm TS1000 were sized with coating composition
described in example 1 in the same manner as described in example 2. the
resultant rolls was converted into 8.5" X ll"sheets, grain long. Test prints were
generated off of an HP960C printer set to normal default print mode and best ink
jet photo grade matte finish. Both sides of the substrate were printed. Optical
density values were measured using an X-Rite® densitometer, model type 418,
normalized against a Macbeth® black/white standard plate. Optical densities
values are listed in the following table.
In addition to the optical density values, the prints generated using best mode
had better image quality compared to normal mode prints. These same images
printed using best mode had very good pigmented ink adhesion as measured
using a coin rub test. The printed surface was rubbed with a coin until the
substrate began to fatigue and fail.
The printed surface maintained an acceptable distinctness of image with very
little ink rub off.
Example 4
A treated sheet (sample A) from the substrate prepared in the previous
example was printed with a test print pattern; using printer type HP960c set on
best mode, ink jet photo grade matte finish. The optical density of color bars
representing the five primary color/ink types: composite black, cyan, magenta,
yellow and pigment black were measured. The printed color bars were
submerged in de-ionized water for 24 hours and the resultant optical densities
measured. The procedure was then repeated after a total of 96 hours of
continuous soaking. The test was repeated on two additional samples (B & C)
from the same lot of substrate and both printed in the same manner. The optical
density values are given in the following tables.
Optical Density Retention (Sample C)
All color bars remained solid after 96hours of soaking time. Also only some slight
bleed was off of the composite and pigment black color bars. Bold 10point font
that was part of the test print samples remained legible.
Example 5
Several 6,600ft rolls of 287µm Teslin TSlOOOwere sized with coating
composition described in example 1 in accordance the technique described in
example 2. The resultant rolls was converted into 8.5" X 11" sheets, grain long.
Test prints were generated off of an HP960C printer, set to best ink jet photo
grade matte finish. Both sides of the substrate were printed. The optical density
of color bars representing the five primary color/ink types: composite black,
cyan, magenta, yellow and pigment black were measured. The printed color bars
were submerged in tap water for 15minutes and the resultant optical densities
measured. The procedure was then repeated after a total of 24hours of
continuous soaking. The optical density values are given in the following tables.
Optical Density Retention - Side A
24hrs, Tap Water
Optical Density Retention - Side B
24hrs, Tap Water
All color bars remained solid after 24hours of soaking time in tap water. No
bleed was visible off of any of the colors. Bold 10point font that was part of the
test print samples, printed in composite black maintained good optical clarity.
Example 6
Samples collected after two coating passes during the campaign
described in the previous example were converted into 8.5" x 11" sheets, grain
long and tested. Test prints were generated off of an HP960C printer, set to best
ink jet photo grade matte finish. Both sides of the substrate were printed. The
optical density of color bars representing the five primary color/ink types:
composite black, cyan, magenta, yellow and pigment black were measured. The
printed color bars were submerged in tap water for 15minutes and the resultant
optical densities measured. The procedure was then repeated after a total of
24hrs of continuous soaking. The optical density values are given in the
following tables.
In addition to the optical density retention results, a slight amount of bleed was
visible off of both the composite and pigment black inks after 24 hours of water
soak time. The 24 hour soaked samples had a very minor grainy pattern and the
all printed text maintain good optical clarity.
Example 7
Substrate samples were produced in accordance with operational settings
outlined in example 2, with the exception of coating sequence and with the
coating adjusted from 10% to 7% active solids. Samples were collected after 2,
3 and 4 passes. The coating sequence followed for the 2 pass samples is: Pass
#1 (7bcm-face/5bcm-back) + Pass #2 (5bcm-face/7bcm-back). The coating
sequence followed for the 3 pass samples is: Pass #1 (7bcm-face/5bcm-back) +
Pass #2 (7bcm-face/5bcm-back) + Pass #3 (5bcm-face/7bcm-back). The
coating sequence followed for the 4 pass samples is: Pass #1 (7bcm-
face/5bcm-back) + Pass #2 (7bcm-face/5bcm-back) + Pass #3 (5bcm-
faceA7bcm-back) + Pass #4 (5bcm-face/7bcm-back). The samples collected
after two, three and four coating passes were converted into 8.5" x 11" sheets,
grain long and tested. Test prints were generated off of an HP960C printer, set
to best ink jet photo grade matte finish. Both sides of the substrate were printed.
The optical density of color bars representing the five primary color/ink types:
composite black, cyan, magenta, yellow and pigment black were measured. The
printed color bars were submerged in tap water for 15minutes and the resultant
optical densities measured. The procedure was then repeated after a total of
24hrs of continuous soaking. The optical density values are given in the
following tables.
Optical Density Retention - Side A, 7% solids, 2 - pass
24hrs, Tap Water
In addition to optical density retention, differences were observed in the print
quality following the 24hour tap water soak. The 2 and 3 pass samples became
grainy following 24-hour water soak. The grainy appearance was more obvious
for the 2-pass sample than for the 3 pass sample. Some bleed was visible off of
the composite and pigmented black color bars. Bleed resistance improved as the
number of coating passes increased. Bold lOpoint font that was part of the test
print samples, printed in composite black maintained good optical clarity for all
three sample types.
Example 8
Two 6,600ft rolls of 287µm Teslin TS1000 were sized with coating
composition described in example 1, formulated at 12.5% active solids in
accordance with operational settings described in example 2. The prints were
generated off the substrate were printed. Optical density values were measured
using an X-Rite® densitometer, model type 418, normalized against a Macbeth®
black/white standard plate. Optical densities values are listed in the following
table.
In addition to optical density the prints had excellent overall aesthetics,
distinctness of image and quality.
Example 9
A coating composition prepared as in example 1, with the exception that
the resultant solids content was 12.5% instead of 10%. The coating composition
was applied to a 2012m roll of 283µm Teslin SP1000 microporous substrate by a
flexographic or gravure coating method as described in example 2. The resultant
roll was converted into 8.5" X 11" sheets, grain long. Test prints were generated
off of an HP960C printer, set to best ink jet photo grade matte finish. Both sides
of the substrate were printed. Optical density values were measured using an X-
Rite® densitometer, model type 418, normalized against a Macbeth® black/white
standard plate. Optical densities values are listed in the following table.
In addition to optical density the prints had good overall aesthetics, distinctness
of image and quality.
Composite Sheet and Card Fabrication
Example 10 - Hydraulic Platen Lamination (One Composite Sheet)
Sheet 66 X 97cm of treated Teslin TS1000 substrate 287µm thick, were
cut from a master roll in the grain long direction. The Teslin had been coated
with 3 passes on each side (3 X 3) using the same coating composition as
described in example 1 and the same Flexographic coating technology described
in example 2. One coated Teslin sheet was placed on top of one 26-inch X 38-
inch sheet of 0.21-inch polyvinylchloride (PVC), supplied by Empire Plastic. The
PVC sheet was cut in the grain long direction. A sheet (69 X 99cm) of (50.8µm)
clear polyester was placed over the Teslin sheet to act as a release liner. (Note!
This release liner is removed from the composits sheets.) This construction was
placed between two 69 X 99cm X 762µm polished stainless steel metal plate.
The resultant stack was then placed between two 69 X 99cm X 3.175mm unpolished
non-corrosive metal plates. This entire construction was placed in a
200- Ton Wabash laminating press, preheated to 104°C. The composite
construction was compression laminated pressure of 13.8 X 105 pas for 8minutes
at a temperature of 104°C. While under press, the platens were cooled to less
than 38°C, which took approximately 22minutes. After being removed from the
press, the resultant composite sheet had good integrity; any attempt to
delaminate destroyed the Teslin layer, which demonstrated a good adhesive and
seamless bond between the Teslin layer, which demonstrates a good adhesive
and cut from the resultant 66 X 97cm X 795µm composite sheet. The finished
cards had good integrity and good lat flat. Any attempt to delaminate destroyed
the Teslin layer, which demonstration a good adhesive and seamless bond
between the Teslin and the PVC.
Example 11- Hydraulic Platen Lamination (Four Composite Sheet/Book)
Sheet 66 X 970cm of treated Teslin Substrate 987µm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastic. The PVC sheet was cut in the
grain long direction. A sheet 69 X 99cm of 50.8um clear polyester was placed
over the Teslin sheet to act as a release liner. This construction was placed
between two (69 X 99cm) X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated twice more
so that four pre-pressed multi-layer ply's existed in the stack. The resultant stack
was then placed between two 69 X 99cm X 1.175µm un-polished non-corrosive
metal plates. This entire construction, referred to as a book, was placed in a 200-
Ton Wabash laminating press, preheated to 104°C. The composite construction
was compression laminated at a pressure of 13.8 X 105 pas for 8 minutes at a
temperature of 109°C. While under press, the platens were cooled to less than
38°C, which took approximately 22minutes. After being removed from the press,
all four finished composite sheets had good integrity; any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC. ISO7910 ID-1 cards were die cut from the
each of the 66 X 97cm X 775µm composite sheets. The finished cards from each
composite sheet had good integrity and good lat flat. Any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC.
Example 12 - Hydraulic Platen Lamination (10 Composite Sheets/Book)
Sheets 66 X 97cm of treated Teslin substrate, 287µm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one (66 X 97cm) sheet of 0.5cm
polyvinylchloride (PVC), supplied by Empire Plastic. The PVC sheet was cut in the
grain long direction. A sheet (69 X 99cm) of 50.8cm clear polyester was placed
over the Teslin sheet to act as a release liner. This construction was placed
between two 69 X 99cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated eight more
times so that ten pre-pressed multi-layer ply's existed in the stack. The resultant
stack was then placed between two 69 X 99cm un-polished non-corrosive metal
plates. This entire construction, referred to as a book, was placed in a 200-Ton
Wabash laminating press, preheated to 104°C. The composite construction was
compression laminated at a pressure of 13.8 X 105pas for 8minutes at a
temperature of 104°C. While under press, the platens were cooled to less than
38°C, which took approximately 22minutes. After being removed from the press,
all ten composite sheets were removed from the book. All ten finished composite
sheets had good integrity; any attempt to delaminate destroyed the Teslin layer,
which demonstrated a good adhesive and seamless bond between the Teslin and
the PVC. ISO7910 ID-1 cards were die cut from the each of the 66 X 97cm X
775µm composite sheets. The finished cards from each composite sheet had
good integrity and good lat flat. Any attempt to delaminate destroyed the Teslin
layer, which demonstrated a good adhesive and seamless bond between the
Teslin and the PVC.
Example 13 - (10 composite Sheets/Book. Other Process Conditions)
Sheets 26-inch X 38-inch of treated Teslin substrate, 287µm thick, were
out from a master roll in the grain long direction. The Teslin had been coated
with 3 passes on each side (3 X 3) using the same coating composition as
described in example 1 and the same Flexographic coating technology described
in example 2. One coated Teslin sheet was placed on top of one 66 X 97cm
sheet of 0.21-inch polyvinylchloride (PVC), supplied by Empire Plastics. The PVC
sheet was cut in the grain long direction. A sheet 69 X 99cm of 50.8µm clear
polyester was placed over the Teslin sheet to act as a release liner. This
construction was placed between two 69 X 99cm X 762µm polished stainless
steel metal plate. An identical polyester/treated Teslin sheet/PVC lay-up was
placed on top of a stainless plate from the existing construction. A polished metal
plate was placed over the exposed polyester release liner. The pattern was
repeated eight more times so that ten pre-pressed multi-layer ply's existed in the
stack. The resultant stack was then placed between two 69 X 99cm X 3.175mn
un-polished non-corrosive metal plates,, This entire construction, referred to as a
book, was placed in a 200-Ton Wabash laminating press, preheated to 93°C. The
composite construction was compression laminated at a pressure of 12.4 X 105
pas for 6minutes at a temperature of 93°C. While under press, the platens were
cooled to less than 28°C, which took approximately 18minutes. After being
removed from the press, all ten composite sheets were removed from the book.
All ten finished composite sheets had good integrity; any attempt to delaminate
destroyed the Teslin and the PVC. ISO7910 ID-1 cards were die cut from the
each of the 66 X 97cm X 775µm composite sheets. The finished cards from each
composite the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC.
Example 14 - (10 Composite Sheets/Book, Other Process Conditions)
Sheets 66 X 97cm of treated Teslin substrate, 287um thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same Flexographic coating technology
described in example 2. One coated Teslin sheet was placed on top of one 66 X
97cm sheet of 0.53cm polyvinylchloride (PVC), supplied by Empire Plastic. The
PVC sheet was cut in the grain long direction. A sheet 69 X 99cm of 50.8µm clear
polyester was placed between two 69 X 99cm X 762µm polished stainless steel
metal plate. An identical polyester/treated Teslin sheet/PVC lay-up was placed on
top of a stainless plate from the existing construction. A polished metal plate was
placed over the exposed polyester release liner. The pattern was repeated eight
more times so that ten pre-pressed multi-layer ply's existed in the stack. The
resultant stack was then placed between two 69 X 99cm X 3.175mn un-polished
non-corrosive metal plates. This entire construction, referred to as a book, was
placed in a 200-TON Wabash laminating press, preheated to 149°C. The
composite construction was compression laminated at a pressure of 17.23 X 105
pas for 10minutes at a temperature of 149°C. While under press, the platens
were cooled to less than 38°C, which took approximately 25minutes. After being
removed from the press, all ten composite sheets were removed from the book.
All ten finished composite sheets had good integrity; any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC. ISO7910 ID-1 cards were die cut from the
each of the 66 X 97cm X 775µm composite sheets. The finished cards from each
composite sheet had good integrity and good lat flat. Any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC.
Example 15 - (7 Composite Sheets/Book. Other Process Condition)
Sheets 66 X 97cm of treated Teslin substrate, 287µm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. one coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastic. The PVC sheet was cut in the
grain long direction. A sheet 69 X 99cm of 50.8µm clear polyester was placed
between two 69 X 99cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated six more
times so that seven pre-pressed multi-layer ply's existed in the stack. The
resultant stack was then placed between two 69 X 99cm X 3.175µm un-polished
non-corrosive metal plates. This entire construction, reffered to as a book, was
placed in a 200-Ton Wabash laminating press, preheated to 104°C. The
composite construction was compression laminated at a pressure of 15.16 X
105pas for 7 minutes at a temperature of 104°C. While under press, the platens
were cooled to less than 38°C, which took approximately 22minutes. After being
removed from the press, all seven composite sheets were removed from the
book. All seven finished composite sheets had good integrity; any attempt to
delaminate destroyed the Teslin layer, which demonstrated a good adhesive and
seamless bond between the Teslin and the PVC. ISO7910 ID-1 cards were die
cut from the each of the 66 X 97cm X 775um composite sheets. The finished
cards from each composite sheet had good integrity and good lat flat. Any
attempt to delaminate destroyed the Teslin layer, which demonstrated a good
adhesive and seamless bond between the Teslin and the PVC.
Example 15 -(7 Composite Sheet/Book. Other Process Condition)
Sheet 66 X 97cm of treated Teslin substrate, 287pm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastic. The PVC sheet was cut in the
grain long direction. A sheet 69 C 99cm of 50.8µm clear polyester was placed
over the Teslin sheet to act as a release liner. This construction was placed
between two 69 X 99cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated six more
times so that seven pre-pressed multi-layer ply's existed in the stack. The
resultant stack was then placed between two 69 X 99cm X 3.175µm un-polished
non-corrosive metal plates. This entire construction, referred to as a book, was
placed in a 200-Ton Wabash laminating press, preheated to 104°C. The
composite construction was compression laminated at a pressure of 15.16 X 105
pas for 7 minutes at a temperature of 104°C. While under press, the platens
were cooled to less than 38°C, which took approximately 22 minutes. After
being removed from the press, all seven composite sheets were removed from
the book. All seven finished composite sheets had good integrity; any attempt to
delaminate destroyed the Teslin layer, which demonstrated a good adhesive and
seamless bond between the Teslin and the PVC. ISO7310 ID-1 cards were die
cut from the each of the 66 X 97cm X 775µm composite sheets. The finished
cards from each composite sheet had good integrity and good lat flat. Any
attempt to delaminate destroyed the Teslin layer, which demonstrated a good
adhesive and seamless bond between the Teslin and the PVC.
Example 16 -(7 Composite Sheet/Book. Other Process Condition)
Sheets 66 X 91cm of treated Teslin substrate, 287pm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut in
the grain long direction. A sheet 69 X 99cm of 50.8µm clear polyester was placed
between two 69 X 99cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A pattern was repeated six more
times so that seven pre-pressed multi-layer ply's existed in the stack. The
resultant syack was then placed between two 69 X 99cm X 3.175µm un-polished
non-corrosive metal plates. This entire construction, referred to as a book, was
placed in a 200-Ton Wabash laminating press, preheated to 93°C. The composite
construction was compression laminated at a pressure of 17.23 X 105pas for
7minutes at a temperature of 93°C. While under press, the platens were cooled
to less than 38°C, which took approximately 22minutes. After being removed
from the press, all seven composite sheets were removed from the book. All
seven finished composite sheets had good integrity; any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC. ISO7910 ID-1 cards were die cut from the
each of the 66 X 97cm X 762µm composite sheets. The finished cards from each
composite sheet had good integrity and good lat flat. Any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC.
Example 16A -(7 Composite Sheet/Bookf Other Process Conditions)
Sheets 66 X 97cm of treated Teslin substrate, 287µm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut in
the grain long direction. A sheet 69 X 99cm of 50.8um clear polyester was placed
over the Teslin sheet to act as a release liner. This construction was placed
between two 69 X 99cm X 762um polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated six more
times so that seven pre-pressed multi-layer ply's existed in the stack. The
resultant stack was then placed between two 69 X 99cm X 3.175µm un-polished
non-corrosive metal plates. This entire construction, referred to as a book, was
placed in a 200-Ton Wabash laminating press, preheated to 149°C. The
composite construction was compression laminated at a pressure of 6.2 X 105pas
for 7minutes at a temperature of 149°C. While under press, the platens were
cooled to less than 38°C, which took approximately 26minutes. After being
removed from the press, all seven composite sheets were from the book. All
seven finished composite sheets had good integrity; any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC. ISO7910 ID-1 cards were die cut from the
each of the 66 X 97cm X 775µm composite sheets. The finished cards from each
composite sheet had good integrity and good lat flat. Any attempt to delaminate
destroyed the Teslin layer, which demonstrated a good adhesive and seamless
bond between the Teslin and the PVC.
Example 17 -(7 Composite Sheet/Book, Other Process Conditions)
Sheets 66 X 97cm of treated Teslin substrate, 287pm thick, were cut from
a master roil in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastic. The PVC sheet was cut in the
grain long direction. A sheet 69 X 99cm of 50.8pm clear polyester was placed
between two 69 X 99cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated six more
times so that seven pre-pressed multi-layer ply's existed in the stack. The
resultant stack was then placed between two 69 X 99cm X 3.175µm un-polished
non-corrosive metal plates. This entire construction, referred to as a book, was
placed in a 200-Ton Wabash laminating press, preheated to 149°C. The
composite construction was compression laminated at a pressure of 17.23 X
105pas for 7minutes at a temperature of 149°C. While under press, the platens
were cooled to less than 38°C, which took approximately 26minutes. After being
removed from the press, all seven composite sheets were removed from the
book. All seven finished composite sheets had good integrity; any attempt to
delaminate destroyed the Teslin layer, which demonstrated a good adhesive and
seamless bond between the Teslin and the PVC. ISO7910 ID-1 cards were die
cut from the each of the 66 X 97cm X 775µm composite sheets. The finished
cards from each composite sheets had good integrity and good lat flat. Any
attempt to delaminate destroyed the Teslin layer, which demonstrated a good
adhesive and seamless bond between the Teslin and the PVC.
Example 18 -(7 Composite Sheet/Book. Other Process Condition - failed)
Sheets 66 X 97cm of treated Teslin substrate, 287µm thick, were cut from
a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 66 X 97cm sheet of 0.53cm
polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut in
the grain long direction. A sheet 69 X 99cm of 50.8pm clear polyester was placed
over the Teslin sheet to act as a release liner. This construction was placed
between two 69 X 99cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC lay-up was placed on top of a
stainless plate from the existing construction. A polished metal plate was placed
over the exposed polyester release liner. The pattern was repeated six more
times so that seven pre-pressed multi-layer ply's existed in the stack. The
resultant stack was then placed between two 69 X 99cm X 3.175µm un-polished
non-corrosive metal plates. This entire construction, referred to as a book, was
placed in a 200-Ton Wabash laminating press, preheated to 93°C. The composite
construction was compression laminated at a pressure of 6.2 X 105pas for
7minutes at a temperature of 93°C. While under press, the platens were cooled
to less than 38°C, which took approximately 20minutes. After being removed
from the press, all seven composite sheets were removed from the book. The
Teslin/PVC were pealed apart, indicating lack of bond strength. No attempt to
febricate ISO7910 ID-1 cards was made.
Example 19 -(12 Composite Sheet/Book. Other Process Conditions)
Sheets 51 X 63.5cm of treated Teslin substrate, 287µm thick, were cut
from a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
in example 1 and the same Flexographic coating technology described in
example 2. One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet
of 0.10-inch polyvinylchloride (PVC), supplied by Empire
plastic. The PVC sheet was cut in the grain long direction. Below the PVC ply was
a second ply of 51 X 63.5cm X 254µm PVC, cut grain short. Below the 254µm
PVC grain short ply was a 51 X 63.5cm X 50.8µm PVC sheet cut grain long. A
sheet 53 X 66cm of 50.8µm clear polyester was placed over the Teslin sheet to
act as a release liner. This construction was placed between two 53 X 66cm X
762µm polished stainless steel metal plate. An identical polyester/treated Teslin
sheet/PVC/PVC/PVC lay-up was placed on top of a stainless plate from the
existing construction. A polished metal plate was placed over the exposed
polyester release liner. The pattern was repeated ten more times so that twelve
pre-pressed multi-layer ply's existed in the stack. The resultant stack was placed
between buffer pads. The buffer pads are a combination polymide fiber and
mechanical rubber, manufactured and supplied by Yamauchi Corporation,
designed to more uniformally distribute temperature and press during thermal
lamination. The resultant stack plus buffer pads was then placed between two
slightly larger 3.175pm un-polished non-corrosive metal plates. This entire
construction, referred to as a book, was placed in a TMp laminating press,
preheated to 149°C. The composite construction was compression laminated at a
pressure of 14 X 105pas for 18minutes at a temperature of 149°C. While under
press, the platens were cooled to less than 38°C, which took approximately
19minutes. After being removed from the press, all twelve composite sheets
were removed from the book. All twelve finished composite sheets had good
integrity; any attempt to delaminate destroyed the Teslin layer, which
demonstrated a good adhesive and seamless bond between the Teslin and the
PVC. ISO7910 ID-1 cards were die cut from the each of the 51 X 63.5cm X 762
µm composite sheets. The finished cards from the each of the composite sheet
had good integrity and good lat flat. Any attempt to delaminate destroyed the
Teslin layer, which demonstrated a good adhesive and seamless bond between
the Teslin and the PVC.
This foregoing example was also conducted using Teslin SP1000 which
produced the same results as the Teslin TS1000.
Example 20 -(12 Composite Sheets/Book. Other Process Conditions)
Sheets 51 X 63.5cm of treated Teslin substrate, 287µm thick, were cut
from a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet of 0.10-
inch polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut
in the grain long direction. Below the PVC ply was a second ply of 51 X 63.5cm X
254µm PVC, cut grain short. Below the 254um PVC grain short ply was a 51 X
63.5cm X 50.8µm PVC sheet cut grain long. A sheet 53 X 66cm of 50.8µm clear
polyester was placed over the Teslin sheet to act as a release liner. This
construction was placed between two 53 X 66cm X 762µm polished stainless
steel metal plate. An identical polyester/treated Teslin sheet/PVC/PVC/PVC lay-up
was placed on top of a stainless plate from the existing construction. A polished
metal plate was placed over the exposed polyester release liner. The pattern was
repeated ten more times so that twelve pre-pressed multi-layer plys existed in
the stack. The resultant stack was placed between two slightly larger 3.175cm
un-polished non-corrosive metal plates. This entire construction, referred to as a
book, was placed in a TMP laminating press, preheated to 121°C. The composite
construction was compression laminated at a pressure of 14 X 105pas for
18minutes at a temperature of 121°C. While under press, the platens were
cooled to less than 38°C, which took approximately 17minutes. After being
removed from the press, all twelve finished composite sheets were pealed apart.
None of the Teslin plys could be delaminated from the adjacent PVC sheet,
indicating a good adhesive and seamless bond between the Teslin and the PVC.
Since the PVC plys did not laminate, no attempt to fabricate ISO7910 ID-1 cards
was made.
Example 21 -(12 Composite Sheets/Bookf Other Lay-up Pattern and Process
Conditions)
Sheets 51 X 63.5cm of treated Teslin substrate, 287µm thick, were cut
from a master roll in the grain short direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet of 0.10-
inch polyvinlychloride (PVC), supplied by Empire Plastics. The PVC sheet was cut
in the grain short direction. Below the PVC ply was a second ply of 51 X 63.5cm
X 254µm PVC, cut grain long. Below the PVC ply was a second ply of 51 X
63.5cm X 254µm PVC sheet cut grain long. A sheet 53 X 66cm of 50.8µm clear
polyester was placed over the Teslin sheet to act as a release liner. This
construction was placed between two 53 X 66cm X 762µm polished stainless
steel metel plate. An identical polyester/treated Teslin sheet/PVC/PVC/PVC lay-up
was placed on top of a stainless plate from the existing construction. A polished
metal piste was placed over the exposed polyester release liner. The pattern was
repeated ten more times so that twelve pre-pressed multi-layer plys existed in
the stack. The resultant stack was placed between buffer pads. The resultant
stack plus buffer pads was then placed between two slightly larger 3.175cm unpolished
non-corrosive metal plates. This entire construction, referred to as a
book, was placed in a TMP laminating press, preheated to 149°C. While under
press, the platens were cooled to less than 38°C, which took approximately
19minutes. After being removed from the press, all twelve composite sheets
were removed from the book. All twelve finished composite sheets had good
integrity; any attempt to delaminate destroyed the Teslin layer, which
demonstrated a good adhesive and seamless bond between the Teslin and the
PVC. ISO7910 ID-1 cards were die cut from the each of the 51 X 63.5cm X
775µm
composite sheets. The finished cards from each composite sheets had good
integrity and good lat flat. Any
attempt to delaminate destroyed the Teslin layer, which demonstrated a good
adhesive and seamless bond between the Teslin and the PVC.
Example 22 —(12 Composite Sheet/Book, Other Lay-up Pattern and process
Condition - failed)
Sheet 51 X 63.5cm of treated Teslin substrate, 287µm thick, were cut
from a master roll in the grain short direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Fleographic coating technology described in example 2.
One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet of 0.10-
inch polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut
in the grain short direction. Below the PVC ply was a second ply of 51 X 63.5cm
X254µm, cut grain long. Below the 254µm PVC grain short ply was a 51 X
63.5cm X 50.8µm PVC sheet cut grain long. A sheet 53 X 66cm X 50.8µm clear
polyester was placed over the Teslin sheet to act as a release liner. This
construction was placed between two 53 X 66cm X 762µm polished stainless
steel metal plate. An identical polyester/treated Teslin sheet/PVC/PVC/PVC lay-up
was placed on top of a stainless plate from the existing construction. A polished
metal plate was placed over the exposed polyester release liner. The pattern was
repeated ten more times so that twelve pre-pressed multi-layer plys existed in
the stack. The resultant stack was placed between buffer pads. The resultant
stack plus buffer pads was then placed between two slightly larger 3.175cm unpolished
non-corrosive metal plates. This entire construction, referred to as a
book, was placed in a TMP laminating press, preheated to 121°C. The composite
construction was compression laminated at a pressure of 14 X 105pas for
18minutes at a temperature of 121°C. While under press, the platens were
cooled to less than 38°C, which took approximately 17minutes. After being
removed from the press, all twelve composite sheets were removed from the
book. The PVC less than 38°C, which took approximately 17minutes. After being
removed from the press, all twelve composite sheets were removed from the
book. The PVC plys from all twelve finished composite sheets were pealed apart.
None of the Teslin plys could be delaminated from the adjacent PVC sheet,
indicating a good
adhesive and seamless bond between the Teslin and the PVC. Since the PVC plys
did not laminate, no attempt to fabricate ISO7910 ID-1 cards was made.
Example 23 -(12 Composite Sheets/Book. Magnetic Stripe Version)
Sheets 51 X 63.5cm of treated Teslin substrate, 287(jm thick, were cut
from a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet of 0.10-
inch polyvinylchloride (PVC), supplied by Empire Plastic. The PVC sheet was cut
in the grain long direction. Below the PVC ply was a second ply of 51 X 63.5cm X
254µm PVC, cut grain short. Below the 254pm PVC grain short ply was a 51 X
63.5cm X 50.8µm PVC Magnetic Stripe master sheet, fabricated with the
magnetic stripe running parallel to the short (20") dimension of the sheet. The
magnetic stripes were 3 level, 2750 coercivity type. A sheet 53 X 66cm X 50.8µm
clear polyester was placed over the Teslin sheet to act as a release liner. This
construction was placed over the Teslin sheet to act as a release liner. This
construction was placed between two 53 X 66cm X 762um polished stainless
steel metal plate. An identical polyester/treated Teslin sheet/PVC/PVC/magnetic
stripe master sheet lay-up was placed on top of a stainless plate from the
existing construction. A polished metal plate was placed over the exposed
polyester release liner. The pattern was repeated ten more times so that twelve
pre-pressed multi-layer plys existed in the stack. The resultant stack was placed
between buffer pads. The resultant stack plus buffer pads was then placed
between two slightly larger 3.175cm un-polished non-corrosive metal plates. This
entire construction, referred to as a book, was placed in a TMP laminating press,
preheated to 149°C. The composite construction was compression laminated at a
pressure of 14 X 105pas for 18minutes at a temperature of 149°C. While under
press, the platens were cooled to less than 38°C, which took approximately
19minutes. After being removed from the press, all twelve composite sheets
were removed from the book. All twelve finished composite sheets had good
integrity; any attempt to delaminate destroyed the Teslin layer, which
demonstrated a good adhesive and
seamless bond between the Teslin and the PVC. ISO7910 ID-1 cards were die
cut from the each of the 51 X 63.5cm X 762pm composite sheets. The finished
cards from each composite sheet had good integrity and good lat flat. The
finished cards from each composite sheet had good integrity and good lat flat.
Any attempt to delaminate destroyed the Teslin layer, which demonstrated a
good adhesive and seamless bond between the Teslin and the PVC.
Example 24 -(12 Composite Sheets/Book. Magnetic Stripe Version)
Sheets 51 X 63.5cm of treated Teslin substrate, 287pm thick, were cut
from a master roll in the grain short direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet of 0.10-
inch polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut
in the grain short direction. Below the PVC ply was a second ply of 51 X 63.5cm
X 254µm PVC, cut grain long. Below the 254pm PVC grain short ply was a 51 X
63.5cm X 50.8µm PVC Magnetic Stripe master sheet, fabricated with the
magnetic stripe running parallel to the short (20") dimension of the sheet. The
magnetic stripes were 3 level, 2750 coercivity type. A sheet 53 X 66cm of
50.8pm clear polyester was placed over the Teslin sheet to act as a release liner.
This construction was placed between two 53 X 66cm X 762µm polished stainless
steel metal plate. An identical polyester/treated Teslin sheet/PVC/PVC/magnetic
stripe master sheet lay-up was placed on top of a stainless plate from the
existing construction. A polished metal plate was placed over the exposed
polyester release liner. The pattern was repeated ten more times so that twelve
pre-pressed multi-layer plys existed in the stack. The resultant stack was placed
between buffer pads. The resultant stack plus buffer pads was then placed
between two slightly larger 3.175cm un-polished non-corrosive metal plates. This
entire construction, referred to as a book, was placed in a TMP laminating at a
pressure of 14 X 105pas for 18minutes at a temperature of 149°C. While under
press, the platens were cooled to less than 38°C, which took approximately
19minutes. After being
removed from the press, all twelve composite sheets were removed from the
book. All twelve finished composite sheets had good integrity; any attempt to
delaminate destroyed the Teslin layer, which demonstrated a good adhesive and
seamless bond between the Teslin and the PVC. ISO7910 ID-1 cards were die
cut from the each of the 51 X 63.5cm X 775pm composite sheets. The finished
cards from each composite sheet had good integrity and good lat flat. Any
attempt to delaminate destroyed the Teslin layer, which demonstrated a good
adhesive and seamless bond between the Teslin and the PVC.
Example 25 -(12 Composite Sheets/Book, Magnetic Stripe Version - failed)
Sheets 51 X 63.5cm of treated Teslin substrate, 287um thick, were cut
from a master roll in the grain long direction. The Teslin had been coated with 3
passes on each side (3 X 3) using the same coating composition as described in
example 1 and the same Flexographic coating technology described in example
2. One coated Teslin sheet was placed on top of one 51 X 63.5cm sheet of 0.10-
inch polyvinylchloride (PVC), supplied by Empire Plastics. The PVC sheet was cut
in the grain long direction. Below the PVC ply was a second ply of 51 X 63.5cm X
50.8µm PVC Magnetic Stripe master sheet, fabricated with the magnetic stripe
running parallel to the short (20") dimension of the sheet. The magnetic stripes
were 3 level, 2750 coercivity type. A sheet 53 X 66cm X 50.8µm clear polyester
was placed over the Teslin sheet to act as a release liner. This construction was
placed between two 53 X 66cm X 762µm polished stainless steel metal plate. An
identical polyester/treated Teslin sheet/PVC/PVC/magnetic stripe master sheet
lay-up was placed on top of a stainless plate from the existing construction. A
polished metal plate was placed over the exposed polyester release liner. The
pattern was repeated ten more times so that twelve pre-pressed multi-layer plys
existed in the stack. The resultant stack was placed between buffer pads. The
resultant stack plus buffer pads was then placed between two slightly larger
3.175pµ un-polished non-corrosive metal plates. This entire construction,
referred to as a book, was placed in a TMP laminating press, preheated to 121°C.
The
composite construction was compression laminated at a pressure of 14 X 105pas
for 18minutes at a temperature of 121°C. While under press, the platens were
cooled to less than 38°C, which took approximately 17minutes. After being
removed from the press, all twelve composite sheets were removed from the
book. The PVC plys from all twelve finished composite sheets were pealed apart.
None of the Teslin plys could be delaminated from the adjacent PVC sheet,
indicating a good adhesive and seamless bond between the Teslin and the PVC.
Since the PVC plys did not laminate, no attempt to fabricate ISO7910 ID-1 cards
was made.
Example 26 (Condition of cards/ Composite Sheets)
Cards fabricated according to example 19, were individually soaked in
deionized water for 15minutes then allowed air dry for 24 hours. Resultant
conditioned cards demonstrated easier separation from a stack and slip
characteristics compared to the unconditioned version.
Example 27 (Conditioning of Cards/Composite Sheets)
Cards fabricated according to example 19, were individually conditioned at
75% RH and 25C for 16hours. Resultant conditioned cards demonstrated easier
separation from a stack and slip characteristics compared to the unconditioned
version.
Example 28 (Conditioning of Cards/Composite Sheets)
Cards fabricated according to example 19, were individually conditioned at
75% RH and 25C for 16hours. Resultant conditioned cards demonstrated easier
separation from a stack and slip characteristic compared to the unconditioned
version.
Example 29 (Condition of Cards/Composite Sheets)
Composite sheets fabricated according to example 19, were individually
soaked in deionized water for 15minutes then allowed air dry for 24 hours.
ISO7910ID-1 cards were die cut from the each of the 51 X 63.5cm X
775pm composite sheets. The finished cards from each composite sheet had
good integrity and good lat flat. Any attempt to delaminate destroyed the Teslin
layer, which demonstrated a good adhesive and seamless bond between the
Teslin and the PVC. Resultant conditioned cards demonstrated easier separation
from a stack and slip characteristics compared to the unconditioned version.
The following table compares the optical density retention performance of the
new offering (8181-67-09 recipe) to standard IJ1000WP (2 component recipe).
Test print patterns used in this study were produced off of an HP970 color inkjet
printer, set on best quality and photo grade ink jet glossy paper.
Optical Density following De-Ionized Water Soak
The invention has been described with reference to specific embodiments.
Obvious modifications and alterations will occur to others upon reading and
understanding the detailed description. It is intended that the invention be
construed as including all such modification and alterations insofar as they come
within the scope of the invention or the equivalents thereof.
we Claim:
1. A substantially water-resistant ink jet recordable substrate coating composition comprising:
a. an aqueous polyurethane dispersion;
b. a cationic nitrogen-containing polymeric dye fixative compound; and
c. an acrylic polymer,
wherein said coating composition has a pH of 7 or less.
2. The coating composition as claimed in claim 1 wherein said polyurethane dispersion is
chosen from anionic polymers, cationic and nonionic polyurethanes dispersible in
water.
3. The coating composition as claimed in claim 1 wherein said polyurethane dispersion
comprises a polyisocyanate and a polyol.
4. The coating composition as claimed in claim 1 wherein said polyurethane dispersion
contains from 1 weight percent to less than 70 weight percent of polyurethane.
5. The coating composition as claimed in claim 1 wherein said cationic nitrogen-
containing polymeric dye fixative compound has a pH of 7 or less.
6. The coating composition as claimed in claim 1 wherein said cationic nitrogen-
containing polymeric dye fixative compound comprises an aqueous containing from 5
weight percent to 50 weight percent or less of a nitrogen-containing polymer.
7. The coating composition as claimed in claim 1 wherein said nitrogen-containing
polymeric dye fixative compound comprises polymine and epichlorohydrin.
8. The coating composition as claimed in claim 1 wherein said acrylic polymer comprises
a cationic acrylic polymer.
9. The coating composition as claimed in claim 8 wherein said cationic acrylic polymer is
chosen from polyacrylates, polymethacrylates, polyacrylonitriles and polymers having
monomer types selected from acrylonitrile, acrylic acid, acrylamide and mixture
thereof.
10. The coating composition as claimed in claim 8 wherein said cationic acrylic polymer
has a number average molecular weight of from 1500 to 8150, preferably from 2900 to
7125.
11. The coating composition as claimed in claim 1 wherein said composition comprises
from 20 to 75 weight percent of said aqueous polyurethane dispersion, from 5 to 75
weight percent of said cationic nitrogen-containing polymeric dye fixative compound,
and from 1 to 75 weight percent of said acrylic-polymer, based on total weight of said
coating composition.
12. A method of preparing a substantially water-resistant ink jet recordable substrate
coating composition comprising the step of mixing a nitrogen-containing polymeric dye
fixative compound with an aqueous polyurethane dispersion and an acrylic polymer to
produce a substantially homogeneous mixture having a pH of 7 or less.
13. The method as claimed in claim 12 wherein said polyurethane dispersion, said nitrogen-
containing polymeric dye fixative compound and said acrylic polymer is defined as in
any of claims 2 to 11.
14. A substantially water-resistant ink jet recordable substrate at least partially coated with
a coating composition according to any of claims 1-12.
15. The ink jet recordable substrate as claimed in claim 14 wherein said substrate
comprises a cellulosic-based paper.
16. The ink jet recordable substrate as claimed in claim 14 wherein said substrate
comprises a microporous material.
17. The ink jet recordable substrate as claimed in claim 14 wherein said substrate
comprises a matrix containing polyolefin; a siliceous filler, and a porous structure.
18. The ink jet recordable substrate as claimed in claim 17 wherein said substrate has a
porosity of at least 35 percent by volumn of said substrate.
19. The ink jet recordable substrate as claimed in claim 17 wherein said polyolefin is
chosen from polyethylene, polypropylene and mixtures thereof.
20. The ink jet recordable substrate as claimed in claim 19 wherein said polyethylene
comprises a linear high molecular weight polyethylene having an intrinsic viscosity of
at least 10 deciliters/gram and said polypropylene comprises a linear high molecular
weight polypropylene having an intrinsic viscosity of at least 5 deciliters/gram.
21. The ink jet recordable substrate as claimed in claim 17 wherein said siliceous filler is
chosen from silica, mica, montmorillonite, kaolinite, asbestos, talc, diatomaceous earth,
vermiculite, natural and synthetic zeolites, cement, calcium silicate, aluminum silicate,
sodium aluminum silicate, aluminum polysilicate, alumina silica gels, glass particles
and mixtures thereof.
22. The ink jet recordable substrate as claimed in claim 21 wherein said siliceous filler is
chosen from precipitated silica, silica gel or fumed silica.
23. The ink jet recordable substrate as claimed in claim 14 wherein said coating
composition is applied to said substrate such that said substrate has a coating thickness
of from 1 to 40 microns.
24. The ink jet recordable substrate as claimed in claim 14 further comprising at least one
layer of a substantially nonporous material bonded to said substrate.
25. The ink jet recordable substrate as claimed in claim 24 wherein said nonporous material
is chosen from substantially nonporous thermoplastic polymers, substantially
nonporous metalized thermoplastic polymers, substantially nonporous thermoset
polymers, substantially nonporous elastomerics, substantially nonporous metals, and
mixtures thereof.
26. A method of preparing an at least partially coated substantially water-resistant ink jet
recordable substrate comprising the steps of:
a. providing an ink jet recordable substrate is defined as in any as
claimed in claim 15 to 22.
b. at least partially the coating composition according to any of claims
1-12 to at least one side of said ink jet recordable substrate.
27. The method as claimed in claim 26 wherein said substrate is defined as in any as
claimed in claims 15 to 22.
28. The method as claimed in claim 26 wherein said coating composition is applied to said
substrate such that said substrate has a coating thickness of from 1 to 40 microns.
29. The method as claimed in claim 26 further comprising bonding said substrate to at least
one layer of a substantially nonporous material.
30. The method as claimed in claim 29 wherein said substantially nonporous material is
chosen from substantially nonporous thermoplastic polymers, substantially nonporous
metalized thermoplastic polymers, substantially nonporous thermoset polymers,
substantially nonporous elastomerics, substantially nonporous metals, and mixtures
thereof,
31. The method as claimed in claim 26 further comprising the step of drying the coated ink
jet recordable substrate by applying a temperature of from ambient to 177°C (350°F).
32. A coated microporous substrate comprising:
a. a microporous substrate having an upper surface and a lower
surface comprising:
(i) a polyolefin;
(ii) a siliceous filler;
(iii) a porosity such that pores constitute at-least 35 percent
by volumn of said microporous substrate; and
b. a coating derived from a coating composition according to any as
claimed in claim 1 to 12 at least partially applied to at least one
surface of said microporous substrate.
33. A multilayer article comprising an ink jet recordable substrate at least partially
connected to a substantially nonporous material, said ink jet recordable substrate and at
least partially coated with a substantially water-resistant coating composition according
to any as claimed in claims 1-12.
34. The multilayer article as claimed in claim 33 further comprising a friction-reducing
coating composition wherein at least one of said ink jet recordable substrate and
substantially nonporous material is at least partially with said friction reducing coating
composition.
35. A method for producing a multiplayer article comprising the step of:
a. providing an ink jet recordable substrate having a top surface and a
bottom surface;
b. at least partially applying a coating composition according to any
as claimed in claims 1 to 12 to at least one surface of said ink jet
recordable substrate;
c. at least partially connecting said ink jet recordable substrate of (b)
to substantially nonporous material having a top surface and a
bottom surface; and
d. at least partially applying a friction-reducing coating composition
to at least one surface of at least one of said ink jet recordable
substrate and said substantially nonporous material.
Dated this 9th day of November 2004
OF L S DAVAR & CO.
APPLICANTS' AGENT
A substantially water-resistant ink jet recordable substrate coating composition comprising:
d. an aqueous polyurethane dispersion;
e. a cationic nitrogen-containing polymeric dye fixative compound; and
f. an acrylic polymer,
wherein said coating composition has a pH of 7 or less.

Documents:


Patent Number 224139
Indian Patent Application Number 01693/KOLNP/2004
PG Journal Number 40/2008
Publication Date 03-Oct-2008
Grant Date 01-Oct-2008
Date of Filing 09-Nov-2004
Name of Patentee PPG INDUSTRIES OHIO, INC.
Applicant Address 3800 WEST 143RD STREET, CLEVELAND, OH
Inventors:
# Inventor's Name Inventor's Address
1 PARRINELLO, LUCIANO M. 2709 CHAMPLAIN DRIVE ALLISON PARK, PA 15101
2 NOWAKOWSKI, PETER M. 3130 MOHAWK DRIVE GIBSONIA, PA 15044
PCT International Classification Number C09D175/04
PCT International Application Number PCT/US03/11964
PCT International Filing date 2003-04-16
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/411,311 2003-04-11 U.S.A.
2 60/373,957 2002-04-19 U.S.A.