WO1999039908A1 - Procede et appareil de revetement de surface - Google Patents

Procede et appareil de revetement de surface Download PDF

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Publication number
WO1999039908A1
WO1999039908A1 PCT/US1999/002358 US9902358W WO9939908A1 WO 1999039908 A1 WO1999039908 A1 WO 1999039908A1 US 9902358 W US9902358 W US 9902358W WO 9939908 A1 WO9939908 A1 WO 9939908A1
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WO
WIPO (PCT)
Prior art keywords
coating composition
temperature
coating
heat exchanger
deposition roller
Prior art date
Application number
PCT/US1999/002358
Other languages
English (en)
Inventor
Joseph Frazzitta
Original Assignee
Joseph Frazzitta
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
Application filed by Joseph Frazzitta filed Critical Joseph Frazzitta
Publication of WO1999039908A1 publication Critical patent/WO1999039908A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/08—Print finishing devices, e.g. for glossing prints

Definitions

  • the present invention relates to a method and an associated apparatus for the deposition of coating compositions, particularly including but not limited to aqueous coating compositions, in printing processes including wet-trap, gravure, offset (waterless or using water) , silk-screen, flexography, off-line dry-trap, and related printing processes.
  • the present invention relates to a method for depositing barrier coatings on paperboard trays and related items for use in the food industry. These barrier coatings are particularly useful for influencing the moisture vapor transition rate (MVTR) and oil and water resistance in paperboard packing to be used to store moisture sensitive foods.
  • MVTR moisture vapor transition rate
  • the present invention allows the adaptation of an aqueous coating to virtually any printing method without changing the chemical content of that formulation.
  • the present invention utilizes exceptionally high levels of solids in printing coating compositions and unexpectedly obtains acceptable viscosity, flow characteristics and mechanical transfer for these compositions.
  • the present invention is readily adaptable to virtually every type of coating process used to coat inked, uninked and related surfaces .
  • the method according to the present invention may also be adapted for use in the food industry to deposit barrier coatings on paperboard for food storage in order to influence the MVTR and oil and water resistance of the underlying packing or storage material .
  • Aqueous coating compositions of a resinous thermoplastic coating material such as thermoplastic, (meth) acrylic or (meth) acrylic-styrene copolymer in the form of emulsions are well known in the printing industry and presently are being used to coat inked and uninked layers during wet-trap, off-line dry-trap, gravure, offset, silk-screen, flexography and related printing or coating processes using an aqueous coating composition.
  • an ink layer is first put down on a substrate in the form of paper, cloth, fiberboard, corrugated box, etc. and depending upon the process, the ink layer is first allowed to dry before it is coated, or is coated wet.
  • the coating may simply be placed onto an uninked or ink-free substrate.
  • the aqueous coating serves to provide certain film characteristics including gloss, mar resistance, oil and water resistance, MVTR, and protection of the inked, uninked or related surface, adhesion and other characteristics. These film characteristics are generally determined by the weight of the coating applied and the amount or percent of solids used in the coating composition.
  • the prior art materials used as coatings in combination with the current print coating techniques are grossly limited in the solid contents that may be uniformly deposited onto a substrate from a coating composition and the degree of gloss value that a coating may obtain.
  • the formulation of one aqueous coating may only be used in one or perhaps two processes; it is virtually impossible using the present methods without the present invention to provide one formulation which may be readily adapted for use in wet-trap, off-line dry-trap, gravure, offset, silk-screen, flexography and other printing processes.
  • an ink coating (usually a hydrophobic ink) is first deposited onto paper, fiberboard, cardboard, corrugated paper or similar material, as a wet ink and then an aqueous coating is deposited onto the wet ink layer such that the ink is "trapped" under the aqueous coating to provide adequate film characteristics.
  • dry-trap off-line printing processes the ink is first dried before an aqueous coating is deposited onto the ink layer.
  • Gravure and flexography printing processes employ plates or etched cylinders (generally containing inverted pyramids) to deposit the ink layer (usually a water-based or solvent-based ink) which is generally dried before being coated by an aqueous coating.
  • the ink layer usually a water-based or solvent-based ink
  • the result is a smooth finish without screen or dot pattern.
  • it is critical to have adequate mechanical transfer and flow characteristics to obtain adequate surface tension and favorable film characteristics after deposition.
  • the image to be reproduced is copied photographically upon a metal plate with a solution containing water to prevent the ink from adhering to the non-image area.
  • the metal plate When placed upon the appropriate cylinder of an offset press, the metal plate is inked in the image area only and makes an imprint of the image on a rubber- covered cylinder, which in turn, prints upon sheets of paper which are automatically fed into the machine.
  • the image After the image has been deposited onto the paper, it may be coated using an aqueous coating in order to enhance the physical characteristics of the ink surface.
  • Newer techniques in offet utilize waterless plates which keep the ink from adhering to the non- image area without the use of water, alcohol or fountain solution.
  • Silk-screen is a process employing a stencil to print a flat color design through a piece of silk or other fine cloth on which all parts of the design not to be printed have been stamped out by an impermeable substance .
  • the viscosity and consequently, the flow characteristics and mechanical transfer of an aqueous coating composition as used in printing processes, are directly influenced by the chemistry of the formulation, in particular, the percentage of solids that are present in the composition.
  • the mechanical transfer of the coating generally suffers, because the coating composition becomes too viscous to be efficiently deposited using the techniques presently available in the art.
  • the viscosity of an aqueous composition is the limiting factor in determining the transfer and the degree of usefulness of the coating composition.
  • aqueous coating composition upon application of an aqueous coating composition onto an inked, uninked or related layer, acceptable mechanical transfer will provide for a coating evidencing acceptable flexibility, durability, film-thickness and gloss, among other favorable film characteristics.
  • compositions which are too viscous, i.e., have poor flow characteristics and thus evidence inadequate mechanical transfer the tendency is to produce a coating which evidences a "ribbing" or an uneven deposition of the coating. Inconsistency generally results from a coating having high viscosity.
  • the standard measure of aqueous coating viscosity in the printing industry is generally determined using a Zahn cup or equivalent.
  • Zahn cups are identified with numbers representing the size of flow holes in cups. For example, the #2 cup is designed with a smaller hole than the #3 cup.
  • a cup is chosen and then dipped into the aqueous coating composition until it is filled to the top. The composition will exit the cup from the hole depending upon the size of the hole and the viscosity of the composition measured. The composition stream leaving the cup is then timed with a stopwatch until the cup empties. The time that the composition takes to completely exit the Zahn cup hole in seconds represents the composition's viscosity.
  • the viscosities of compositions may be compared directly based upon the equipment and the mechanical application used. Often the selection of a type of Zahn cup design used is based on the type of printing method utilized.
  • the viscosity values (measured using a Zahn Drip Cup or equivalent measuring device) necessary for effective mechanical transfer for all printing methods will vary, based upon the mechanics of that printing process.
  • the viscosity for an aqueous coating useful in this process ranges from about 15 to about 60 seconds measured with a #2 Drip Cup.
  • Silk screen printing requires a viscosity range of about 12 to about 23 seconds (#2 Drip Cup) .
  • the viscosity of the aqueous coating ranges from about 20 to about 60 seconds (#2 Drip Cup) .
  • the viscosity of the aqueous coating ranges from about 15 to 30 seconds (#3 Drip Cup) .
  • #3 Drip Cup the viscosity of the aqueous coating ranges from about 15 to 30 seconds
  • the method employed for changing the viscosity of an aqueous coating formulation once it reaches the printing plant is to change the chemistry of the formulation, i.e., adjust the viscosity of the formulation by adding resinous material to increase viscosity or alternatively, by adding solvent to decrease viscosity.
  • This is a time consuming and inefficient practice, especially where there is a need to use an aqueous coating in more than one type of printing process.
  • One aqueous coating formulation will simply not suffice .
  • the transfer of the aqueous coating composition is limited by the viscosity, which is affected by the amount of solids contained in the composition. As one increases the amount of solids, the viscosity of the aqueous coating also increases. It is generally recognized that as the amount of resin in the aqueous coating increases, the gloss, durability, film-thickness and related coating characteristics may tend to increase.
  • Present coatings are limited in the amount of solids that can be used without so dramatically increasing the viscosity of the coating formulations that they cannot be used in traditional printing processes.
  • the present invention seeks to address this limitation to produce coatings having extremely high gloss, durability and film-thicknesses heretofore unknown in the printing industry using coating compositions which can be easily adapted for use in virtually all printing processes.
  • VOC's volatile organic compounds
  • a major component of an aqueous coating composition is water
  • VOC's are added to the aqueous composition to lower the viscosity of high solids content compositions.
  • VOC volatile organic compounds
  • the present invention may be adapted to provide extremely favorable coating characteristics, including high gloss value, increased film integrity and enhanced mar resistance without having to resort to the inclusion of substantial quantities of VOC's (which is the present practice) .
  • VOC's which is the present practice
  • a single aqueous composition containing low VOC's or even an absence of VOC's can be generally adapted to a number of printing methods to provide exceptionally favorable coating and mechanical transfer.
  • paperboard having a moisture barrier coating has recently been used to replace polyboard (for use as food trays and related plastic food packaging material) for providing MVTR and oil and water resistance in storing food.
  • a moisture barrier coating (in preferred embodiments also incorporating oil and water resistance) is coated onto the surface of the paperboard so as to ultimately create a surface which can influence the moisture vapor transition rate and lower it to a level which is compatible with the storage of food, especially meat, poultry and other perishable items.
  • an aqueous coating solution must be applied at least two or three times on a paperboard surface and subsequently dried.
  • TJ Q ar TJ X) ra - OJ 0 ⁇ 0 TJ Hi 0 ⁇ 3 ii ⁇ - 0 ⁇ TJ Hi ⁇ - ii ⁇ - OJ Pi ra ti ⁇ ti ra 0 Hi Pi Hi 0 ⁇ ⁇ rt ⁇ 0 ti ⁇ 0 ti ⁇ - ⁇ rt ⁇ - ra 0 C ⁇
  • CD 3 3 ti 0J ⁇ - 0 P. OJ ⁇ ⁇ - ⁇ 0 ii ⁇ ⁇ - Hi ⁇ ⁇ J ⁇ 0 0 0 ti i ⁇ ⁇ ⁇ - ⁇ ⁇ J ra ⁇ 1 rt ⁇ XI ⁇ - 10 !*! ⁇ - ⁇ ra ⁇ TJ ⁇ ⁇ CD Pi CQ ⁇ OJ ⁇ J & 0 rt rt ⁇ 0 0 0 ⁇ Hi • ⁇ ⁇ - ⁇ !
  • VOC volatile organic compound
  • aqueous coating compositions according to the present invention contain no greater than about 5% by weight of a VOC and most preferably, an absence of VOC's.
  • Coating is used to describe the film that remains on the ink, uninked or related surface after deposition and drying of the aqueous coating composition.
  • Coatings which are conventionally used in the coatings industry include for example, Blister Card Coatings, characterized primarily by excellent adhesion, heat reaction and fiber tear; MATT Coatings, a low gloss coating characterized by a low gloss value of about 10° to about 30°; Semi-gloss coatings (relatively low gloss value) characterized by low gloss value of about 30°- 40°; Barrier Coatings, characterized by MVTR and water and oil resistance; Heat Resistant Coatings; Anti -Porosity Coatings; Mold Resistant Coatings; Heat Resistant Barrier Coatings, characterized by MVTR, water, oil and heat resistance; Overprint Coatings, characterized by high gloss, mar resistance, exceptional durability and adhesion and protection of the underlying substrate; Prime Coatings, characterized by their primer characteristics including good holdout and minimal absorption; and
  • film-forming polymer and “film-forming resin” or “resin” are used synonymously throughout the specification to describe the low or high molecular weight polymers or resins which are added to the aqueous coating compositions according to the present invention to instill favorable film characteristics to the dried coating.
  • Film-forming polymers 12 are used synonymously throughout the specification to describe the low or high molecular weight polymers or resins which are added to the aqueous coating compositions according to the present invention to instill favorable film characteristics to the dried coating.
  • thermoset resins for use in the present invention include thermoset resins, thermoplastics, UV-cured or curable film-forming polymers and mixtures of these film-forming polymers or resins.
  • the present invention relates to methods for depositing aqueous coatings onto an ink layer to provide adequate film characteristics such as mar or scuff resistance, durability, rub resistance and gloss.
  • an aqueous coating in the form of a solution, dispersion or emulsion is deposited onto a dry or wet ink layer.
  • the ink may be any chemical composition typically used in printing, but is preferably insoluble in a hydrophilic (aqueous) solvent and in particular, the polar aqueous solvent or solvent mixtures used in the aqueous coating compositions according to the present invention.
  • the ink coating may be comprised of hydrophilic or hydrophobic inks as typically used in the printing industry, with the proviso that the dried ink preferably should not be miscible with or soluble in the coating composition used to coat the ink layer.
  • the coating may produce smudging or smearing of the ink layer during deposition as the coating and ink layer interact, a condition to be avoided if possible.
  • it may be preferred to use hydrophobic inks (wax-free or containing wax) or hydrophilic inks to impart favorable characteristics to the final coated substrate.
  • the ink used is wet (i.e., still contains significant amounts of solvent) during the deposition of the aqueous coating.
  • a hydrophobic ink After deposition of the ink layer, the aqueous coating, preferably in the form of a porous coating, can be deposited onto the ink layer.
  • the use of a hydrophobic ink will generally minimize the tendency of the ink to smudge while both layers are still wet, at least in part.
  • the amount of ink deposited as the first layer and the amount of aqueous coating composition deposited as the second layer will vary over a wide range, and conse- 13
  • the aqueous coating composition may be deposited by any process, including rolling the composition onto the substrate.
  • viscosity is virtually eliminated as a critical characteristic .
  • the aqueous coating composition used in the present method employs at least three, and preferably four components:
  • a high molecular weight film-forming polymer or resin solid in an amount effective to support the low molecular weight film-forming polymer and preferably, provide adequate film characteristics including mar or scuff resistance, rub resistance, durability and film integrity to the dried coating alone or in combination with optional additives;
  • polar solvent preferably an aqueous solvent containing less than about 5% of at least one VOC and most preferably containing an absence of VOC ' s .
  • the amount of film- forming polymer solid (1 and 2, above) used in the aqueous coating composition ranges from about 15% to about 85% by weight of the composition, with a preferred range of at least about 40% within this range.
  • the more film- forming polymer solid used in the aqueous coating composition the greater will be the viscosity of the coating composition and the more favorable will be the dry film characteristics of the final coating.
  • ⁇ CO ⁇ M ⁇ ⁇ 0 ⁇ J ⁇ ⁇ - TJ ⁇ 0 0 tr ⁇ - 0 > rt 0 M Hi J tr ⁇ Pi ⁇ ⁇ J rt
  • ⁇ 0 0 cj 0 Pi tr 0 ⁇ CO D ⁇ - ⁇ i ti ti rt ⁇ ⁇ ii ⁇ - Pi ⁇ J 0J Pi ⁇ ⁇ - OJ s- rt VO rt CQ ⁇ ] ti • rt ⁇ M ⁇ - CQ tr i ⁇ ⁇ rt 0 rt rt 0 10 ⁇ - Pi ⁇ 0 ⁇ - 0 o
  • viscometer 4 and/or thermocouple 3 may be operatively coupled to a keyboard or pad 5 for inputting predetermined viscosity and/or temperature values or ranges.
  • Keyboard 5 is connected to a microprocessor 6 in order to facilitate the maintenance of viscosity of the aqueous coating.
  • microprocessor 6 controls heat exchanger 2 to vary the temperature inside reactor 1.
  • a display monitor 7 provides visual feedback of temperature, viscosity settings, etc. to an operator.
  • Viscometer 4 may serve as a gauge to constantly measure the viscosity of the aqueous coating to ensure that the aqueous coating always has the same viscosity as is desired for a particular application.
  • Microprocessor 6 may be driven by simple software which can be stored in a read only memory (ROM) , erasable, programmable read only memory (EPROM) or other standard memory devices with the proviso that the software may be easily modified to accommodate the temperature and/or viscosity measurements desired for the printing process to be employed.
  • the software may allow for the input and/or storage of set ranges of viscosities and/or temperatures.
  • reactor 1 may simply be operatively connected to heat exchanger 2 to manually regulate temperature.
  • a thermocouple 3 may be operatively connected to heat exchange 2 to provide electronic regulation of the temperature of the aqueous coating in reactor 1.
  • the viscosities of a coating composition will fall within certain values.
  • the viscosity of an aqueous coating composition ranges from about 15 to about 60 seconds measured with a #2 Drip Cup. This translates to a viscosity measurement range of about 19 to about 60 centipoises.
  • silk screen printing this requires a viscosity TJ Hi rt TJ et ⁇ J rt TJ • ⁇ ro ⁇ OJ rt J J ⁇ ! 0 ⁇ > ⁇ TJ J 0 CO ⁇ rt TJ rt 3 ⁇ OJ J OJ ti Hi 0 ii
  • Control unit 50 may be programmed with a basic table or algorithm for selecting changes in control parameters in response to changes in operating parameters, with the table or algorithm being incrementally modified by control unit 50 to calibrate the automatic temperature and viscosity control for the particular circumstances of the retrofitted machine.
  • the apparatus of Figures 3-5 can be used with all coatings, including aqueous coatings, coatings with nonaqueous solvents and UV coatings, and on a range of substrates 29 including paper, cardboard and plastic.
  • the viscosity of the coating composition is controlled by controlling the temperature of the coating composition in conduit 32. That temperature is controlled to compensate for any viscosity/temperature change arising from a difference between the temperature of the coating composition in conduit 32 and the temperatures of rollers 34 and 84.
  • an aqueous coating composition according to the present invention was formulated from a (meth) acrylic/styrene copolymer. This composition was thereafter exposed to varying temperatures to establish a correlation between viscosity and temperature .
  • An aqueous coating composition according to the present invention was prepared for use in three known printing processes. It contained the following components in the indicated formula . 32
  • the high molecular weight polymer emulsion contains 50 grams of solid and the low molecular weight polymer emulsion contains 63 grams of solid, the remainder being aqueous solvent .
  • the above coating composition was prepared by agitating a mixture of the above components in an electronic blender and agitating until thoroughly mixed.
  • This composition was sufficiently dispersed by homogenizing in a homogenizing mixture for 5 minutes at which time the temperature of the composition was taken using a TEL TRU thermometer. The temperature was 82 °F.
  • the viscosity of the composition was measured by use of a #3 and a #2 Zahn drip cup and an Aristo Apollo stopwatch. The viscosity of the composition at 82 °F was 17 seconds with a #3 cup and 43 seconds with a #2 cup.
  • the useful offset range is 15 to 30 seconds with a #3 cup; the useful gravure range is 15 to 60 seconds with a #2 cup, and the useful flexography range is 20 to 60 seconds with a #2 cup, the present method can accommodate each of these printing processes to produce commercially viable results.
  • the viscosity of the composition at the starting temperature was outside of the useful range for gravure until it was sufficiently heated to bring it within the gravure range. Higher temperatures would be needed to lower the viscosity of the composition even further.
  • Coating compositions having the following recipes were prepared as a coating liquid for application in all the printing processes.
  • the above coating compositions were prepared by agitating the mixtures of the above components in an elec ⁇ tronic blender and agitating until thoroughly mixed.
  • composition Temp. (°F) Vise. (#3 Cup) Vise. (#2 Cup)
  • the use ⁇ ful offset range is 15 to 30 seconds with a #3 cup; the useful gravure range is 15 to 60 seconds with a #2 cup, and the useful flexography range is 20 to 60 seconds with a #2 cup evidencing that the present invention may be used in numerous printing processes to produce commercially viable results.
  • Workable viscosity for use in printing processes may be managed through temperature control despite increased solids which would otherwise negatively impact mechanical transfer and take the composition out of workable mechanical application ranges desirable for use in the printing processes.
  • Test compositions were those from Example 2, above. For each composition, the temperature was maintained for a period of time to determine whether or not it was possible to maintain the viscosity of a composition by maintaining the temperature.
  • Example 1 Low Molecular Weight Polymer Solution 135 grams Same as Example 1
  • the above coating compositions were prepared by agitating the mixtures of the above components in an electronic blender and agitating until thoroughly mixed.
  • Example 2 Same test as Example 2 gave same results a set forth in Example 2, as previously described.
  • the present invention ameliorates concerns regarding changes in viscosity which often occur within 48 hours after the formulation is made and before the composition reaches an equilibrium (molecular structure of particles still in excitable state and not at equilibrium) .

Abstract

Ensemble permettant de déposer une composition de revêtement sur une couche d'encre ou une surface exempte d'encre dans un procédé d'impression. Selon la présente invention, ledit ensemble comporte un récipient (30) destiné à contenir une composition de revêtement, une presse d'impression (36) comprenant un cylindre (34) à blanchet et des moyens de transfert qui s'étendent du récipient (30) au cylindre (34) à blanchet pour transférer la composition de revêtement sur une trajectoire prédéterminée du récipient (30) au cylindre (34) à blanchet en vue du dépôt sur un substrat (29) par le cylindre (34). Un échangeur de chaleur (40) placé le long de la trajectoire de transfert sert à modifier la température de la composition de revêtement pour l'amener à une température prédéterminée différente de la température ambiante pendant le transfert de ladite composition du récipient (30) au cylindre (34). Une unité de commande (50) est connectée de manière opérationnelle à l'échangeur de chaleur (40) si bien que la composition de revêtement transférée sur le cylindre (34) à blanchet atteint une viscosité prédéterminée.
PCT/US1999/002358 1998-02-04 1999-02-04 Procede et appareil de revetement de surface WO1999039908A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US1826398A 1998-02-04 1998-02-04
US09/018,263 1998-02-04

Publications (1)

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WO1999039908A1 true WO1999039908A1 (fr) 1999-08-12

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7877895B2 (en) * 2006-06-26 2011-02-01 Tokyo Electron Limited Substrate processing apparatus

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5052921A (en) * 1990-09-21 1991-10-01 Southern California Gas Company Method and apparatus for reducing NOx emissions in industrial thermal processes
US5272971A (en) * 1992-08-14 1993-12-28 Electro Sprayer Systems, Inc. Ink temperature control system for waterless lithographic printing

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5052921A (en) * 1990-09-21 1991-10-01 Southern California Gas Company Method and apparatus for reducing NOx emissions in industrial thermal processes
US5272971A (en) * 1992-08-14 1993-12-28 Electro Sprayer Systems, Inc. Ink temperature control system for waterless lithographic printing

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7877895B2 (en) * 2006-06-26 2011-02-01 Tokyo Electron Limited Substrate processing apparatus

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