CN1192902C - 用于记录层的载体材料及其制备方法 - Google Patents

用于记录层的载体材料及其制备方法 Download PDF

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CN1192902C
CN1192902C CN01103994.9A CN01103994A CN1192902C CN 1192902 C CN1192902 C CN 1192902C CN 01103994 A CN01103994 A CN 01103994A CN 1192902 C CN1192902 C CN 1192902C
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马蒂纳·维歇
弗兰克·罗默曼
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Felix Scholeller Jr Foto-Und Spezialpapiere & Co KG GmbH
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Abstract

一种载体材料，该载体材料的至少一个面上涂有一种合成树脂，该载体材料含有至少在正面上涂有颜料层的原纸，其中所述颜料层含有至少5重量%的颜料，该颜料的颗粒尺寸分布很窄，至少70%的颜料颗粒尺寸低于约1μm，并且至少40重量%的颜料颗粒尺寸为0.35至0.8μm，或其中颜料层为结构碳酸钙，例如表面改性的碳酸钙，二者的表面性质得到改善。

Description

用于记录层的载体材料及其制备方法
技术领域
本发明涉及一种用于记录层的载体材料，该载体材料按照本发明的一个实施方式可以为一种涂有树脂的载体材料。
背景技术
涂有聚烯烃的胶片载体材料通常含有上胶的原纸，该原纸的两面都用聚烯烃涂覆，在多数情况下采用挤压涂覆。
在挤压涂覆原纸时，由于涂覆作用，在聚合物的表面形成坑形的疵，称作凹点。在骤冷辊高速旋转时，包裹在骤冷辊表面上的微细凹陷处的气泡在与热的树脂接触之前无法溢出，结果直到涂覆原纸后，包裹的气体也无法溢出，在聚合物的表面形成坑形的凹点。这些表面的缺陷对载体材料所要求的表面性质产生负的影响，所述表面性质如光滑性对图象的质量具有决定性作用。
增加施用树脂的体积确实可以达到改善表面的效果，但这一措施在高的挤压速度下并不可行而且也增加了生产成本。
EP 0 285 146 A2提出将一种比空气轻的并可透过挤出薄膜溢出的气体用于骤冷辊表面以排除气泡、抑制凹陷的生成。但其缺点是高的技术投资。
US 4 994 357建议增加将涂覆聚乙烯的纸压在骤冷辊上的压力以抑制凹点的生成。但是高的接触压力只能在低的生产速度下进行，这是因为在更高的速度下，聚乙烯会从纸上松散下来。
EP 0 952 483 A1描述了一种具有高质量的聚乙烯表面的胶片载体材料，其甚至在高的挤出速度的生产中也不被损坏。为达到此目的，EP 0 952 483 A1建议向原纸提供一含有粘土的层，其粘土的量一定不能超过3.3g/m2。该载体材料的缺点是，在含颜料层和在其上挤出的聚乙烯层之间不能充分地粘合。
载体材料的均匀表面不只对胶片记录材料有意义。为达到与照片类似的外观，将涂有聚烯烃的纸用于非胶片记录材料如喷墨用纸的制造。载体材料的不均匀的或带有缺陷的表面由于记录的图象上的光斑而变得十分明显，这是在用这些记录材料时所不希望的。
发明内容
因此，本发明的目的是开发一种用于记录材料的涂有树脂的载体材料，其可由高速挤出获得，并具有均匀光滑的表面和少的凹点。
本发明的另一目的是消除将树脂涂于原纸表面的粘合性问题，并为载体材料提供高的白度和硬挺度。
本发明还有一个目的是提供一种具有优良抗起邹性的喷墨记录材料。
这些问题可以通过用一种合成树脂涂覆载体材料(原纸)的至少一个面而得到解决，其特征是含有至少在正面上涂有一颜料层的原纸，该颜料层含有至少5重量％的颜料，该颜料的颗粒尺寸分布很窄，至少70％的颜料颗粒尺寸低于约1μm，至少40重量％的颜料颗粒尺寸为0.35至0.8μm。
此外，喷墨应用所关心的低起皱问题也可以由一种包含原纸作为载体的喷墨记录材料解决，其中至少在所述原纸的正面上涂有一颜料层，该颜料层含有至少5重量％的颜料，该颜料的颗粒尺寸分布很窄，至少70％的颜料颗粒尺寸低于约1μm，至少40重量％的颜料颗粒尺寸为0.35至0.8μm。因此，该喷墨记录材料不具有作为载体的涂有树脂的原纸。
优选的情况下，50-80重量％的颗粒具有小于1μm的直径，其颗粒尺寸在0.35至0.8μm。相对于颜料层的总颜料量，窄颗粒尺寸分布的颜料量为10-90重量％，更优选30-80重量％。
本发明中术语窄颗粒尺寸分布的颜料可理解为也包括其中至少70重量％的颜料颗粒尺寸低于约1μm，以及40-80重量％的最大颗粒尺寸(直径)与最小颗粒尺寸的差小于约0.4μm的那些颜料颗粒。
本发明的载体材料不同于EP 0 952 483A1的载体材料，使用了具有特定颗粒尺寸分布的颜料或使用了选择性表面改性的碳酸钙。本发明的载体材料没有限定颜料层中包含的粘土的上限3.3g/m2。本发明通过颜料的选择而获得一系列意想不到的优点。
令人惊讶的是与EP 0 952 483 A1相比，本发明显著地获得了聚烯烃层与原纸的颜料层之间更好的粘合性。载体材料的粗糙度和光滑度得到改善。与EP 0 952 483 A1相比，由于其粘合性的问题，其粗糙度值不可能低于0.5μm，而本发明不仅可以获得好的粘合性而且粗糙度值低于0.5μm。
在通常的速度200-250米/分钟，甚至在高达600米/分钟的速度下可以用挤压涂覆的方法而不会增加任何粘合性的问题或凹点数量。同时可以节省聚烯烃15-30％。
所述颜料选自金属氧化物、硅酸盐、碳酸盐、硫化物和硫酸盐所组成的组中。特别合适的是高岭土、滑石、碳酸钙和/或硫酸钡。在本发明中，约50％的颜料颗粒直径为0.7μm。例如具有约0.7μm的d50％值的碳酸钙证明具有特别的优越性。本发明的一个优选的实施方式使用了碳酸钙和粘土的颜料混合物。碳酸钙与高岭土(粘土)的重量比优选为30∶70至70∶30。令人惊讶的是尽管加入了会使载体材料变黄的高比例的粘土，但载体材料的白度基本没有受到影响。
本发明可采用表面被一种片晶形的无机物质改性的碳酸钙。
作为颜料层的粘合剂，可以使用造纸工业中常规使用的天然的或合成的聚合物。特别合适的是淀粉、凝胶、苯乙烯/丁二烯乳胶、苯乙烯/丙烯酸酯乳胶、聚乙烯醇或它们的混合物。淀粉与苯乙烯乳胶以2∶1至1∶2比例混合的混合物证明是特别合适的。
颜料层中颜料与粘合剂的重量比为30∶70至90∶10，特别是85∶15。
原纸和树脂之间的颜料层可以是在原纸上的单层或多层。涂覆量可用所有的常规装置控制，按此方式选择的量为干燥后每层施用的最大量为20g/m2，特别是8-17g/m2。
在本发明的特定实施方式中，所述原纸在用本发明的颜料层涂覆前被另一含有颜料的初级层覆盖。适合用作颜料的为所有常规的白色颜料，如沉淀的碳酸钙、二氧化钛、粘土(高岭土)、滑石或硫酸钡，颗粒尺寸为0.1-10μm，特别是0.1-2μm。所施用的初级层的重量一定不能超过约20g/m2。优选直到初级层干燥后才能施用本发明的颜料层。
对于所述原纸的制造，各种类型的纤维素纤维和合成纤维都适用。对于上胶剂，造纸工业中已知的上胶剂和粘合剂都适用。所述原纸可含有颜料和填充剂如粘土、碳酸钙或二氧化钛以及其它的添加剂如消泡剂、光亮剂和着色剂。
所述原纸用Fourdrinier或圆筒造纸机制造。原纸的基重可为50-250g/m2，特别是80-170g/m2。
为制造本发明的载体材料也可使用非高质量的纸，为生产这种纸，例如可以使用回收的纸浆纤维。原纸可以非压缩的或压缩的(光滑的)形式使用。可以采用稍微压缩的密度低于1g/cm3的原纸，特别适合的是非压缩的密度低于0.9g/cm3的原纸，以利于降低原料成本。
本发明的颜料层表面被合成树脂以及两种或多种烯烃共聚物以挤压方式涂覆，所述合成树脂为，例如，聚烯烃如聚乙烯、聚丙烯或聚丁烯。特别适合的是低密度聚乙烯型(LDPE)、高密度聚乙烯型(HDPE)、乙烯/α-烯烃共聚物(LLDPE)，以及它们的混合物。聚合物层可含有白色颜料如二氧化钛以及其它的添加剂如光亮剂、着色剂或分散助剂。施用的聚合物的重量为5-30g/m2，特别是10-25g/m2。发现，即使施用量降低了15-30重量％，也可获得可以接受的凹点数量。所述聚合物层可以是挤压的单层或是共挤压的多层。
在本发明的优选的实施方式中，原纸的反面用清亮的，即无颜料的聚烯烃，特别是聚乙烯，涂覆。所述载体材料的反面也可用其它的功能层，如抗静电或抗蜷缩层，覆盖。
本发明的载体材料可用作胶片乳液、喷墨记录层和热颜色迁移加工(D2T2)的记录层的载体。
具体实施方式
下面的实施例用于对本发明做进一步的说明。
实施例1-10
使用基重为162g/m2的标准的胶片原纸，其由含100重量％的硬木硫酸纸浆，和基于所述纸浆，0.5重量％烷基烯酮二聚物和0.7重量％聚酰胺-聚胺表氯醇树脂制造，并用氧化的淀粉上胶。
所述原纸以非压缩的形式，即非平滑的形式使用，其密度为0.84g/cm3。
用弯曲的叶片装置将各种涂层施于原纸上并使其干燥。所述颜料层的组成列于表1中。
                                               表1
    成分   1   2   3   4   5   6   7   8   9   10
    CaCO3(d50％＝0.7μm)   30   30   30   100   -   -   30   50   -   70
    改性的CaCO3 *   -   -   -   -   -   -   -   -   30   -
    粘土1**)   70   70   70   -   100   -   -   -   70   30
    粘土2***)   -   -   -   -   -   -   70   -   -   -
    滑石   -   -   -   -   -   100   -   50   -   -
    苯乙烯/丁二烯乳胶   8   8   8   8   8   8   8   8   8   8
    淀粉   6   6   6   6   6   6   6   6   6   6
    硬脂酸钙   0.8   0.8   0.8   0.8   0.8   0.8   0.8   0.8   0.8   0.8
    施用重量(g/m2)   5   11   17   10   10   10   10   10   10   10
*)用粘土改性的碳酸钙
**)96-100％颜料颗粒＜2μm，(Hydragloss90)
***)94-98％颜料颗粒＜2μm，(HydraglossE)
实施例11-18
用于实施例1的原纸借助压膜机用实施例1的涂层在线涂覆和干燥。施用量为10g/m2。组成列于表2。
                                               表2
  成分   11   12   13   14   15   16   17   18
  CaCO3 *(d50％＝0.7μm)   30   70   100   -   -   30   50   -
  改性的CaCO3   30
  粘土1**)   70   30   100   70
  粘土2***)   70
  滑石   100   50
  苯乙烯/丁二烯乳胶   8   8   8   8   8   8   8   8
  淀粉   6   6   6   6   6   6   6   6
  硬脂酸钙   0.8   0.8   0.8   0.8   0.8   0.8   0.8   0.8
  施用重量(g/m2)   10   10   10   10   10   10   10   10
*)用粘土改性的碳酸钙
**)96-100％颜料颗粒＜2μm，(Hydragloss90)
***)94-98％颜料颗粒＜2μm，(HydraglossE)
实施例19
将实施例1中使用的原纸首先借助压膜机用含有30重量％的常规的碳酸钙溶液涂覆，施用量为12g/m2。干燥后，在下一步用本发明的颜料层(表1)覆盖，施用量为10g/m2。
将按照实施例1-19涂覆的原纸用72重量％的低密度聚乙烯(LDPE，0.923g/m2)、15重量％二氧化钛母炼胶(50重量％LDPE和50重量％二氧化钛)和13重量％的其它添加剂如光亮剂、硬脂酸钙和蓝色颜料的混合物，以不同的施用量28g/m2、23g/m2、18g/m2和13g/m2)，以挤压速度为250米/分钟和350米/分钟进行涂覆。
实施例20
将实施例4中的碳酸钙涂覆的纸用具有下列组成的油墨记录层覆盖：
  Al2O3(平均颗粒尺寸为1.2μm)     25重量％
  氧化硅(平均颗粒尺寸为6.5μm)     40重量％
  聚乙烯醇(完全皂化的)     21重量％
  季聚铵盐     14重量％
记录层的涂覆量为20g/m2。将该记录材料进行起邹指数测试，结果如下所示。
对比例1
实施例1-10的表面上胶的原纸，在其正面用实施例1-19的聚乙烯混合物以200米/分钟和250米/分钟的挤压速度涂覆。
对比例2
将EP 0952 483A1的实施例1的用淀粉上胶的原纸用粘土和聚丙酸的混合溶液涂覆。粘土在该层的用量为1.9g/m2。然后，将该颜料层用二氧化钛和LDPE的混合物以300米/分钟的挤压速度涂覆，用量为29g/m2。所述原纸的反面用清亮的聚乙烯涂覆。
对比例3
作为对实施例20的喷墨记录材料的比较，使用没有实施例4的颜料层的原纸。在该原纸上所涂覆的具有实施例20的组成的喷墨记录层的量为20g/m2。
对比例4
作为对实施例20的喷墨记录材料的比较，测试常规的复印纸。该常规的复印纸上有一层颜料层。
测试实施例和对比例中制备的载体材料。
凹点数量的确定
将涂有聚烯烃的纸表面用显微镜放大并用CCD相机扫描。从30个测量点获得由图象加工程序绘制的凹点数量的分布。结果列于表3中。
从表3可以看出，本发明的样品比对比例V1的样品具有更低的凹点数量。实施例1-10的样品的凹点数量与对比例V2的样品的凹点数量相当。实施例11-19的样品的凹点水平相对于实施例1-10的样品的凹点水平仅有略微的下降。
光滑度的测量
用三角光滑度测量仪按照DIN 67 530的方法以60°角测量。结果见表3。
相对于V1和V2，除实施例4、10和11外，实施例1-19的样品的光滑度得到改善。
粗糙度的测定
在挤压涂覆前将纸切成0.8mm，用UBM测量仪按照DIN 4768的方法测定粗糙度。
本发明的样品也显示比V1和V2更好的粗糙度，而V1的样品明显比V2的样品的粗糙度差。
色值测定
用Elrepho 2000色值测量仪对单片纸的L，a，b值进行测量(D65，10°，UVI)。
聚乙烯的粘合性
在挤压涂覆后，立刻用Lorentzen和Wettre制造的张力强度测量仪测定，纸宽10mm，拉出角度180°，拉出速度50毫米/分钟。测量值以N/15mm为单位给出，并列于表3中。
相对于V1和V2，本发明的样品显示出树脂和颜料层的粘合性的更显著的改善。
硬挺度
用Lorentzen和Wettre制造的硬挺度测量仪按照标准的SCAN-P29.69的方法测定。测量值以mN为单位给出，并给出纵向的硬挺度。
在与对比例V1比较中，所有的样品都显示出明显的硬挺度的改善。相对于对比例V2的样品，本发明实施例1和2的样品有略微的改善。
起皱指数
按照Darmstadt技术大学开发的方法由肉眼观测样品的起皱性。为了检测，将被测试的纸放置在一个平面上，并将其暴露于有角度地排列的光源下。低于10的起皱指数表示不起皱，在10-16之间表示低到中等起皱，在16-20之间表示严重起皱，高于20表示非常严重的起皱。与对比例V3(24.3)和V4(29.7)相比，本发明的样品表现出优良的起皱指数(10.7)。
                                    表3
  性质  实施例
 1   2   3   4   5   6   7   8   9   10   11   12   13   14   15   16   17   18   19   V1   V2
  凹点  1.5   1.5   1.6   1.5   1.4   1.4   1.5   1.6   1.5   1.5   1.8   1.9   2.0   1.8   1.8   1.8   1.9   1.8   1.6   4.8   1.5
  粗糙度μm  0.49   0.45   0.47   0.50   0.49   0.48   0.46   0.49   0.48   0.50   0.50   0.49   0.50   0.48   0.46   0.48   0.49   0.49   0.48   1.46   0.95
  光滑度(s)  78   77.6   78.8   75.3   78.8   78.8   77.1   78.8   78.0   75.1   75.1   78.7   77.7   76.4   76.8   76.0   78.4   75.1   78.8   75.2   74.8
  硬挺度mN/15nm  557   557   622   606   577   609   598   602   655   641   655   666   651   628   598   602   576   655   665   519   540
  L色值b  97.5-3.79   97.6-1.55   97.40.45   98.2-4.49   97.5-0.86   96.6-6.48   97.1-0.95   97.4-3.59   97.4-3.94   97.9-2.92   97.4-3.94   97.9-5.44   97.9-5.96   97.4-4.07   97.4-6.48   96.9-2.34   97.4-5.89   97.4-3.94   97.9-4.48   93.0-8.00   93.8-2.50
  粘合性N/15mm  2.5   2.3   2.2   3.0   2.9   2.8   2.9   2.7   2.8   2.8   2.8   2.7   2.7   1.5   2.6   2.8   2.7   2.9   2.8   1.5   1.2

Claims (12)

1.载体材料，该载体材料的至少一个面上涂有一种合成树脂，该载体材料含有至少在正面上涂有一颜料涂层的原纸，其中相对于颜料涂层的总颜料量，所述颜料涂层含有至少5重量％的颜料，该颜料的颗粒尺寸分布很窄，至少70％的颜料颗粒尺寸低于1μm，并且至少40重量％的颜料颗粒尺寸为0.35至0.8μm。
2.用于喷墨记录材料的载体材料，该载体材料含有至少在正面上涂有一颜料涂层的原纸，其中相对于颜料涂层的总颜料量，所述颜料涂层含有至少5重量％的颜料，该颜料的颗粒尺寸分布很窄，至少70％的颜料颗粒尺寸低于1μm，并且至少40重量％的颜料颗粒尺寸为0.35至0.8μm。
3.权利要求1或2的载体材料，其中颜料为碳酸钙。
4.权利要求1或2的载体材料，其中涂层含有颜料混合物，该颜料混合物含有至少30重量％的高岭土。
5.权利要求1的载体材料，其中所用涂层的最大量为20g/m2。
6.权利要求1的载体材料，其中所述原纸为稍微压缩的密度低于1g/cm3的纸。
7.权利要求1的载体材料，其中的碳酸钙表面被一种片晶形的无机物质改性。
8.权利要求1的载体材料，其中颜料涂层含有颜料混合物，该颜料混合物含有至少30重量％的粘土。
9.权利要求6的载体材料，其中所用涂层的最大量为20g/m2。
10.制造一种载体材料的方法，所述载体材料的至少一个面涂有一种合成树脂，该载体材料含有至少在正面上涂有一颜料涂层的原纸，其中所述颜料涂层含有至少5重量％的颜料，该颜料的颗粒尺寸分布很窄，至少70％的颜料颗粒尺寸低于1μm，并且至少40重量％的颜料颗粒尺寸为0.35至0.8μm，所述方法包括将含有至少一种颗粒尺寸分布很窄的颜料的颜料层涂于原纸的正面并以最高为600米/分钟的速度将树脂挤压涂覆于涂有颜料的原纸上。
11.权利要求10的方法，其中以350-600米/分钟的速度将树脂挤压涂覆于原纸的颜料层上。
12.权利要求11的方法，其中原纸的涂层以两步施用，首先以最多20g/m2的使用量将含有颜料的初级层涂于所述原纸上，然后涂覆含有窄颗粒尺寸范围分布的颜料，其中50％的颜料颗粒的直径为0.7μm。
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EP1126081A3 (de) 2003-04-16
DK1126081T3 (da) 2005-02-14
JP2001334750A (ja) 2001-12-04
EP1126081B1 (de) 2004-10-13
CN1311103A (zh) 2001-09-05
US20010026869A1 (en) 2001-10-04
PT1126081E (pt) 2005-02-28
DE50104058D1 (de) 2004-11-18
JP3964625B2 (ja) 2007-08-22
DE10007484C2 (de) 2001-12-13
US7014893B2 (en) 2006-03-21
ES2230188T3 (es) 2005-05-01
DE10007484A1 (de) 2001-09-06
ATE279578T1 (de) 2004-10-15

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