Production of a simulated glossy coating

Abstract: A method of forming a high-gloss coating on xerographic images residing on a sheet of support material (25) that is generally opaque. A transparent carrier substrate (117) having an adhesive coating (118) on one side is placed on the images on the support material with the adhesive coating in contact with the support material containing the images. The carrier substrate and support material are heated under pressure, so that the adhesive adheres to the support material and images thereon. The carrier substrate is separated from the support material leaving a high-gloss coating covering the support material and images thereon.

Description: This invention relates generally to a method for producing a simulated gloss coating over images on a recording medium. In the practice of conventional xerography, it is the general procedure to form electrostatic latent images on a xerographic surface by first uniformly charging a charge retentive surface such as a photoreceptor. The charged area is selectively dissipated in accordance with a pattern of activating radiation corresponding to original images. The selective dissipation of the charge leaves a latent charge pattern on the imaging surface corresponding to the areas not exposed by radiation. This charge pattern is made visible by developing it with toner by passing the photoreceptor past one or more developer housings. In monochromatic imaging, the toner generally comprises black thermoplastic powder particles which adhere to the charge pattern by electrostatic attraction. The developed image is then fixed to the imaging surface or is transferred to a receiving substrate such as plain paper to which it is fixed by suitable fusing techniques. Recently, there has been a great deal of effort directed to the development of color copiers/printers which utilize the xerographic process. Such efforts have resulted in the recent introduction of the Xerox™ 5775™ copier/printer and the Fuji Xerox A-Color 635 machine. The quality of color xerographic images on paper has approached the quality of color photographic prints. However, color xerographic prints have some disadvantages; viz., they do not have the uniform gloss, dynamic range or brilliance typical of photographic prints, and they do not have the feel of photographic prints because the paper usually used is too lightweight and too limp. Typically, the surface of colored toner images is irregular and, therefore, rather rough or lumpy. The behavior of incident white light vis-a-vis such colored toner images is believed to be as follows: 1. Some of the white light incident on the substrate carrying the color toner images specularly reflects off the substrate. 2. Some of the light goes down into the paper, scatters around and comes back out in various directions, some through the toner and some not. 3. Some of the light incident thereon is reflected off the toner in various directions, because the toner surface is rough or irregular . 4. Some of the light incident on the irregular toner surfaces passes through the toner into the paper and comes back out in various directions. One problem encountered with colored toner images is that white light becomes colored due to selective absorption as it passes through toner, and at least some of the light then goes down to the paper and is reflected back out through the toner where it becomes more colored. As will be appreciated, any white light which does not pass through the toner diminishes the appearance of the final print. Attempts to correct this problem in conventionally formed color toner images have led to the lamination of xerographic images on paper using a transparent substrate. This procedure has been only partially successful because the lamination process tends to reduce the density range of the print resulting in a print that has less shadow detail. The lamination process also adds significant weight and thickness to the print. In addition, laminations tend to separate when applied to a toner rich xerographic image while requiring trimming as a secondary step. Additionally, the aforementioned lamination process does not produce good results because, typically, the colored toner images at the interface between the laminate and the toner do not make suitable optical contact. That is to say, the initially irregular toner image at the interface, is still irregular (i.e. contains voids) enough after lamination that light is reflected from at least some of those surfaces and is precluded from passing through the toner. When there are voids between the transparency and toner image, light gets scattered and reflected back without passing through the colored toner. Loss of image contrast results when any white light is scattered, either from the bottom surface of the transparent substrate or from the irregular toner surfaces, so that the light does not pass through the toner. One known method of improving the gloss of color xerographic images on a transparent substrate comprises re-fusing the color images. Such a process was observed at a NOMDA trade show in 1985 at a Panasonic exhibit. The process exhibited was carried out using an off-line transparency fuser, available from Panasonic as model FA-F100, in connection with a color xerographic copier which was utilized for creating multi-color toner images on a transparent substrate for the purpose of producing colored slides. Since the finished image from the color copier was not really suitable for projection, it was re-fused using the aforementioned off-line re-fuser. To implement the process, the transparency is placed in a holder which consists of a clear, relatively thin sheet of plastic and a more sturdy support. The holder is used for transporting the imaged transparency through the off-line re-fuser. The thin clear sheet is laid on top of the toner layer on the transparency. After passing out of the re-fuser, the transparency is removed from the holder. This process resulted in an attractive high gloss image useful in image projectors. The re-fuser was also used during the exhibit for refusing color images on paper. However, the gloss is image-dependent. Thus, the gloss is high in areas of high toner density because the toner re-fuses in contact with the clear plastic sheet and becomes very smooth. In areas where there is little or no toner the gloss is only that of the substrate. US-A-4,066,802 discloses a method of decalcomania in which a toner image pattern is formed on a transfer member which has been overcoated with an adhesive material A polymeric sheet is interposed between the toner image and a cloth or other image receiving medium. The polymeric sheet assists in the permanent adherence of the toner imaging pattern to.the cloth material or other medium when the composite is subjected to heat and pressure. The transfer member and method of its use are set forth. Another embodiment discloses the use of a solvent to fix the image to a cloth material. US-A-5,126,797 discloses a method and apparatus for laminating toner images wherein a toner image on a receiving sheet is laminated using a transparent laminating sheet fed from the normal copy sheet supply of a copier, printer or the like. The laminating sheet is fed into laminating contact with the toner image after the toner image has been formed on a receiving sheet. The resulting sandwich is fed through the fuser laminating the image between the sheets. The invention is particularly usable in forming color transparencies. US-A-4,756,963 describes a protective member comprised of a substrate and a transfer layer provided releasably thereon. The transfer layer has a fluorescent whitening agent and an ultraviolet light absorber and a light stabilizer. A method for protecting a print having an image formed from a dye is disclosed. The method includes the step of laminating and contact bonding the protecting member on a surface of a side of the image of the print and the step of releasing the substrate from the laminated print. EP-A-0 285 039 describes a method of providing an image bearing surface with a protective covering. The method includes laminating a thin substantially transparent integral polymeric film to the surface, such that the polymeric film consists essentially of a mixture of at least two slightly incompatible polymers, whereby the film exhibits a 20° specular gloss that is at least 5% lower than the gloss of a film prepared from any one of the polymer constituents. When the film is applied to an imaged surface with a tacky composition which has been toned with a colored particulate material, an additional adhesive layer is disposed between the polymeric film and the imaged surface. WO-A-93/04868 describes a security printing device comprised of a substrate, a toner image adhered to the substrate, and a layer of an optically variable material adhered solely to the toner image. In one embodiment, the toner image is first fused to the substrate. Then, an optically variable tape is placed over the toner image and heated under pressure The toner image is thereby caused to remelt and adhere to the optically variable layer. The tape is then removed from the image so that only the layer of the optically variable material remains adhered to the toner image. One object of the present invention is to provide a method for producing a simulated gloss coating over toner images. Another object of the present invention is to create simulated high-gloss, flexible, protective overcoated, xerographically printed covers for books whether color or black and white. Still another object of the invention is to create color photographic prints using xerography wherein the print has the look and feel of a conventional photograph. A further object of the invention is to provide improved resistance to damage on the imaged surface of a sheet from handling or contamination. Another object of the invention is to provide for the avoidance of vinyl offset for styrene - acrylate based toners when copies are made from these toners are placed in vinyl ring binders. In accordance with the aspect of the present invention, a method of forming a high gloss coating on xerographically created toner images is provided including the steps of: providing an image on a support material; providing a carrier substrate with an adhesive coating on one side thereof; contacting said image on said support material with said one side of said carrier substrate; simultaneously applying heat and pressure at predetermined values to said carrier substrate and said image on said support material whereby said adhesive coating of said carrier substrate melts and adheres to said image on said support material to form the high-gloss, protective coating on said image;and separating said carrier substrate from said support material. Pursuant to another aspect of the invention, a multi-color or black and white toner image is first created on an opaque substrate. The multi-color toner image is xerographically created by sequentially forming different color toner images on the opaque substrate followed by the use of heat and pressure or other suitable means to affix or fuse the multi-color image to the opaque substrate. A smooth carrier member, which can be transparent, is provided with the carrier member including an adhesive gloss coat coating thereon that is heat transferred to the opaque substrate through heat and pressure. The carrier member with the gloss coat coating is placed on top of the xerographic image and heated top platen is used to apply pressure and heat to the carrier member and the xerographic image on the opaque substrate. Afterwards, the carrier member is peeled off the imaged substrate leaving a high gloss protective coating thereon. The same process is used to coat xerographically images of photographs resulting in an attractive and brilliant appearance which is more fade resistance and durable than commercially available photographic prints. Prints created in the foregoing manner have the look and feel of photographic prints but appear to have more brilliance. This is thought to be attributable to the xerographically formed prints having a lesser minimum density than conventional photographic prints resulting in whiter whites. A further aspect of this invention is that exceptionally good quality prints can be more quickly and more cost effectively produced than with conventional photographic printing techniques, especially in the case of larger size prints. Additionally, this process does not require silver, photographic chemicals, or intermediary negatives even when a black and white print is created from a color original. Still another aspect of the present invention is the capability of creating a high quality black and white print from a color original without the need to create an intermediary negative as is the case with existing photographic methods. This attribute enhances the potential uses of the process by making it far more cost effective than photographic processes would be in this case. Existing color xerographic copier/printer systems can be used for the process. Thus, all the resources associated with these products, particularly the ones which utilize state of the art electronic devices such as film scanners, image composition enhancers, color adjusters and editors can be utilized. The present invention will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 is a schematic illustration of a device and materials for making glossed xerographic images or simulated photographic prints using the principles of xerography. Figure 2 is a front elevational view of the heater device in Figure 1. Figure 3 is an enlarged partial front view of the heater device of Figure 2. A schematic representation of the high-gloss coating process of the present invention is shown in Figure 1. The process includes the steps of: providing a xerographic image on, for example, a paper sheet 25; providing a pre-cut carrier sheet 117 with a dry, gloss-coat coating 118 on one surface thereof and sandwiching the carrier sheet on top of the paper sheet with the gloss coat coating on the carrier sheet being in contact with the image on the paper sheet; inserting the sandwiched materials into a heater device 91; applying a predetermined amount of heat and pressure to the sandwiched materials; removing the sandwiched materials from the heater device; and removing the carrier sheet 117 from the paper sheet 25 thereby revealing a high-gloss protective coating on the paper sheet image 25. The imaged sheet can be of textured or matte finish with equally pleasing results. In addition, the toner on the imaged sheet can be applied by a dry or liquid development process. The carrier sheet can be selected from a number of materials suitable for this purpose, such as, crosslinked silicon resins. The dry gloss coat coating 118 on carrier sheet 117 is preferably an ethylene/vinyl acetate copolymer. The vinyl acetate is preferably selected in the amount range of from about 30 to about 45, and preferably about 35 percent by weight with from about 55 to about 70 and preferably 65 weight percent of ethylene. The composition ratio and molecular weight of the coating polymer can effect the final properties of the film. For example, at a give molecular weight, increasing the vinyl acetate amount will increase gloss, increase tackiness and decrease toughness. Increasing the ethylene amount will increase toughness, decrease gloss and decrease tackiness. Also, at a given composition ratio, increasing the molecular weight of the copolymer will increase toughness, decrease gloss and decrease tackiness. Coating thickness can vary, for example, from about 1 to about 10 µm (microns). Examples of polymers that may be selected include those that result in high gloss and smoothness with a low melt point (optimum). It may be easiest to meet these criteria with ethylene/vinyl acetate copolymers. Other polymers which it is believed would provide similar properties include polyesters of the SPAR™ family, such as, SPAR I™, SPAR II™: fumarates and terephthates with polyethylene oxide or polypropylene oxide bisphenol-A's or mixtures of the two; ethylene/ethyl acrylate copolymers or ethylene/ethyl acrylate/hexyl acrylate terpolymers; long chain polyamides like Versamids; Polyterpenes, for example, 75 to 90 percent by weight. Piccolytes; and Styrene/butadiene block copolymers with a high level of butadiene. A suitable gloss coating is disclosed in Japanese reference JP 3050720 82 directed to a transferring method. A conventional heating device 91 usable with the high-gloss coating process of the present invention (Figures 2 and 3) includes upper and lower platen structures 92 and 94, respectively. The lower platen comprises a rigid metal plate or base member 96 containing a silicone rubber pad 98 having a thickness of approximately 1.27 cm (0.5 inch). The upper platen 92 contains a heater structure 102 including heating elements 104 (Figure 3). The plate or base member 96 is provided with a leg structure 106 for supporting the the heating device 91 on a suitable work surface such as a table. The upper platen 92 is hingedly secured via hinge structure 108 to an upper platen support structure 110. The support structure 110 is, in turn, operatively supported by a post member 112 received in a cylindrically shaped receiver member 114 forming an integral part of the plate or base member 96. The support structure is adapted to be pivoted relative to the base member 96 through the use of an arm and knob arrangement 115 attached to the support structure 110. The upper heated platen can thus be rotated either to the left or right (as viewed in figure 1) from its home position overlying rubber pad 98 in order to provide easy access thereto for inserting the material to be glossed. A suitable transparent carrier substrate 117 with a release agent included thereon is commercially available from Xerox Corporation, Rochester, NY under the Reorder No. 3R3108. A releasable coating is placed onto the carrier substrate for release to an imaged sheet. The hinge mechanism 108 is located centrally of the upper platen 92 and serves to allow movement of the upper platen 92 relative to the support structure 110, such movement being toward the lower platen 94 for exerting pressure on the carrier sheet 117 and imaged copy sheet 25 supported on the rubber pad 98. Movement of the upper platen is effected through the use of a lever arm 126 adapted to be moved in a direction out of the drawing sheet as viewed in Figure 2. Pressure variation or adjustment is effected through a pressure adjusting knob 128 and suitable linkage, not shown. The adjustment of the knob through its associated linkage mechanism serves to control the amount of pressure exerted between the upper and lower platens when the lever lever arm 126 is actuated. An electric cord, not shown, provides electrical current to the heating elements 104. The heating elements and thus the operating temperature of the print creation structure 91 is controlled via a temperature control 132 carried by the support structure 110 as shown in Figure 2. The operating temperature of the device is in the range of 104 to 232°C (220 to 450° F). The pressure and heat are applied for between 15 to 20 seconds depending on the weight of the imaged document, the time being settable via a timer knob 134. During formation of a high-gloss onto an imaged sheet, the adhesive gloss coated transparent substrate 117 and imaged sheet 25 are subjected to a total pressure in the order of 22.2 to 44.5 N (5 to 10 pounds) applied over the area of 21.6 x 27.9 and 27.9 x 43.2 cm (8½ x 11 and 11 x 17 inch) sheets. The time substrates 117 and 25 are left in the heating device 91 and temperature are dependent upon the different weights of imaged sheets. Typically, 60 and 75 g/m 2 (16 and 20 pound) imaged sheets are placed into heating device 91 for 15 seconds at a temperature of 174 to 175°C (345 to 347° F). Once the substrate 117 and imaged sheet 25 are removed from the heating device 91, the substrate is peeled from the imaged sheet leaving the coating which has now adhered to the image on the imaged member and thus creating a high-glossed imaged sheet. Although the preferred embodiment of the carrier sheet or base stock 117 has been described as being a transparency, it should be understood that this may not be the most cost effective option. The functions needed are an ultra smooth surface when a gloss surface is needed plus an appropriate release coating. The base stock may be different if a matte or other textured surface is required. The simulated gloss process of the present invention has many advantages over processes that employ film lamination, spray-on gloss materials, press applied varnish or precoated papers that do not perform well in most xerographic copiers/printers. For example, image enhancement is obtained in that smooth or textured surfaces can be glossed. Also, adhesion of toner to the surface of a sheet is enhanced for both solid and liquid images since the toned image is exposed to heat a second time. The durability of an imaged sheet is enhanced because the gloss treatment provides improved resistance to damage on the imaged surface from handling or contamination. Further, post fuser sheet curl is minimized on single sided documents. And one can use copies made by this process with styrene - acrylate based toners in vinyl ring binders without vinyl offset. While the high-gloss process of the present invention is disclosed in an off-line environment, it is contemplated that a high-gloss could be given to each imaged sheet on-line as the sheet leaves an imaging apparatus by employing the carrier substrate configured in roll form with a gloss adhesive on it downstream from the exit of the imaging apparatus. A heating device would be placed downstream of the carrier substrate and after the gloss adhesive has adhered to the sheet, a take-up roll could decouple the carrier substrate from the imaged sheet with the imaged sheet being subsequently deposited in an output tray. Also, while a transparency is disclosed herein as the base stock on which the releasable adhesive is attached, it should be understood that other stock can be used as long as the functions of an ultra smooth surface when a gloss surface is needed plus an appropriate release coating. The base stock may be different, for example, if a matte or other textured surface is required. While creation of simulated gloss prints has been disclosed in connection with one specific apparatus it will be appreciated that other apparatuses may be utilized for this purpose. For example, the transparent substrate and backing sheet may be bonded together using a pair of heat and pressure rolls forming a nip through which the substrate and sheet are passed.

Claims: Method of forming a high-gloss, protective coating on xerographically formed images, said method including the steps of: xerographically forming an image on a support material (25); the image including areas of toner; providing a carrier substrate (117) with an adhesive coating (118) on one side thereof; contacting said image on said support material with said one side of said carrier substrate; simultaneously applying heat and pressure to said carrier substrate and said image on said support material whereby said adhesive coating of said carrier substrate melts and adheres to said image on said support material to form the high-gloss, protective coating on said image; and separating said carrier substrate from said support material. The method as claimed in claim 1, wherein said step of providing a carrier substrate with an adhesive coating on one side thereof includes said carrier substrate being a transparency with a release agent thereon. The method as claimed in claims 1 or 2, wherein said adhesive coating on one side of said carrier substrate is an ethylene/vinyl acetate copolymer. The method as claimed in claim 3, wherein said copolymer adhesive coating has a thickness of from 1 to 10 µm. The method as claimed in claims 3 or 4, wherein said copolymer contains an ethylene content of from 55 to 70 weight percent and a vinyl acetate content of from 30 to 45 weight percent. The method as claimed in any of claims 1 to 5, wherein the support material is opaque. The method as claimed in any of claims 1 to 6, wherein said step of simultaneously applying heat and pressure further comprises the step of: positioning said carrier substrate and said imaged support material between a pair of platens (92,94) at least one of which is provided with a source of heat energy capable of elevating the temperature of said carrier substrate and said imaged support material, and wherein the pressure is effected by applying a force to one of said platens in order to urge it in the direction of the other of said platens. The method as claimed in claims 1 or 2, wherein the adhesive coating is a polyester obtainable from the reaction of propoxylated bisphenol A, and an unsaturated dicarboxylic acid. The method as claimed in claims 1 or 2, wherein said adhesive coating on said carrier substrate comprises polyterpenes or long chained polyamides. The method as claimed in claims 1 or 2, wherein said adhesive coating on said carrier substrate comprises styrene/butadiene block copolymers, and wherein said block copolymer coating is butadiene in an amount of from 75 to 90 percent by weight.

Inventors: PANE SHARON G, PANE, SHARON G.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1995
Main classification: G03G8
IPC codes: G03G13, G03G8