JP2009527659A - Substrate treatment method - Google Patents

Abstract

The present invention relates to a method for treating a substrate. According to one aspect of the present invention, there is provided a processing method characterized in that a polymer paint is applied to a substrate and the polymer paint is brought into contact with a heated surface before the polymer paint dries. Optionally, the polymer coating may contain a crosslinkable material, and a crosslinking agent may be used to promote crosslinking. The polymer paint reflects the heated surface. The present invention also relates to a product produced by the method described above. This product is characterized by a void below the surface of the coating.

Description

  This application has priority under United States Patent Law Section 119 (e), based on US Application No. 60/776114, provisionally filed February 23, 2006, which is hereby incorporated by reference.

  The present invention relates to a method of treating a substrate using a polymer thin film forming composition. In particular, the present invention relates to a paper or paperboard manufacturing method comprising a method of applying a coating for forming a polymer thin film to a substrate and a method of bringing a polymer coating into contact with a heated surface before the polymer coating dries. The obtained polymer layer has a smooth surface and has voids (for example, bubbles) just below the surface. In one embodiment, a cross-linkable hydrogel is contained in the polymer paint, and a cross-linking solution is further applied to the surface of the substrate on which the polymer paint is applied to form a polymer film at least partially cross-linked. In contact with the heated surface. The invention also relates to a processed substrate product.

  Paper is basically manufactured by a continuous manufacturing method. A dilute aqueous slurry of cellulosic fibers is allowed to flow into the wet end of a paper machine, and a dried and solidified web with a non-constant length is fed from the dry end of the paper machine. Discharge continuously. The wet end of the paper machine is provided with one or more head boxes, a drainage unit, and a compression unit. A dry end of a modern paper machine is provided with a plurality of rotating shell cylinders heated by steam along a web meandering under a heat sealing hood structure. Each part of these paper machines has a number of structures, of which the most important commercially is the long net paper machine. In a long net paper machine, slurry is sprayed over a wide area on a moving screen of very fine eyes in a head box.

  The screen is constructed and operated like an endless belt carried by a plurality of support rolls or foils. As the screen moves along the platform portion of the circulating screen path, moisture is drawn from the slurry through the screen due to the pressure difference between the side in contact with the slurry and the opposite side. As the dilution water of the slurry is drawn, the fibrous components in the slurry accumulate on the screen surface, resulting in a wet but fully reinforced mat. By the time the end of the orbiting screen platform is reached, the mat is large enough and tensile strength to carry a short distance between the screen and the first press roll. In the first press roll, the mat is drawn into the first press nip where most of the water remaining in the mat is removed by pressing the roll nip. In addition, one or more additional press nips may follow.

  After the compression section, the mat continuum becomes a so-called web, which is sent to the drying section of the paper machine to remove the remaining moisture thermodynamically.

  In general, the most important fibers in papermaking are those obtained from coniferous and hardwood tree species, but fibers from straw and bagasse are also used in certain cases. Chemical and mechanical disaggregation methods well known in the prior art are performed to separate papermaking fibers from natural fibers. Papermaking fibers obtained from chemical disaggregation methods and methods are generally referred to as chemical pulp, whereas papermaking fibers obtained from mechanical disaggregation methods and methods are referred to as ground pulp or mechanical pulp. There are also complex disaggregation methods such as semi-chemical, thermochemical, or thermomechanical methods. Any tree species can be disaggregated by either chemical or mechanical methods, but some tree species and disaggregation methods are better in economic or functional combinations than others.

  A significant difference between chemical and mechanical pulp is that mechanical pulp can be sent directly to the paper machine from the disaggregation stage. On the other hand, in chemical pulp, after chemical digestion, it must be mechanically disaggregated at least and washed and screened. Usually, after screening, chemical pulp is mechanically refined before being sent to the paper machine. Although the average fiber length of mechanical pulp is generally shorter than that of chemical pulp, the fiber length is highly dependent on the type of wood from which the fiber is made, and coniferous fibers are usually about three times longer than hardwood fibers.

  Most of the basic properties of a particular paper are determined by the type of raw materials used and the way these raw materials are processed in the paper machine and web forming process. The key operating elements in the web forming mechanism are the headbox and screen.

  Coated paper or paperboard used for printing and packaging is generally required not only to have a certain strength and rigidity, but also to have a strong gloss, be very smooth, and have excellent printability.

  If the coated paper or paperboard has a high rigidity, it can be smoothly passed through a high-speed printing machine or a high-speed packaging machine, and there are few paper jams. Furthermore, the stiff paper has a hardness and weight feeling similar to that of a hardcover book, so it is convenient for use in books, magazines, and catalogs. For packaging, high rigidity is required to maintain the entire structure of the paperboard product during packaging and subsequent handling.

  Rigidity is closely related to basis weight and paper density. As a general trend, the stiffness increases with increasing basis weight and decreases with increasing paper density. Increasing basis weight can improve stiffness and other properties, but this uses more fiber in the product, leading to increased cost and weight. For this reason, a coated paper or paperboard having a high rigidity and a reduced basis weight is desired. Paper with a reduced basis weight is more economical because the amount of raw material (fiber) used is small. Further, since the basis weight of the paper is low, the transportation cost determined by the weight is reduced.

  In addition to high rigidity, the coated paper or paperboard to be printed often requires strong gloss and smoothness. In coated paper or paperboard having such quality characteristics, the density is usually increased to some extent in order to obtain a printing surface suitable for use. Although the smoothness is usually given by calendering, the calendering reduces the thickness of the paper, and accordingly the rigidity decreases accordingly. In calendering, the thickness is significantly reduced and the density is increased, so that the rigidity of the paper is lowered. In order to obtain a surface roughness sufficient to produce a coated surface acceptable in the industry, the density of the conventional base paper for coated paperboard is made extremely high by calendering. These calendering processes, including wet lamination, can increase the density by about 20-25%.

  As described above, the relationship between gloss and rigidity and the relationship between smoothness and rigidity are generally inversely proportional to the amount of fibers per unit area. Since packaging paper is sold on the basis of thickness, a manufacturing method in which the thickness decreases (the density of the paperboard increases) reduces the selling price. Material costs can be saved by reducing the thickness. Thickness is measured in “points”, where 1 point = 0.001 inch. For example, to make a 10-point paperboard by a conventional method, a paperboard having a thickness before calendering greater than 12 points must be used. Therefore, it is desired that a paperboard having the same thickness as the first base material can be produced.

  Although improved slightly in rigidity at any thickness due to improvements in calendering methods including humidity gradient calendering, heat calendering, soft calendering, and belt calendering, between thickness, stiffness, smoothness, and printing characteristics The fundamental ratio of has not changed.

  Various proposals have been made to improve the rigidity of coated paper or paperboard without calendering for printing. For example, in one proposal, a raw material containing a large amount of conifers, specially processed fibers and highly branched polymers added thereto, starch, or a copolymer having a high glass transition temperature (usually expressed as “Tg”) A large amount of latex is contained in the paint component.

  However, while these methods for improving stiffness are useful for increasing the stiffness of the paper, the potential for reduced smoothness, gloss, and / or printability of the resulting coated paper is possible. There are some disadvantages.

  For the above reasons, it has been very difficult to obtain sufficient paper smoothness without increasing the density. Other methods can be used to change the density / smoothness relationship in paper and paperboard. In the calendering necessary to obtain a predetermined smoothness, the paper density is usually affected by the degree of addition, but as a way to improve the paper surface properties without significantly increasing the paper density, Coating is common. Preferably, the final coated surface is uniform in order to obtain a certain degree of appearance and printing characteristics.

  Accordingly, it is desirable to provide a paper or paperboard product having the desired properties while maintaining the original density of the paper or minimizing the increase in density. Further, in the conventional smoothing method, the density increases as the smoothness is improved. However, it is desirable to improve the smoothness without increasing the density and to provide paper or paperboard. There is a cast coating method that can provide a very smooth surface, but generally this method is slower in production than many paper machines.

  According to one embodiment of the present invention, the product includes a substrate having a coating film, the coating film contains a water-soluble polymer and a release agent, and voids are formed in the coating film. .

  According to another embodiment of the present invention, the product comprises a substrate having a coating, the coating containing a water-soluble polymer and essentially free of elastomeric material. In addition, voids are formed in the coating film.

  According to another embodiment of the invention, the product comprises a substrate having a coating, and the surface of the coating has a Sheffield smoothness of less than about 300. A void is formed under the surface of the coating film.

  According to another embodiment of the present invention, the product comprises a substrate having a coating film, the coating film contains a water-soluble polymer and a release agent, and is essentially free of elastomeric material. Further, the surface of the coating film has a Sheffield smoothness of less than about 300, and voids are formed under the coating film surface.

  According to another embodiment of the present invention, in a method of treating a substrate, a wet film of a water-soluble polymer solution is applied to the substrate, and the water-soluble polymer solution is brought into contact with a heated surface to thereby improve the water solubility. The molecular solution is boiled and at least part of it is dried and fixed.

  According to another embodiment of the present invention, in a method of treating a substrate, a wet film of a water-soluble polymer solution is applied to the substrate, and the water-soluble polymer solution is brought into contact with a heated surface to thereby improve the water solubility. The molecular solution is boiled to form voids remaining in the water-soluble polymer solution, and at least a part of the water-soluble polymer solution is dried and fixed.

  According to another embodiment of the present invention, in a method of treating a substrate, a water-soluble polymer solution paint is applied to the substrate as a wet film. The paint contains a water-soluble polymer and a release agent. Then, by bringing the membrane into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds, the water-soluble polymer solution is boiled to form voids in the membrane, and at least a part of the membrane is dried and fixed. To do.

  According to another embodiment of the present invention, in a method of treating a substrate, a water-soluble polymer solution paint is applied to the substrate as a wet film. The paint contains a water-soluble polymer and essentially no elastomer material. Then, by bringing the membrane into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds, the water-soluble polymer solution is boiled to form voids in the membrane, and at least a part of the membrane is dried and fixed. To do.

  According to another embodiment of the present invention, in a method of treating a substrate, a water-soluble polymer solution paint is applied to the substrate as a wet film. The paint contains a water-soluble polymer and essentially no elastomer material. Then, by bringing the membrane into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds, the water-soluble polymer solution is boiled to form voids in the membrane, and at least a part of the membrane is dried and fixed. To do. The surface of the paint after drying has a Sheffield smoothness of less than about 300.

  According to another embodiment of the present invention, in a method of treating a substrate, a water-soluble polymer solution paint is applied to the substrate as a wet film. The paint contains a water-soluble polymer and a release agent, and basically contains no elastomer material. Then, by bringing the membrane into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds, the water-soluble polymer solution is boiled to form voids in the membrane, and at least a part of the membrane is dried and fixed. To do. The surface of the paint after drying has a Sheffield smoothness of less than about 300.

  According to another embodiment of the present invention, in a method for treating a cellulosic substrate, a wet film of a water-soluble polymer solution is applied to the substrate. The water-soluble polymer solution contains at least about 60% of the water-soluble polymer by dry weight and 10% or less of the release agent by dry weight. Then, by bringing the water-soluble polymer solution into contact with the heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds, the water-soluble polymer solution is boiled to form voids in the water-soluble polymer solution. At least a part of the polymer solution is dried and fixed.

  In preferred embodiments of the present invention, specific terminology is used for the sake of clarity. Such terms include not only the described embodiments but also all technical equivalents used in a similar manner for the purpose of obtaining similar results. Citation of any document is not to be construed as prior art to the present invention. Unless otherwise stated or indicated otherwise by context, all weights, percentages, and ratios are by weight.

  The present invention relates to a method for treating a substrate using a coating material for forming a polymer thin film. In particular, the present invention relates to a paper or paperboard manufacturing method comprising a method of applying a polymer coating to a substrate and a method of bringing the polymer coating into contact with a heated surface before the polymer coating dries. By boiling water in the polymer coating, voids are formed under the surface of the coating film, but the film surface is smooth. A paper or paperboard made according to an embodiment of the present invention achieves a desired level of surface smoothness without significantly increasing the density of the base paper. In the embodiment, a polymer thin film forming composition in which at least a part of the polymer coating composition is crosslinked by applying a crosslinking solution onto a substrate on which the polymer coating composition contains a crosslinking material and the polymer coating composition is coated on the surface. May be formed. In such cases, the paint is usually applied to the web first, then the cross-linking solution is applied, and then the processed web is brought into contact with the heated surface. In the case of a polymer having a weak cross-linking, the polymer can be used as a cross-linking solution in the coating material.

  The advantage of treating the substrate with the polymer film-forming coating according to the present invention is that smoothness can be improved without significantly increasing the paper density or decreasing the paper thickness. When producing paper having printing characteristics equivalent to those of conventional coated paper, strong calendering of the cellulose web used in the prior art is not necessary. Furthermore, even when the cellulose web is made smooth, it can be carried out at a very low pressure, and the same printing characteristics are given to the paper with increased rigidity. According to certain embodiments of the invention, the cellulose web is smoothed so that the thickness reduction is about 7% or less, usually about 2% to 5%. In contrast, conventional coated papers are usually calendered at very high pressures before application, increasing the density by about 20-25%. According to one aspect of the present invention, the cellulose web may be calendered to a Parker Print Surf (PPS) smoothness of about 2-6 μm before applying the polymer film. . Moreover, you may use the base material whose parka print surf value is still higher. For example, you may use the base material whose parka print surf smoothness is about 9 micrometers. Parker print surf smoothness is defined by TAPPI standard T555 om-99.

  FIG. 1 illustrates an apparatus 10 useful for practicing certain embodiments of the present invention. In order to form a layer of the polymer coating film 16 on the substrate 12, the substrate 12 is coated with a crosslinkable polymer coating 14 on one surface thereof. The crosslinked polymer coating film 20 may be formed on the substrate 12 by applying an arbitrary crosslinking solution 18 to the layer of the polymer coating film 16 before the polymer coating dries. The polymer coating 20 is usually at least partially crosslinked. While the polymer coating is not yet dried, the web 12 is pressed against the surface of the high-temperature polished drum 22 by a press roll 24 and brought into contact with the drum 22. By boiling the wet polymer film by heat from the drum surface, voids are formed in the polymer below the surface of the film. The polymer coating is crosslinked with a crosslinking solution to form an essentially continuous layer or film-like semi-solid liquid. Usually, the obtained thin film shows higher strength than the base paper. The polymer-treated paper may be sent to the second heater 26 without being completely dried. Any type of second heater device can be used as long as it can be dried without adversely affecting the properties of the treated paper. The treated paper is discharged from the second heater 26 as the polymer thin film treated substrate 28, and the smoothness is improved. Optionally, the coated product 32 may also be produced using the coating method 30 (and other methods such as coating and gloss calendering).

  As shown in FIG. 1, the web covers most of the hot polished drum 22. The amount covered depends on operating conditions such as web speed, moisture content of the polymeric film-forming composition 20, drum temperature, and other process elements. It can also be set so that contact with the hot polished drum 22 is sufficient even in a short time. Moreover, although the web-shaped base material is used, you may use it in a sheet form.

  For application of crosslinkable polymer paints and optional crosslinking solutions, dip coating, rod coating, doctor blade coating, gravure roll coating, reverse roll coating, quantitative size press, smooth roll coating, extrusion coating, curtain coating, and spray coating Any technique may be used such as. The cross-linkable polymer coating and the cross-linking solution may be applied by the same application technique, or may be applied by different application methods.

One embodiment according to the invention is based on coagulation or gelation caused by the reaction of polyvinyl alcohol and borax. In such a reaction system, polyvinyl alcohol (PVOH) is an example of a crosslinkable polymer, and a borax solution is an example of a corresponding crosslinking agent. When the PVOH solution 14 is applied, about 25% is solidified, and the coating rate when dried is about 5 g / m ^{2. When} the crosslinking solution 16 is applied at a certain ratio, the solution is solidified and the borax coating rate when dried is at least About 0.1 g / m ² . Next, the wet crosslinked polymer thin film 20 is brought into contact with the drum 22 by pressing the web 12 against the surface of the drum polished at a high temperature with a press roll 24. The temperature of the drum surface is at least about 150 ° C., or in some embodiments at least about 190 ° C., so that the paint dries away from the drum surface. The time for bringing the polymer thin film into contact with the drum may be in the range of about 3.0 seconds or less, particularly about 0.5 to 2.0 seconds. This time is sufficient for fixing and solidifying the polymer thin film, and the surface of the polymer thin film is smooth, reflecting the drum surface. The immobilization of the polymer thin film is performed by at least partially drying the thin film. The paint need not be completely dry when leaving the drum, in which case further drying 26 is required. Further, the method may be advanced and before the web is rolled up, a layer of coating may be further layered on the web, for example with a conventional paint. The polymer coating can be applied in a single layer or in two or more layers. Limited tests show that the polymer thin film can be fixed or solidified by momentary contact with the heated drum without the need for extra web wrapping around the hot drum. This is considered to be achieved by pressing the web 12 against the hot drum 22. However, any felt 23 may be used to wrap the web around the hot drum several times or to easily press the web in contact with the hot drum. When the felt 23 is used so as to easily press the web in order to contact the high temperature drum, the felt 23 is used between the press roll 24 and the heated drum 22.

  When the polymer thin film comes into contact with the high-temperature drum, the polymer thin film boils and voids or bubbles are generated in the film. The nip condition may be adjusted so that boiling occurs. Good test results have been obtained using an elastic press roll, a 9 inch wide web and setting the nip load between about 2-15 pounds per linear inch. Whether or not the polymer thin film boils depends on the hardness of the press roll, the diameter of the high-temperature drum, and the diameter of the press roll, so it is necessary to adjust each condition.

A specific example of a crosslinkable polymer useful in certain embodiments of the present invention is a crosslinkable hydrogel. The following crosslinkable hydrogels are particularly effective: starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate. Among these, one or more polymers can be used. Usually, the crosslinkable polymer is used in a liquid state and generally used as an aqueous solution. The concentration of the polymer in the solution is not particularly limited, but can be easily set by those skilled in the art. For example, in the case of a solution containing about 20% starch, it can be used as follows. By using this crosslinkable polymer, the surface coverage (on an anhydrous basis) can be about 3 to about 15 g / m ² , especially about 4 to about 8 g / m ² . According to certain embodiments of the invention, the crosslinkable polymer may be used in the range of about 60 to about 100% by dry weight of the material.

Specific examples of the crosslinking agent include borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof. Usually, the crosslinking agent is used in a liquid state and generally used as an aqueous solution. The concentration of the crosslinking agent in the solution is not particularly limited, but can be easily set by those skilled in the art. A crosslinking agent may be used so that the surface coverage (on an anhydrous basis) is about 0.1 to about 0.5 g / m ² , particularly about 0.2 to about 0.3 g / m ² .

  The temperature of the heating surface is set to a temperature exceeding that normally used in dip coating. The higher the temperature of the heating surface, the faster the operating speed. Paper or paperboard made in accordance with certain embodiments of the present invention can be made at speeds in the range of about 750 to 3000 feet / minute, particularly about 1500 to 1800 feet / minute. Without being limited by theory, the higher temperature and contact time are set so that the coating composition is heated to its boiling point and the contact area between the coating and the drum increases during boiling of the coating. Increasing the contact area improves the smoothness and gloss of the heated surface of the polymer thin film. Furthermore, the processing surface can easily receive ink. The surface of the drum polished by the boiling of the paint becomes smooth, and the gloss and smoothness of the resulting polymer thin film-treated substrate are remarkably improved.

  Usually, the polymer paint on the substrate is pressed against the heating surface for a sufficient time so that the paint is boiled to obtain a smooth and glossy finish. According to a specific embodiment, the time for contacting the formed polymer thin film with the drum may be in the range of about 3.0 seconds or less, particularly about 2.0 seconds or less, and most preferably about 0.5 seconds or less.

  One or more pigments may be contained in the polymer paint. Effective pigments include but are not limited to kaolin, talc, calcium carbonate, calcium acetate, titanium dioxide, viscosity, zinc oxide, alumina, aluminum hydroxide, and amorphous silica, amorphous silica, or finely divided silica, etc. Examples of the synthetic silica are: Organic pigments may also be used.

  Moreover, you may make a crosslinkable polymer coating material and / or a crosslinking solution contain 1 or more types of mold release agents. The effective release agent is not limited here, but specifically, wax such as petroleum wax, plant wax, animal wax, and synthetic wax, fatty acid metal soap such as metal stearate, fatty acid ester, aliphatic amide Long chain alkyl derivatives such as aliphatic amines, fatty acids, and fatty alcohols, polymers such as polyolefins, silicone polymers, fluoropolymers, and natural polymers, fluorinated products such as fluorinated fatty acids, and mixtures thereof. It is done. A person skilled in the art can easily set the amount of the release agent used for a specific application. Usually, it is preferable to contain about 0.3 to 10% of the release agent in the paint, and particularly about 2 to 5% by weight. Instead of the release agent in the paint or in addition to the release agent in the paint, the release agent may be sprayed onto the surface of the coating film, or the release agent may be applied to the heated drum surface. When a non-adhesive surface can be provided on a heated drum by a release agent or other means, it is not necessary to include a release agent in the paint or to apply a release agent to the coating film surface.

  The polymer paint used in an embodiment of the present invention contains at least the aforementioned polymer, and is usually prepared in the state of an aqueous composition. The appropriate ratio of these components varies depending on the polymer composition, application conditions, and the like, but may be set so that the produced processed paper satisfies the quality required for the intended use, and is not particularly limited. Furthermore, according to an embodiment of the present invention, the polymer paint can contain any additive, such as a dispersant, a humectant, a thickener, an antifoaming agent, a preservative, a colorant, a waterproofing agent. , Wetting agents, drying agents, initiators, plasticizers, fluorescent dyes, UV absorbers, mold release agents, lubricants, and cationic polyelectrolytes.

  In a particular embodiment of the invention, the substrate is treated with a polymer paint near the center of the paper machine, such as a size press. In addition, in order to apply the polymer thin film to both sides of the web to be produced, an apparatus for applying a polymer coating to the base material may be installed at a position related to the paper machine. One or more devices may be used to apply the polymer film to both sides of the web to be produced.

  These advantages can provide paper or paperboard that is weakly calendered, so that rigidity can be maintained while providing good printing properties.

Conventionally, fibers conventionally used are used for the production of the base paper, but in a specific embodiment, kraft pulp or bleached kraft pulp is contained unexposed to the base paper. Pulp is composed of hardwood, softwood, or a mixture thereof. The basis weight of the cellulose fiber layer may be in the range of about 30 to about 500 g / m ² , particularly about 150 to about 350 g / m ² . The base paper may further contain organic or inorganic fillers, sizing agents, retention agents, and other auxiliaries well known in the art. The final paper product contains one or more cellulose fiber layers and polymer thin film layers, and in some embodiments, further contains other functional layers.

  According to one embodiment, the present invention provides a paper or board for printing or packaging, the paper or board being coated on one or both sides. The parka print surf smoothness of the paper and paperboard after the coating and all the methods are finished is determined according to TAPPI standard paper and pulp test method No. When measured by 5A, the value is lower than about 2-3 μm.

One or more coating films may be additionally provided on the paper or paperboard described here. In order to improve certain properties of the paper or paperboard, a topcoat containing conventional components may be provided. Examples of such conventional components include pigments, binders, fillers, and other special additives. If there is a top coat, it should be applied at a much lower coating weight than the conventional coating film, and the printing characteristics should be similar. Therefore, the weight of the top coat is preferably about 4 to 9 g / m ² when the coating film is a single layer, or about 8 to 18 g / m ² when the coating film is two layers. On the other hand, in order to obtain equivalent surface characteristics, the conventional coated paper is usually about 10 to 20 g / m ² when the coating film is a single layer, and about 18 to 30 g / m when the coating film is two layers. ^{2 is} required. Such coating may be performed on the non-treated surface side of paper or paperboard.

  Although the present invention has been disclosed so far, a specific example will be described below. This specific example does not limit the scope of the claims.

A base paper having a thickness of about 10 points, a Parker Print Surf (PPS) value of about 9 μm (measured under soft backing, pressure of 10 kg), and a Sheffield smoothness of about 310 is processed according to an embodiment of the present invention. Thus, it is possible to obtain a treated paper having an improved smoothness while minimizing a decrease in thickness. A PVOH solution that solidifies about 25% may be applied to the base paper so that the coverage during drying is about 5 g / m ² . Next, a crosslinking solution is applied at a certain ratio, and the solution is solidified so that the borax coverage during drying is at least about 0.1 g / m ² . The wet cross-linked polymer thin film is brought into contact by pressing the base paper against the hot polished drum surface. The surface temperature of the drum is at least about 190 ° C. The paint was then dried away from the drum surface. The contact time of the polymer thin film with the drum was usually in the range of about 0.5 to 2.0 seconds. The thickness of the treated paper was about 9.6 to 10.0 points, the PPS value was about 2.4 to 3.0, and the Sheffield smoothness was about 140 to 170.

  In a preferred embodiment, a starch solution may be used as the polymer material for the polymer coating.

  One embodiment of the present invention relates to a method for manufacturing paper or paperboard. According to one embodiment of the present invention, a polymer coating containing a crosslinkable hydrogel is applied to a substrate, and a polymer thin film is formed that is at least partially crosslinked by applying a crosslinking solution to the polymer coating on the surface of the substrate. A manufacturing method is characterized in that a paint is formed and the polymer thin film-forming paint is brought into contact with the heating surface before the polymer thin film-forming paint is dried. As the heating surface, a high-temperature polished drum with a smooth surface finish may be used. The temperature of the heating surface is usually in the range of about 150 ° C to about 240 ° C. For example, the temperature may be set higher in the range of about 300 ° C. or lower. In some embodiments, the temperature of the heated surface ranges from about 180 ° C to about 200 ° C, and in some embodiments is at least about 190 ° C.

  According to certain embodiments of the invention, the crosslinkable polymer may be selected from starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate. In certain embodiments of the present invention, it is preferred to use the crosslinkable polymer in the range of about 60 to about 100% by weight of the material upon drying.

  Specifically, the cross-linking agent includes borate and borate derivatives such as borax, sodium tetraborate, boric acid, phenylboronic acid, or butylboronic acid. The crosslinking agent may be used in an amount ranging from about 1 to about 12% with respect to the crosslinkable polymer.

  The present invention also relates to a processed paper produced by the method described in the specification. The processed paper is characterized in that the smoothness is improved while the increase in density is relatively less than that of the original paper.

  Desirably, the paint is not dry when it is brought into contact with the heated drum, so the paint may be moistened, for example, by hydration. Although there is a method of spraying water on the paint before the paint is brought into contact with the high temperature drum, according to an embodiment, the operation is possible without further humidification.

  According to certain embodiments, starch may be used as the soluble polymer. In addition, according to an embodiment, a starch-based paint can be used satisfactorily without a cross-linking agent, and good results can be obtained without gelation (also called coagulation).

  Under the above conditions, a starch solution containing 2 to 5% of the release agent was brought into contact with a heated drum. When it is desirable to humidify the paint under certain conditions, the surface of the polished drum can be satisfactorily reflected in the coating film by using only water as a spraying agent. If the solidification of the paint is sufficiently slow, the method can proceed satisfactorily without spraying water for humidification. When the starch coating containing 20% solid was applied to the web and brought into contact with a heated drum, the surface of the polished drum could be reflected well in the coating.

  Also tested were starch paints containing 25% or 30% solids. Although both of these paints peeled off without adhering to the drum, the drum surface was not reproduced well. The paint surface with 25% solids reproduced the drum surface to a good extent, but with the paint with 30% solids, the reproduced drum surface was not very smooth. It can be seen that if a certain amount of moisture is present on the surface, the entire coating is likely to boil. When the moisture on the surface is less than a certain amount, a part of the surface is sufficiently boiled and the drum surface is reproduced well, but the drum surface is not reproduced well on other surfaces. Thus, as the solids in the paint increase by more than 20%, the proportion of the area that reflects the smooth drum surface decreases unless water is sprayed on the coating surface to humidify it. At about 30% solids, little or no drum surface smoothness is reflected in the coating. If water is sufficiently sprayed on the paint containing 30% solid before contacting with the heated drum, the surface of the drum can be completely reflected in the coating film. In addition, this relationship is considered to be affected by the absorbency of the raw material, the coating weight, the viscosity of the paint, and the processing speed. The effects of these factors can be confirmed by further testing.

  The above examples were performed using a heated drum chrome surface. In the example described below, the surface of the tungsten carbide coating was newly prepared on the drum. In each case, several runs were performed to collect data. The operation is performed by heating the drum to about 190 ° C., setting the spraying speed, applying the paint to the web by the quantitative rod method, and optionally spraying for humidification (optionally containing a crosslinking agent). The web was brought into contact with the drum at 35 ft / min. The drum temperature varied between 180 ° C and 190 ° C during operation. During operation, only the weight of application by the quantitative rod was variable. In other tests using this device, the type of paint, the solid in the paint, or the spraying speed was varied. The coating weight was measured by the differential weight and expressed as an anhydrous weight. In some tests, when a material that was not strongly cross-linked, such as starch, was used in the paint, operation was performed using the cross-linking agent in the paint.

Example 1
A minimally pressed base paper having a basis weight of 111 pounds / 3000 square feet was used as a substrate, and a simple coating composition was applied thereto for processing. The first coating film consisted of 95% CELVOL203S polyvinyl alcohol (PVOH) and 5% Emtal 50 VCS by dry weight, and triglyceride was used as a release agent. The solid in the paint was 20% by weight. The paint was applied with a metering rod. The table below summarizes the samples and test conditions. Sample 1.1 was prepared by spraying a coating solution containing 3% by weight of borax and 1% by weight of sulfated oil as a release agent. The spraying speed was 48 ml / min. Sample 1.1 reproduced the drum surface well, peeled off without adhering to the drum, and noticeably improved smoothness while minimizing thickness reduction. Sample 1.2 had the same conditions as Sample 1.1 except that borax was not used in the spray solution. When borax for crosslinking polyvinyl alcohol was not used, the coating film did not leave the drum surface, and a part of the thin film remained attached to the drum surface. This test revealed the effect of cross-linking polyvinyl alcohol.

table

  In other operations, carboxymethyl cellulose (CMC) was used instead of polyvinyl alcohol, and the performance of the polymer was compared. FINFIXX30 was used for carboxymethylcellulose, and operation was possible only when the solid content in the paint was 7% because of the viscosity of the paint. The paint component is 95% polymer and 5% Emtal. Samples 1.3 and 1.4 had different coating weights, and sprayed with a borax-containing spray solution at 48 ml / min. These paints reproduced the drum surface well and completely peeled off the drum. The smoothness was improved while minimizing the decrease in thickness, but the smoothness was not as good as when polyvinyl alcohol was used. In the operation in which Sample 1.5 was produced, borax was not included in the spray solution. The paint of Sample 1.5 reproduced the drum surface well and completely peeled off the drum. Here, the smoothness was improved as compared with samples 1.3 and 1.4 by removing borax. From this, it can be seen that the surface of the drum can be reproduced even with a non-crosslinked paint, and it can be peeled off from the drum, and it can be said that materials other than the crosslinkable material can also be used in this method.

Example 2
A minimally pressed base paper having a basis weight of 111 pounds / 3000 square feet was used as a substrate, and a simple coating composition was applied thereto for processing. The first coating film consisted of 95% CLERER-COTE625 starch (viscosity modified waxy corn starch) and 5% Emtal 50 VCS by dry weight, and triglyceride was used as a release agent. The solid in the paint was 20% by weight, and coating was performed with a quantitative rod. Sample 2.1 was prepared by spraying the coating film with a crosslinking solution containing 3% by weight of borax and 1% of sulfated oil as a release agent. The spraying speed was 48 mm / min. Sample 2.1 reproduced the drum surface well and peeled off without adhering to the drum. Smoothness was significantly improved while minimizing thickness reduction. Samples 2.2, 2.3, 2.4, and 2.5 were prepared using the same paint and changing the coating weight without containing borax. All of these samples reproduced the drum surface well and peeled completely from the drum. Samples 2.6 and 2.7 were made without spraying. These samples reproduced the drum surface well and peeled completely from the drum. The smoothness is not very good, but it is much improved while minimizing the decrease in thickness. Thereby, it turns out that a method can be advanced even if it does not use the spray liquid for humidification.

Example 3
This test is a continuation of Example 2, in which the effect of solids in the paint was examined. Samples 3.1 and 3.2 were made with 23% solids in the paint and no humidified spray. These reproduced the drum surface well and peeled off the drum well. Samples 3.3 and 3.4 were made without increasing the solids in the paint to 25.7% and using a humidified spray. These completely peeled off the drum, but the reproduction of the drum surface was incomplete. According to visual inspection, only about 90-95% of the drum surface was reproduced. In Samples 3.5 and 3.6, the solid in the paint was similarly 25.7%, and the humidified spray was sprayed at 48 ml / min. These samples perfectly reproduced the drum surface and greatly improved the smoothness. In samples 3.7 to 3.12, the solid in the paint was 30%. When the humidified spray was not used (3.7), the sample completely peeled off the drum surface, but the drum surface was only slightly reproduced. When the humidified spray was sprayed at 48 ml / min (3.8), the reproduction of the drum surface of the sample was greatly improved, but there was still a portion where the reproduction of the drum surface was poor. When the spray of humidified spray is 98 ml / min (3.9, 3.10.3.11, and 3.12), the drum surface is perfectly reproduced and smooth while minimizing thickness reduction. The degree was greatly improved. Next, the amount of solids in the paint was reduced. When the solid in the paint was 17.5% and the humidified spray was not used (3.13, 3.14), the sample peeled well from the drum and reproduced the drum surface well. When the solid in the paint is 10% and the humidified spray is not used (3.15), the viscosity of the paint is low, so the coating weight decreases and the amount of paint absorbed by the paper increases, resulting in a good drum surface Was not reproduced.

  Compared to a smooth product sample made with 20% solids in the paint and starch as a polymer paint, a conventional colored clay paint (about 2/3 is viscosity and about 1/3 is from carbonate) On the surface of the smooth polymer layer (containing a latex binder and one coat at about 10 pounds / 3000 square feet). And in order to investigate the form of a coating layer, these samples were cut | disconnected in the cross section. The sample was frozen in liquid nitrogen and cut, and the sample was divided in two (freeze fracture). The divided edges (cross section, etc.) of the sample were observed with a microscope.

  In FIG. 2 to FIG. 9, dimension lines for indicating the scale are shown, and from the microphotographs of these figures, it was revealed that voids exist in the polymer coating layer. 2 to 5, the magnification of the microscope is 1000 times, and the dimension line indicates 20 μm. For example, in FIG. 2, a paperboard substrate 110 is shown. Usually, the thickness of the substrate extends below the range of the micrograph. Since the freeze fracture method is used, the substrate 110 shown in the micrograph may be peeled off from the polymer layer 120 or may be partially peeled off. For this reason, the upper boundary of the substrate 110 is roughly indicated by the position of the square brackets indicating the substrate.

  As described above, these samples are obtained by applying the polymer coating layer 120 on the substrate 110 and bringing it into contact with a heated drum and drying it. Further, the top coat 130 was applied and dried. As used herein, the term “polymer paint” means a layer applied as described above. “Top coat” means an outer layer, which is a single layer applied. Needless to say, one or more top coats can be applied, and coating materials other than those used here may be used.

  As shown in FIGS. 2 to 9, the void 121 is clearly present in the polymer coating layer 120. For example, in FIG. 2, several voids 121 are seen in the polymer coating layer 120, and these voids are about 5 to 20 μm in the horizontal direction. It is considered that the size of the gap in the direction from the dividing surface into the sample is similar. Usually, the gap is somewhat flat in the vertical direction, that is, in the thickness direction of the sample. There are “partitions” in the voids, which are relatively smooth and usually thin. These thin barriers are common between adjacent voids. Although it is difficult to determine the thickness of the gap partition wall adjacent to the top coat 130, it is estimated from the smooth lower contour of the top coat 130 adjacent to the gap.

  FIG. 3 is an example of a photomicrograph showing several voids 121 in the polymer coating layer. The voids are spread over a half of the coated surface. The polymer paint layer cannot be distinguished well from this photomicrograph.

  FIG. 4 is an example of a micrograph showing several voids 121 in the polymer coating layer. As can be seen from the somewhat translucent appearance of the partitions in these two voids, the void partitions are found to be relatively thin.

  5-9, the magnification of a microscope is 500 times and a dimension line shows 50 micrometers. In FIG. 5, several voids 121 are shown in the polymer layer 121, and a size line is shown by putting a dimension line in each of the voids, and the size is shown accordingly. From right to left, they are 10.5 μm in the vertical direction, 36 μm in the horizontal direction, 10.6 μm in the vertical direction, and 36.3 μm in the horizontal direction. Moreover, the space | gap has spread in the range exceeding about half of the application | coating surface.

  In FIG. 6, other samples are shown with similar dimension lines, and the size of the gap is, for example, from left to right, 8.66 μm in the vertical direction, 32.1 μm in the horizontal direction, and 11.8 μm in the vertical direction. 22.7 μm in the horizontal direction. These measurements in FIGS. 5 and 6 are used in the graph of FIG. 17 described later.

  In FIG. 7, voids 121 in the polymer layer 120 are shown, and some voids have a substantially flat appearance. The voids extend almost over the entire application surface. In FIG. 8, another sample is shown, and the gap 121 is similarly spread over a wide range. Partition walls are seen in some voids. FIG. 9 shows still another sample, in which the void 121 extends over almost the entire coating surface.

  The other samples of smooth products made with 20% solids in the paint and starch as the polymer paint were not overcoated. To examine the morphology of the paint layer, these samples were cut in cross section. The sample was frozen in liquid nitrogen, the cross section was cut, and the sample was divided into two (freeze fracture). 10 to 12 are marked with dimension lines for showing the scale, and as shown in these figures, the divided edges (cross section, etc.) of the sample were observed with a microscope. The magnification of the microscope is 1000 times, and the dimension line indicates 20 μm. In FIG. 10, a polymer layer 120 is shown, which contains voids 121 and has a very smooth outer surface. The polymer layer is on a paperboard substrate 110 with one cellulose fiber 112 shown. Usually, the thickness of the substrate extends below the micrograph range.

  FIGS. 11 and 12 further show micrographs of samples that were coated with the polymer paint and not overcoated. It can be clearly seen that the void 121 is on the lower side and the polymer layer 120 is smooth. The gap partition is largely coincident with the surface of the polymer paint.

  FIG. 13 (magnification 200) and FIG. 14 (magnification 500) show the surface of the sample observed with a scanning electron microscope. The top coat 130 is not applied to these samples. The large string-like structure 112 is the cellulose fiber of the substrate 110. Each small cellular structure 122 such as a fine mesh is a void in the polymer layer 120. Here, the polymer layer is substantially transparent except for the void partition walls.

  15 and 16 show the surface of the sample observed with a backscattering scanning electron microscope. The top coat 130 is not applied to these samples. The large string-like structure 112 is the cellulose fiber of the substrate 110. Each small cellular structure 122 such as a fine mesh is a void in the polymer layer 120. Here, the polymer layer is substantially transparent except for the void partition walls. It can be seen that voids are dispersed throughout the surface.

  FIG. 17 is a graph showing the distribution of the size of the voids, and was created by measuring the width (horizontal direction) and height (vertical direction in the micrograph) of about 90 voids. From the measurement results, it can be seen that the average value of the width of the void (measured in a direction perpendicular to the thickness of the sample) is about 19 μm and the standard deviation is about 9 μm. From the measurement results, it can be seen that the average value of the height of the voids (measurement in the thickness direction of the sample) is about 10 μm and the standard deviation is about 4 μm.

  The size of these voids is an example of the sample examined here, and these numerical values change when the material and processing conditions are changed, and thus the numerical values are not limited.

  It is inferred that the vapor bubbles create these voids while the paint is in contact with the heated drum, and that the foam provides a force that encourages the paint to continue to contact the drum. Usually, the voids that are obtained make it easier to fill the distance between the originally rough substrate layer 110 and the smooth surface of the heated drum. Thus, the dried polymer coating has a smooth reproduction surface and is smoother than the base material layer 110. Even if the top coat 130 is applied, it remains unaffected by much or most of it. Therefore, since the relatively smooth polymer layer 120 is below, the overcoat functions as a smoothing agent. This is one of the advantages obtained by the present invention. The voids are considered to have an effect of reducing the density of the product in addition to the effect of inferring that it is easy to produce a smooth reproduction surface.

  The condition of the nip between the press roll 24 and the high temperature drum 22 affects whether voids are created in the polymer paint. Whether boiling to create voids occurs in the nip depends on the hardness of the press roll, the diameter of the press roll, and the diameter of the hot drum, so the nip load (eg, nip PLI load) needs to be adjusted .

  The polymer-coated paper or paperboard produced by this method can be used for a smooth substrate or a product having a smooth finish. Polymer-coated paper or paperboard may be used as it is (for example, as shown in FIGS. 10 to 16), and other paints and processing agents (such as topcoat 130 and other paints as shown in FIGS. 2 to 9). You may use as a base material for apply | coating. A finishing material or a finishing method may be further used for the polymer-coated paper or paperboard subjected to additional coating. Further, a finishing material or a finishing method may be used for the polymer-coated paper or paperboard not subjected to additional coating. For example, as in the case of a conventional paper or paperboard substrate, it may be additionally applied one or more times, such as application of a base, application of a top coat, and application of a third layer. The calendar method may be performed before or after any further painting. For example, the gloss calendar method may be performed after one or more additional applications.

  The production method and use method of the polymer-coated material in the present invention can be easily understood by the explanation of the material and method here. For this reason, explanation about these materials and methods is not given.

  Having described preferred embodiments of the invention, it will be apparent that numerous modifications can be made to the embodiments and implementation methods without departing from the essence or scope of the invention. In the preferred embodiment herein, a description has been given with respect to paper or paperboard. However, these embodiments are applicable to other structures such as, but not limited to, fibers, nonwoven fabrics, fibrous materials, polylactic acid substrates, and porous membranes.

  Accordingly, the invention is not limited to the specific embodiments described herein (or apparent from the invention), but is limited to the claims appended hereto.

It is the schematic of the apparatus which processes a base material using the polymer coating material concerning one Embodiment of this invention. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional photomicrograph which shows the form of the sample produced according to one Embodiment of this invention, and is provided with topcoat. It is a cross-sectional microscope picture which shows the form of the sample produced according to one Embodiment of this invention. It is a cross-sectional microscope picture which shows the form of the sample produced according to one Embodiment of this invention. It is a cross-sectional microscope picture which shows the form of the sample produced according to one Embodiment of this invention. It is the surface microscope photograph image | photographed with the scanning electron microscope, and shows the form of the sample produced according to one Embodiment of this invention. It is the surface microscope photograph image | photographed with the scanning electron microscope, and shows the form of the sample produced according to one Embodiment of this invention. It is the surface microscope picture image | photographed with the backscattering type | mold scanning electron microscope, and shows the form of the sample produced according to one Embodiment of this invention. It is the surface microscope photograph image | photographed with the backscattering scanning electron microscope, and shows the form of the sample produced according to one Embodiment of this invention. It is a graph which shows the size distribution of the space | gap in the sample produced according to one Embodiment of this invention.

Claims (162)

In a product comprising a substrate and a first coating on the substrate,
The first coating film contains a water-soluble polymer and a release agent,
A product characterized in that voids are formed in the first coating film.   The product of claim 1, wherein the first coating is essentially free of elastomeric material.   The product of claim 1, wherein the substrate comprises cellulose.   The product according to claim 1, wherein the base material includes at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   The product according to claim 1, wherein the water-soluble polymer contains a crosslinkable polymer.   The product according to claim 1, wherein the first coating film contains a crosslinking agent.   The product according to claim 6, wherein the crosslinking agent contains at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   The product of claim 1, wherein the first coating contains, by dry weight, at least about 60% water-soluble polymer and 10% or less release agent.   The product according to claim 1, wherein the water-soluble polymer contains at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, The product according to claim 1, comprising at least one of a polymer, a polyolefin, a silicone polymer, a fluoropolymer, a natural polymer, a fluorinated product, a fluorinated fatty acid, and a mixture thereof.   The product according to claim 1, further comprising a second coating film on the first coating film.   The product according to claim 11, wherein the second coating film contains at least one of a pigment, a binder, and a filler.   The product according to claim 1, wherein at least 50% of the surface of the first coating film has a void under the surface, and the void has a width of at least 5 μm.   The product of claim 1, wherein the substrate comprises a web.   The product according to claim 1, wherein the substrate is made of a sheet-like material.   The article of claim 1, wherein the surface of the first coating has a Sheffield smoothness of less than about 300.   The article of claim 1, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   The product of claim 1, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. In the product having the first coating film on the substrate and the substrate,
The first coating film contains a water-soluble polymer and basically does not contain an elastomer material,
A product characterized in that voids are formed in the first coating film.   20. A product as set forth in claim 19 wherein the substrate comprises cellulose.   The product according to claim 19, wherein the base material includes at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   The product of claim 19, wherein the water soluble polymer comprises a crosslinkable polymer.   The product of claim 19, wherein the first coating contains a cross-linking agent.   24. The product of claim 23, wherein the cross-linking agent includes at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   20. The product of claim 19, wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 20. The product of claim 19, comprising at least one of a polymer, a polyolefin, a silicone polymer, a fluoropolymer, a natural polymer, a fluorinated product, a fluorinated fatty acid, and mixtures thereof.   The product according to claim 19, wherein the first coating film contains at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soybean protein, and alginate.   20. A product as set forth in claim 19 wherein the first coating comprises starch.   The product according to claim 19, further comprising a second coating film on the first coating film.   The product according to claim 29, wherein the second coating film contains at least one of a pigment, a binder, and a filler.   20. The product of claim 19, wherein at least 50% of the surface of the first coating has a void below the surface, the void having a width of at least 5 [mu] m.   The product of claim 19, wherein the substrate comprises a web.   The product according to claim 19, wherein the base material is a sheet-like material.   The product of claim 19, wherein the surface of the first coating has a Sheffield smoothness of less than about 300.   The product of claim 19, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   20. The product of claim 19, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. In the product having the first coating film on the substrate and the substrate,
The surface of the first coating has a Sheffield smoothness of less than about 300;
A product characterized in that voids are formed in the first coating film.   38. A product as set forth in claim 37 wherein the first coating is essentially free of elastomeric material.   38. A product as set forth in claim 37 wherein the substrate comprises cellulose.   38. The product of claim 37, wherein the substrate comprises at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   38. A product as set forth in claim 37 wherein the first coating comprises a crosslinkable polymer.   38. A product as set forth in claim 37 wherein the first coating comprises a cross-linking agent.   43. The product of claim 42, wherein the cross-linking agent includes at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   38. A product as set forth in claim 37 wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 38. The product of claim 37, comprising at least one of a polymer, a polyolefin, a silicone polymer, a fluoropolymer, a natural polymer, a fluorinated product, a fluorinated fatty acid, and mixtures thereof.   38. The product of claim 37, wherein the first coating comprises at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   38. The product of claim 37, wherein the first coating comprises starch.   38. A product as set forth in claim 37 wherein at least 50% of the surface of the first coating has voids beneath the surface, the voids having a width of at least 5 [mu] m.   38. A product as set forth in claim 37 wherein the substrate comprises a web.   The product according to claim 37, wherein the substrate is made of a sheet-like material.   38. The article of claim 37, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   38. The article of claim 37, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. In the product having the first coating film on the substrate and the substrate,
The first coating film contains a water-soluble polymer and a release agent, and basically does not contain an elastomer material,
The surface of the first coating has a Sheffield smoothness of less than about 300;
A product characterized in that voids are formed in the first coating film.   54. A product as set forth in claim 53 wherein the substrate comprises cellulose.   54. The product of claim 53, wherein the substrate comprises at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   54. The product of claim 53, wherein the water soluble polymer comprises a crosslinkable polymer.   54. A product as set forth in claim 53 wherein the first coating comprises a cross-linking agent.   58. The product of claim 57, wherein the cross-linking agent comprises at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   54. The product of claim 53, wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 54. The product of claim 53, comprising at least one of a polymer, a polyolefin, a silicone polymer, a fluoropolymer, a natural polymer, a fluorinated product, a fluorinated fatty acid, and mixtures thereof.   54. The product of claim 53, wherein the first coating comprises at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   54. A product as set forth in claim 53 wherein the first coating comprises starch.   54. A product as set forth in claim 53 wherein at least 50% of the surface of the first coating has a void below the surface, the void having a width of at least 5 [mu] m.   54. A product as set forth in claim 53 wherein the substrate comprises a web.   54. The product of claim 53, wherein the substrate comprises a sheet.   54. The article of claim 53, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   54. The article of claim 53, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. In a substrate treatment method in which a wet film made of a water-soluble polymer solution is applied to a substrate, and the water-soluble polymer solution is boiled and fixed by bringing the water-soluble polymer solution into contact with a heating surface.
A substrate treatment method, wherein the water-soluble polymer solution is at least partially dried and fixed.   69. The method of claim 68, wherein the wet film is in contact with the heated surface for less than about 3 seconds.   69. The method of claim 68, wherein the wet film is in contact with the heated surface for less than about 2 seconds.   69. The method of claim 68, wherein the wet film is in contact with the heated surface for less than about 0.5 seconds.   69. The method of claim 68, wherein the temperature of the heated surface is greater than about 150 degrees Celsius.   69. The method of claim 68, wherein the wet film of the water soluble polymer solution is contacted with a heated surface at a temperature greater than about 150 ° C. for less than about 3 seconds. A wet film made of a water-soluble polymer solution is applied to a substrate, and the water-soluble polymer solution is boiled by bringing the water-soluble polymer solution into contact with a heated surface. In the substrate treatment method for fixing the water-soluble polymer solution by forming remaining voids,
A substrate treatment method, wherein the water-soluble polymer solution is at least partially dried and fixed.   75. The method of claim 74, wherein the wet film is in contact with the heated surface for less than about 3 seconds.   75. The method of claim 74, wherein the wet film is in contact with the heated surface for less than about 2 seconds.   75. The method of claim 74, wherein the wet film is in contact with the heated surface for less than about 0.5 seconds.   The method of claim 74, wherein the temperature of the heated surface is greater than about 150 ° C.   75. The method of claim 74, wherein the wet film of the water soluble polymer solution is contacted with a heated surface at a temperature greater than about 150 ° C. for less than about 3 seconds. The water-soluble polymer solution is formed by applying a first coating film comprising a water-soluble polymer solution to a substrate as a wet film, and bringing the wet film into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds. In the base material treatment method for fixing the wet film by forming a void remaining in the wet film.
The first coating film contains a water-soluble polymer and a release agent,
A substrate processing method, wherein the wet film is at least partially dried and fixed.   81. The method of claim 80, wherein the wet film is in contact with the heated surface for less than about 2 seconds.   81. The method of claim 80, wherein the wet film is in contact with the heated surface for less than about 0.5 seconds.   The method of claim 80, wherein the substrate comprises cellulose.   81. The method of claim 80, wherein the water soluble polymer solution is essentially free of elastomeric material.   81. The method of claim 80, wherein the substrate comprises at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   81. The method of claim 80, wherein the water soluble polymer comprises a crosslinkable polymer.   81. The method of claim 80, wherein the first coating comprises a crosslinking agent or the crosslinking agent is applied to the first coating before contacting the wet film with the heated surface. .   90. The method of claim 88, wherein the cross-linking agent comprises at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   81. The method of claim 80, wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   81. The method of claim 80, wherein the first coating comprises at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   81. A method according to claim 80, wherein the first coating comprises starch.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 81. The method of claim 80, comprising at least one of a polymer, a polyolefin, a silicone polymer, a fluoropolymer, a natural polymer, a fluorinated product, a fluorinated fatty acid, and mixtures thereof.   81. The method of claim 80, further applying a second coating after at least partially drying the wet film.   The method of claim 80, wherein the second coating film contains at least one of a pigment, a binder, and a filler.   81. The method of claim 80, wherein at least 50% of the surface of the first coating has voids beneath the surface, the voids having a lateral width of at least 5 [mu] m.   The method of claim 80, wherein the substrate comprises a web.   The method according to claim 80, wherein the substrate is made of a sheet.   81. The method of claim 80, wherein the surface of the first coating has a Sheffield smoothness of less than about 300.   81. The method of claim 80, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   81. The method of claim 80, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. The water-soluble polymer solution is formed by applying a first coating film comprising a water-soluble polymer solution to a substrate as a wet film, and bringing the wet film into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds. In the base material treatment method for fixing the wet film by boiling and forming voids in the wet film,
The first coating film contains a water-soluble polymer, basically does not contain an elastomer material,
A substrate processing method, wherein the wet film is at least partially dried and fixed.   102. The method of claim 101, wherein the wet film is contacted with the heated surface for less than about 2 seconds.   102. The method of claim 101, wherein the wet film is contacted with the heated surface for less than about 0.5 seconds.   102. The method of claim 101, wherein the substrate comprises cellulose.   102. The method of claim 101, wherein the substrate comprises at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   102. The method of claim 101, wherein the water soluble polymer comprises a crosslinkable polymer.   102. The method of claim 101, wherein the first coating comprises a crosslinking agent or the crosslinking agent is applied to the first coating before contacting the wet film with the heated surface.   108. The method of claim 107, wherein the cross-linking agent comprises at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   102. The method of claim 101, wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 110. The method of claim 109, comprising at least one of a polymer, a polyolefin, a silicone polymer, a fluoropolymer, a natural polymer, a fluorinated product, a fluorinated fatty acid, and mixtures thereof.   102. The method of claim 101, wherein the first coating comprises at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   102. The method of claim 101, wherein the first coating contains starch.   102. The method of claim 101, further comprising applying a second coating after at least partially drying the wet film.   114. The method of claim 113, wherein the second coating includes at least one of a pigment, a binder, and a filler.   102. The method of claim 101, wherein at least 50% of the surface of the first coating has voids below the surface, the voids having a width of at least 5 [mu] m.   102. The method of claim 101, wherein the substrate comprises a web.   102. The method of claim 101, wherein the substrate comprises a sheet.   102. The method of claim 101, wherein the surface of the first coating has a Sheffield smoothness of less than about 300.   102. The method of claim 101, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   102. The method of claim 101, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. The water-soluble polymer solution is formed by applying a first coating film comprising a water-soluble polymer solution to a substrate as a wet film, and bringing the wet film into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds. In the base material treatment method for fixing the wet film by boiling and forming voids in the wet film,
The wet membrane is at least partially dried and fixed;
The substrate treatment method, wherein the surface of the first coating film after drying has a Sheffield smoothness of less than about 300.   122. The method of claim 121, wherein the wet film is in contact with the heated surface for less than about 2 seconds.   122. The method of claim 121, wherein the wet film is in contact with the heated surface for less than about 0.5 seconds.   122. The method of claim 121, wherein the substrate comprises cellulose.   122. The method of claim 121, wherein the substrate comprises at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   122. The method of claim 121, wherein the water soluble polymer solution is essentially free of elastomeric material.   122. The method of claim 121, wherein the water-soluble polymer solution includes a cross-linking agent.   122. The method of claim 121, wherein the first coating comprises a crosslinking agent, or the crosslinking agent is applied to the first coating before contacting the wet film with the heated surface. .   129. The method of claim 128, wherein the cross-linking agent comprises at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   122. The method of claim 121, wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 131. The method of claim 130, comprising at least one of a polymer, polyolefin, silicone polymer, fluoropolymer, natural polymer, fluorinated product, fluorinated fatty acid, and mixtures thereof.   122. The method of claim 121, wherein the first coating comprises at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   122. The method of claim 121, wherein the first coating comprises starch.   122. The method of claim 121, wherein a second coating is further applied after at least partially drying the wet film.   135. The method according to claim 134, wherein the second coating film contains at least one of a pigment, a binder, and a filler.   122. The method of claim 121, wherein at least 50% of the surface of the first coating has voids below the surface, the voids having a lateral width of at least 5 [mu] m.   122. The method of claim 121, wherein the substrate comprises a web.   122. The method of claim 121, wherein the substrate is a sheet.   122. The method of claim 121, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   122. The method of claim 121, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. The water-soluble polymer solution is formed by applying a first coating film comprising a water-soluble polymer solution to a substrate as a wet film, and bringing the wet film into contact with a heating surface having a temperature exceeding about 150 ° C. for less than about 3 seconds. In the substrate treatment method of fixing the wet film by forming a void in the wet film,
The first coating film contains a water-soluble polymer and a release agent, and basically does not contain an elastomer material,
The wet membrane is at least partially dried and fixed;
The substrate treatment method, wherein the surface of the first coating film after drying has a Sheffield smoothness of less than about 300.   142. The method of claim 141, wherein the wet film is in contact with the heated surface for less than about 2 seconds.   142. The method of claim 141, wherein the wet film is in contact with the heated surface for less than about 0.5 seconds.   142. The method of claim 141, wherein the substrate comprises cellulose.   142. The method of claim 141, wherein the substrate comprises at least one of paper, paperboard, cloth, fibrous material, porous material, porous membrane, or polylactic acid.   142. The method of claim 141, wherein the water soluble polymer includes a crosslinking agent.   142. The method of claim 141, wherein the first coating comprises a crosslinking agent, or the crosslinking agent is applied to the first coating before contacting the wet film with the heated surface. .   148. The method of claim 147, wherein the cross-linking agent comprises at least one of borax, borates, aldehydes, ammonium salts, calcium compounds, and derivatives thereof.   142. The method of claim 141, wherein the first coating comprises, by dry weight, at least about 60% water soluble polymer and 10% or less release agent.   The release agent is wax, petroleum wax, vegetable wax, animal wax, synthetic wax, fatty acid metal soap, stearic acid metal salt, long chain alkyl derivative, fatty acid ester, aliphatic amide, aliphatic amine, fatty acid, fatty alcohol, 142. The method of claim 141, comprising at least one of a polymer, polyolefin, silicone polymer, fluoropolymer, natural polymer, fluorinated product, fluorinated fatty acid, and mixtures thereof.   142. The method of claim 141, wherein the first coating comprises at least one of starch, waxy corn, protein, polyvinyl alcohol, casein, gelatin, soy protein, and alginate.   142. The method of claim 141, wherein the first coating contains starch.   142. The method of claim 141, wherein a second coating is further applied after at least partially drying the wet film.   The method according to claim 153, wherein the second coating film contains at least one of a pigment, a binder, and a filler.   142. The method of claim 141, wherein at least 50% of the surface of the first coating has voids below the surface, the voids having a width of at least 5 [mu] m.   142. The method of claim 141, wherein the substrate comprises a web.   142. The method of claim 141, wherein the substrate comprises a sheet.   142. The method of claim 141, wherein the surface of the first coating has a Sheffield smoothness of less than about 200.   142. The method of claim 141, wherein the surface of the first coating has a Sheffield smoothness of less than about 150. A cellulose-based substrate is prepared, a wet film made of a water-soluble polymer solution is applied to the substrate, and the wet film is brought into contact with a heating surface at a temperature exceeding about 150 ° C. for less than about 3 seconds, thereby In the substrate processing method of fixing the water-soluble polymer solution by boiling a water-soluble polymer solution and forming voids in the water-soluble polymer solution,
The water-soluble polymer solution contains at least about 60% water-soluble polymer by dry weight and 10% or less release agent by dry weight,
A substrate treatment method, wherein the water-soluble polymer solution is at least partially dried and fixed.   164. The method of claim 160, wherein the water soluble polymer solution is contacted with the heated surface for less than about 2 seconds. 171. The method of claim 160, wherein the water soluble polymer solution is contacted with the heated surface for less than about 0.5 seconds.

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