EP0089616B1 - Procédé d'impression et de couchage utilisant des compositions moussées à base d'eau et de pigment - Google Patents

Procédé d'impression et de couchage utilisant des compositions moussées à base d'eau et de pigment Download PDF

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Publication number
EP0089616B1
EP0089616B1 EP83102605A EP83102605A EP0089616B1 EP 0089616 B1 EP0089616 B1 EP 0089616B1 EP 83102605 A EP83102605 A EP 83102605A EP 83102605 A EP83102605 A EP 83102605A EP 0089616 B1 EP0089616 B1 EP 0089616B1
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EP
European Patent Office
Prior art keywords
composition
liquid
membranes
cylinder
foam
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP83102605A
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German (de)
English (en)
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EP0089616A3 (en
EP0089616A2 (fr
Inventor
Charles R. Rosner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
FOAMINK Co
Original Assignee
FOAMINK Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US06/419,233 external-priority patent/US4474110A/en
Application filed by FOAMINK Co filed Critical FOAMINK Co
Priority to AT83102605T priority Critical patent/ATE34942T1/de
Publication of EP0089616A2 publication Critical patent/EP0089616A2/fr
Publication of EP0089616A3 publication Critical patent/EP0089616A3/en
Application granted granted Critical
Publication of EP0089616B1 publication Critical patent/EP0089616B1/fr
Expired legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/40—Distributing applied liquids or other fluent materials by members moving relatively to surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00—Inking and printing with a printer's forme
    • B41M1/10—Intaglio printing ; Gravure printing

Definitions

  • This invention relates generally to the printing of moving webs, and is concerned in particular with improved paper printing and coating processes employing, in the most favorable embodiments, pigmented water based foamable ink or coating compositions.
  • the invention is especially useful in, but not limited to, rotogravure printing. Since its inception in the late 1800's, rotogravure printing has been carried out primarily with solvent based inks. The solvents are toxic and highly flammable, and consequently printing plant personnel are exposed continuously to potentially serious health, fire and explosion hazards. As a result, in spite of the implementation of elaborate and expensive protective measures such as for example solvent recovery and air pollution abatement systems, electrically grounded presses, shielded electric motors, etc., insurance costs have remained extremely high. Moreover, because solvents are extracted from petroleum, their costs have increased dramatically during the last decade, as has the cost of the energy consumed by the dryers required to dry the solvent inks after printing.
  • the subject matter of the present invention includes a process for applying a water-based liquid composition containing dissolved or suspended solids to a moving web comprising the steps of a) foaming said composition; b) applying a coating of the foamed composition to a cylinder having an array of mutually spaced open cells on the surface thereof and c) transferring said composition from the cylinder to the surface of said web and immobilizing said solids on the surface of said web as a residue formed of said solids, characterized in that the foamed composition for applying the coating according to step b) comprises non-uniform foam bubbles having a median size (measured as bubble diameter) larger than the median maximum diagonal dimensions of said cells, that after step b) and prior to step c) the coating of the foamed composition is converted to discrete liquid composition membranes spanning said cells, with the cell volumes beneath said membranes as well as the land areas between said cells being substantially free of said composition, and in that in step c) the composition is transferred in the form of said liquid composition membranes.
  • the present invention also includes a rotary gravure printing process employing a water-based liquid ink composition, said process comprising a) foaming said liquid ink composition; b) applying a coating of said foamed ink composition to the surface of a rotating gravure cylinder, the surface of said cylinder having an array of differently sized open cells spaced one from the other and c) transferring said ink composition from the gravure cylinder onto the surface of a web by pressing said web against said cylinder, characterized in that the foamed ink composition for applying the coating according to step b) has a minimum bubble size (measured as bubble diameter) which is larger than the maximum depth of said cells, that after step b) and prior to step c) the coating is converted into discrete membranes spanning said cells by doctoring the surface of said cylinder, with the surface areas of said cylinder between said cells as well as the cell interiors underlying said membranes being substantially free of ink, and in that in step c) the ink composition is transferred in the form of said membranes.
  • the present invention lies, in part, in the surprising discovery that quite contrary to Kumins' teachings, the relative size and uniformity of the foam bubbles is not a dominant factor in the successful application of pigmented water based foamed ink in a rotary gravure printing process. Rather than attempting to fill cells with small foam bubbles, the present invention relies on an initial distribution of a layer of relatively large foam bubbles over the surface of an engraved cylinder, followed by a conversion of the bubbles through doctoring into discrete membranes spanning each of the cells, with the surface areas or "lands" of the cylinder between the cells as well as the cell interiors underlying the membranes being substantially free of ink.
  • the membranes then may be transferred directly onto the surface of a web by simply pressing the web against the doctored gravure cylinder by means of an impression roller.
  • the membranes may be transferred onto the surfaces of one or more intermediate rolls before finally being applied to the web surface.
  • the dimensional characteristics of the aforesaid membranes are largely independent of the volumetric characteristics of the cells, except that for a given surface tension, membrane thickness will vary in proportion to the open cell area. In any event, however, the membranes will deliver a smaller amount of pigment and liquid vehicle to the substrate being printed as compared with prior art solvent or water based foam systems, which rely on a loading of the cell in order to achieve effective printing.
  • the present invention 's more efficient deposition of ink translates into extraordinary savings in ink costs. Moreover, because the present invention is characterized by a lesser penetration of the liquid vehicle, the printer can employ less expensive papers without resulting show through, thus further reducing the cost of printing.
  • the present invention also makes it possible to apply opacity-contributing or hold-out coatings. These will upgrade the printing and/or aesthetic qualities of the paper. Most importantly, it has been discovered that the extremely quick-drying characteristic of the coatings makes it possible to achieve such coatings on-line, e.g. with a coating process preceding the printing process.
  • the surface-segregation of the coating materials might also facilitate the manufacture of thin two-sided sheet products wherein the sides are to have substantially different, even incompatible, properties.
  • one side can bear an acidic coating while the other side can carry a basic coating.
  • very thin sheets may be prepared having an electro resistive face coat and an electro conductive back coat without unacceptable contamination of one coating by the other.
  • the more efficient transfer of pigment in accordance with the present invention produces higher color intensity for a given gravure cell area as compared with the prior art processes.
  • Another advantage of the present invention is the drastic reduction of "web breaks" which have previously been associated with paper weakened by excessive liquid absorption. This is true despite the fact that, as a general rule, aqueous systems more readily wet most inexpensive, cellulosic substrates.
  • Still another advantage of the present invention relates to the Helio-Klischograph process of engraving gravure cylinders.
  • One of the concerns with this process has been the difficulty of obtaining sufficient cell volume to match the cell volumes obtained by earlier etching techniques. This problem is essentially eliminated with the present invention, since cell volume does not contribute to the efficiency of the printing operation. Rather, it is open cell area that is important, and this can be achieved easily by the Helio-Klischograph process by employing a diamond stylus with a more obtuse cutting angle.
  • the preferred formulations from which the foam is generated include pseudo-plastic or thixotropic additives.
  • such formulations be foamed to an expanded volume of from about 3 to 20 times the volume of the liquid composition.
  • High-stability foams of the prior art are not the most desirable. Rather, foams which have 25% drainage times of less than three hours are preferred. Those having 25% drainage times (NFPA STD 11, 1978, p. 11-98) of well below one hour are entirely acceptable.
  • the best compositions are those in which the drainage liquid is not formed by material drained out of bubbles films; instead, it is preferred that the liquid be largely derived from breaking bubbles.
  • foam compositions which do not dry out before the foam bubbles break and drain.
  • foams can be obtained if one avoids excessively foam-stabilized formulae.
  • a particular advantage of such foams is that they can be readily reworked, without any substantial reformulating, simply by refoaming.
  • the printer may utilize his material efficiently and minimize waste disposal problems.
  • a rotogravure printing apparatus comprising a gravure cylinder 10 rotatably mounted within the confines of an open-top fountain 12.
  • the engraved surface of the gravure cylinder is partially submerged in a body 14 of pigmented water based foamed ink.
  • the gravure cylinder is rotated in the clockwise direction, and its submerged surface is brushed continuously by a rotating cylindrical brush 16 submerged in the foam body 14 and also driven in the clockwise direction.
  • a doctor blade 18 wipes the surface of gravure cylinder 10 prior to its arriving at a printing nip 20 defined between the gravure cylinder 10 and an impression roll 22.
  • a paper web 24 is fed from a supply roll 26 through the printing nip 20 and then over a roll 28 on the way to a conventional cutting and folding apparatus (not shown).
  • the fountain 12 is connected via a supply line 30 to a foam generating unit 32 which operates on demand to foam a water based liquid ink or coating composition being supplied thereto.
  • foam may be continuously recirculated via suction line 34, pump 36 and delivery line 38 back to the opposite side of the gravure cylinder where freshly generated foam is also being delivered via line 30.
  • the surface of the gravure cylinder 10 has been engraved by a Helio-Klischograph, which as is well known to those skilled in the art, utilizes an electronically controlled diamond stylus (not shown) to cut out inverted pyramidal shaped cells of the type shown in Figures 2-6.
  • the cells are spaced one from the other by lands "L" whose dimensions vary depending on the depths and center-to-center spacing of the cells.
  • Open cell area (as viewed in plan) is a function of cell depth, i.e., the greater the depth to which the stylus is allowed to penetrate, the greater the open cell area.
  • foamable ink formulations utilized in the process of the invention are listed below. The following designations are used in these formulations:
  • a thixotropic or pseudoplastic contributing additive 50% by weight Kelco K8A13 (heteropolysaccharide-7) slurried in 150% by weight Butyl Carbitol@ obtained from Union Carbide Corp.
  • High-expansion foam concentrate called "High Expansion Foam” and obtained from National Foam Systems, Inc.
  • Ethylene glycol was added as a foam conditioner and the amount of pseudoplastic material was increased to 0.20%. Although the foam lacked consistency, the formula was applied successfully to a paper web. No change in color intensity was noted after a run of 1-1/2 hours. No indication of growth was noticed.
  • Example A 1% silicon surfactant (L-7129) was added to the formula of Example A. The addition of the surfactant resulted in a uniform foam. The formula was successfully applied to a paper web. No change in color intensity or growth in one hour.
  • Example A The formula of Example A was modified by increasing the weight percent of the resin from 11.0% to 20.0% and correspondingly decreasing the water content from 54.8% to 45.8%. This formula was successfully applied to a paper web. No change in color intensity was noted.
  • Example C The formula of Example C was modified by adding 1 % silicone surfactant (L-7129). This formula was successfully applied to paper web.
  • the foam had the following characteristics:
  • the perfluorocarboxylic acid was added to enhance the surface tension of the foam.
  • the formula was successfully coated on a transfer roll in a flexographic process.
  • the above liquid formulations were mixed by the foam generating equipment 32 with a pressurized gas such as air at the above specified expansion ratios, without attendant mechanical agitation.
  • the resulting foams had non-uniform bubble sizes (determined by bubble diameter) ranging from about 5 to 100,000 microns.
  • the median bubble size was larger than the maximum cell depth of the gravure cylinder, and observations of experimental runs indicated that median bubble size was substantially larger that the median maximum diagonal dimension of the open cell areas.
  • Figure 4 shows the condition of the gravure cylinder surface after it has entered the foam body and has been exposed to the brushing action of roll 16, but prior to its being wiped by the doctor blade 18.
  • the cylinder surface is coated with foamed ink in the form of randomly distributed bubbles 42 which as mentioned above, vary in size, with the minimum bubble diameter being larger than the maximum cell depth, and with the median bubble size being larger than the median maximum diagonal dimension of the open cell areas.
  • Figure 5 shows the condition of the gravure cylinder surface immediately after it has been wiped by the doctor blade 18 but prior to its entry into the printing nip 20. It will be seen that the bubble coating shown in Figure 4 has been converted by doctoring into discrete extremely thin membranes 44 covering or spanning the cells 40a-40e. The above-stated relationship between the bubble size and cell depth is believed to contribute to this result by insuring that a major percentage of the bubbles are only partially received in the cells and thus are exposed to the wiping action of the doctor blade.
  • the lands L between the cells, and the interior cell portions underlying the membranes are free of ink, or at least substantially so.
  • Figure 6 shows the condition of the gravure cylinder surface as it passes through the printing nip 20 where it is brought into contact with the paper web 24. At this stage, the thin membranes 44 are picked up by the web, leaving the cylinder surface free of ink in the condition shown in Figure 3.
  • the process of the present invention also may be employed in flexographic printing.
  • an engraved anilox cylinder 50 is partially submerged in and rotated through a body 52 of foamed ink, the latter having been generated and delivered in accordance with previously described techniques.
  • a rotating submerged brush 54 again is employed to achieve appropriate distribution of foam over the surface of the anilox cylinder.
  • the foamed ink coating is then doctored as at 56 to convert the same to the previously described membranes spanning the engraved cells.
  • the membranes are then transferred to and deposited on the surface of a rotating intermediate rubber transfer roll 58. From here, the membrane deposits are transferred to the raised areas of a flexographic printing plate 60. Finally, the membrane deposits are applied to the surface of a moving web 62 which is pressed against the printing plate by an impression roll 64.
  • the present invention consists of a printing or coating process employing a water-based foamable composition.
  • the formulation is foamed and applied to the surface of gravure or anilox cylinders, with the foam bubbles being randomly sized and significantly larger on average as compared to the average cell size of the cylinders.
  • the cylinder surfaces are then doctored to convert the foam bubbles into thin discrete membranes which span or overlie the open cells, leaving the cell interiors underlying the membranes as well as the lands separating the cells substantially free of ink or coating deposits.
  • the membranes are then transferred, either directly or indirectly, onto the surface of a moving web.

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  • Printing Methods (AREA)

Claims (18)

1. Procédé pour l'application d'une composition liquide à base d'eau contenant des solides dissous ou en suspension, sur un voile en mouvement comprenant les étapes consistant à:
a) faire mousser ladite composition;
b) appliquer un revêtement de la composition moussée sur un cylindre ayant un réseau de cellules ouvertes mutuellement espacées sur sa surface;
c) transférer ladite composition du cylindre à la surface dudit voile et immobiliser lesdits solides sur la surface dudit voile sous la forme d'un résidu constitué par lesdits solides;

caractérisé par le fait que la composition moussée destinée au revêtement conformément à l'étape b) comprend des bulles de mousse non uniformes ayant une taille médiane (mesurée par le diamètre des bulles) supérieure aux dimensions diagonales maximales médianes desdites cellules, qu'après l'étape b), et avant l'étape c), le revêtement de la composition moussée est converti en membranes de composition liquide discrètes couvrant lesdites cellules, les volumes des cellules situés sous lesdites membranes ainsi que les aires planes séparant lesdites cellules étant sensiblement exempts de ladite composition, et par le fait qu'à l'étape c) la composition est transférée sous la forme desdites membranes de composition liquide.
2. Procédé selon la revendication 1, caractérisé par le fait que le voile est un substrat de papier et par le fait que lesdits solides comprennent des encres d'impression sélectivement distribuées sur ledit substrat.
3. Procédé selon la revendication 1, caractérisé par le fait que ledit substrat est un papier, que lesdites membranes sont tout d'abord transférées sur un rouleau de transfert sur lequel elles sont appliquées sous la forme d'un revêtement continu, puis transférées sur ledit papier, et par le fait que lesdits solides comprennent des moyens pour modifier les propriétés superficielles de ladite surface du papier.
4. Procédé selon la revendication 1, 2 ou 3, caractérisé par le fait que le transfert desdites membranes liquides s'effectue immédiatement après conversion de ladite mousse en lesdites membranes liquides.
5. Procédé selon les revendications 1, 2 ou 3, caractérisé par le fait que ladite composition moussée a une densité d'environ 0,096 à environ 0,256 g/cml.
6. Procédé selon la revendication 1, ou 3, caractérisé par le fait que la mousse présente une instabilité à l'écoulement telle qu'elle se rompt et qu'elle donne un liquide d'écoulement qui se prête à un recyclage direct dans ledit procédé.
7. Procédé selon la revendication 1, ou 3, caractérisé en ce que le temps d'écoulement à 25% de ladite composition moussée est inférieur à environ 4,0 heures.
8. Procédé selon la revendication 1, 2 ou 3, caractérisé par le fait que la composition liquide à partir de laquelle ladite mousse est formée, est un liquide pseudo-plastique.
9. Procédé selon la revendication 1, 2 ou 3, caractérisé par le fait que ladite composition moussée est constituée d'une composition liquide pseudo-plastique et est caractérisée par une densité inférieure à environ 0,256 g/cm3 et qu'elle est telle qu'à l'écoulement, les bulles de mousse se rompent en donnant un liquide d'écoulement se prêtant à un recyclage direct dans ledit procédé.
10. Procédé selon la revendication 1, 2 ou 3, caractérisé par le fait que le temps d'écoulement à 25% de ladite mousse est inférieur à environ trois heures, et que le liquide d'écoulement est un liquide pseudo-plastique qui peut être transformé en une mousse ayant une densité inférieure à environ 0,256 g/cm3 en vue de son recyclage dans ledit procédé.
11. Procédé d'impression selon la revendication 1, caractérisé par le fait que le transfert desdites membranes liquides de ladite surface du cylindre vers ledit voile, comprend les étapes supplémentaires consistant à:
a) effectuer un premier transfert desdites membranes liquides vers un système à rouleau de transfert, ledit système à rouleau de transfert comprenant des moyens pour convertir lesdites membranes liquides en une pellicule continue, et
b) effectuer un second transfert de parties de ladite pellicule vers une plaque d'impression suivi par un transfert final desdites parties de pellicule entre ladite plaque d'impression et une surface dudit voile.
12. Procédé selon la revendication 11, caractérisé par le fait que ledit rouleau d'impression est un rouleau d'impression flexographique.
13. Procédé selon la revendication 11, caractérisé par le fait que ledit voile en mouvement est une feuille de papier.
14. Procédé d'impression par gravure rotative utilisant une composition d'encre liquide à base d'eau, ledit procédé consistant à:
a) faire mousser ladite composition d'encre liquide;
b) appliquer un revêtement de ladite composition d'encre moussée sur la surface d'un cylindre de gravure rotative, la surface dudit cylindre ayant un réseau de cellules ouvertes de dimensions différentes espacées les unes des autres; et
c) transférer ladite composition d'encre du cylindre de gravure vers la surface d'un voile, par pressage dudit voile contre ledit cylindre, caractérisé par le fait que la composition d'encre moussée destinée à l'application du revêtement selon l'étape b), a une taille de bulle minimale (mesurée par le diamètre des bulles) qui est supérieure à la profondeur maximale desdites cellules, qu'après l'étape b) et avant l'étape c), le revêtement est converti en des membranes discrètes recouvrant lesdites cellules, par raclage de la surface dudit cylindre, les aires dudit cylindre séparant lesdites cellules, ainsi que les intérieurs des cellules sous-jacents auxdites membranes étant sensiblement exempts d'encre, et par le fait qu'à l'étape c) la - composition d'encre est transférée sous la forme desdites membranes.
15. Procédé d'impression selon la revendication 14, caractérisé par le fait que lesdites cellules ont des profondeurs allant d'environ 2 à 40 microns, et que ladite mousse a une taille de bulle médiane (mesurée par le diamètre des bulles) supérieure à 40 microns.
16. Procédé d'impression selon la revendication 14, caractérisé par le fait que ladite composition d'encre moussée a une taille de bulle (mesurée par le diamètre des bulles) allant d'environ 5 à 100 000 microns, que la profondeur maximale des cellules est d'environ 40 microns, et que la dimension diagonale des superficies des cellules ouvertes lorsqu'elles sont vues dans un plan, va d'un minimum de 40 microns à un maximum d'environ 200 microns.
17. Procédé d'impression selon la revendication 14, caractérisé en ce que l'application dudit revêtement sur la surface dudit cylindre, est réalisée en plongeant partiellement et en faisant tourner. ladite surface dans une masse de ladite composition d'encre moussée.
18. Procédé d'impression selon la revendication 17, caractérisé en ce que la surface dudit cylindre est mécaniquement brossée tout en étant plongée dans ladite masse.
EP83102605A 1982-03-22 1983-03-16 Procédé d'impression et de couchage utilisant des compositions moussées à base d'eau et de pigment Expired EP0089616B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT83102605T ATE34942T1 (de) 1982-03-22 1983-03-16 Druck- und beschichtungsverfahren mit pigmentierten waesserigen schaumzusammensetzungen.

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US36061582A 1982-03-22 1982-03-22
US360615 1982-03-22
US06/419,233 US4474110A (en) 1980-03-22 1982-09-17 Process employing pigmented water based foamed compositions
US419233 1982-09-17

Publications (3)

Publication Number Publication Date
EP0089616A2 EP0089616A2 (fr) 1983-09-28
EP0089616A3 EP0089616A3 (en) 1985-01-16
EP0089616B1 true EP0089616B1 (fr) 1988-06-08

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Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH027663Y2 (fr) * 1985-09-06 1990-02-23
IT1274103B (it) * 1994-11-11 1997-07-15 Gd Spa Dispositivo gommatore
WO2009075339A1 (fr) * 2007-12-12 2009-06-18 Ricoh Company, Ltd. Appareil de formation d'image et dispositif d'application de mousse
FI20085765A0 (fi) * 2008-08-11 2008-08-11 Upm Kymmene Corp Menetelmä painopaperin valmistamiseksi
TW201332780A (zh) * 2011-10-25 2013-08-16 Unipixel Displays Inc 經由苯胺印刷製程減少眩光的方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0089615A1 (fr) * 1982-03-22 1983-09-28 Foamink Company Composition d'encre mousseuse et procédé pour la préparer

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2971458A (en) * 1957-12-30 1961-02-14 Interchem Corp Process of coloring textile materials
US3400658A (en) * 1965-04-20 1968-09-10 Interchem Corp Method of intaglio printing
US3595772A (en) * 1968-10-03 1971-07-27 Xerox Corp Method of breaking particle agglomerates in the photo electrophoretic imaging system
FR2409095A1 (fr) * 1977-11-18 1979-06-15 Peintures Ind Ass Procede de traitement de surface d'un support poreux

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0089615A1 (fr) * 1982-03-22 1983-09-28 Foamink Company Composition d'encre mousseuse et procédé pour la préparer

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DE3376968D1 (en) 1988-07-14
EP0089616A3 (en) 1985-01-16
EP0089616A2 (fr) 1983-09-28

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