Anti-blocking clear ink receiving sheet

Abstract: The present invention is directed to an ink receiving sheet having anti-blocking properties, containing: a) a polymer substrate, b) an ink receptive coating disposed on at least one layer which having a water-soluble component, and c) particulates dispersed in the ink receptive coating, having an average particle size of from 15 µm to about 50 µm, a particle size span is equal to or smaller than 1.0, and a refractive index of from about 1.2 to about 2.4. The present invention is also directed to the ink receptive coating per se, and to methods of ink jet printing using the above ink receiving sheet.

Description: Background of the invention Field of the invention The present invention relates to an ink receiving sheet, and more particularly, to a transparent ink receiving sheet having anti-blocking properties for use with ink jet printers. Description of the related arts In order to achieve high color density and fidelity during ink jet printing on an ink receiving sheet, the laydown of the ink receiving sheet is usually high. However, current commercial ink receiving sheets, in particular transparent ink receiving sheet, do no allow high ink laydown because of blocking between image that is formed on the ink receiving sheet and any materials that may come into contact with the image. In other words, because of the nature of the ink and the ink receiving sheet, ink undesirably transfers from the ink receiving sheet to materials in contact with the ink receiving sheet. The blocking has become one of the major problems in the field, particularly with high speed ink jet printers. There have been many attempts in improving anti-blocking performance of ink receiving sheets. A number of designs have been proposed for use in various ink receiving sheets. Iqbal et al., US Patent 4,935,307, discloses an ink permeable protective layer containing a particulate material; Desjarlais, US Patent 4,775,594, discloses use of silica as an anti-blocking agent; Light, US Patent 5,084,338, discusses inert particles having a particle size of 25 µm or less; Bedell, US Patent 4,547,405, also discusses use of particles such as glass beads in the ink receiving sheet. Although these proposals disclose use of particles, none of them have specified three key functional parameters: particle size distribution, particle size limitation and refractive index. Desired anti-blocking property and clarity only can be achieved when the particle size, particle size distribution and refractive index are optimized. When the particle size is too small, the particles do not pretrude through the ink receiving coating and anti-clocking property is poor. When the particles are too large, the particles will be projected when the ink receiving sheet is used as a transparency for presentation. In addition, the difference in refractive indices between the particle and the ink receiving coating affects the clarity and projection quality. Obviously, the solutions proposed in the prior arts do not solve the problems in the field. These designs have to compromise anti-blocking properties and clarity. As a result, an undesirable compromise must be made between ink laydown and anti-blocking property. The present invention discloses an optimized design that offers both excellent anti-blocking property and high clarity of the ink receiving sheet. Summary of the invention An object of the present invention is to provide a transparent ink receiving sheet which will avoid the blocking problems associated with prior art ink receiving sheets, while still maintaining high ink laydown and clarity. Another object of the present invention is to provide an ink receptive coating for an ink receiving sheet which will impart anti-blocking properties without the need for a separate ink permeable protective coating, while still maintaining high ink laydown and good clarity. A further object of the present invention is to provide an improved ink jet printing process for printing images on transparent ink jet receiving sheets, which avoids the problems associated with prior art processes. These and other objects and advantages are obtained by the present invention, which presents a solution to the need for an anti-blocking clear ink receiving sheet. The improvements in anti-blocking property and clarity are attained, according to the invention, by using specific particulates as a spacer in the ink receiving sheet. More particularly, the objects and advantages of the present invention are obtained by a transparent ink receiving sheet having anti-blocking properties, comprising a) a polymer substrate, b) an ink receptive coating disposed on at least one side of the substrate, and comprising at least one layer which comprises a water-soluble component, c) particulates dispersed in said ink receptive coating, having an average particle size of from about 15 µm to about 50 µm, preferably from about 20 µm to about 40 µm and a particle size span is equal to or smaller than 1.0, preferably < 0.8, and d) particulates dispersed in said ink receptive coating having a refractive index of from about 1.2 to about 2.4, wherein the ink receptive coating is present in an amount of from 2 g/m 2 to 30 g/m 2 . The objects and advantages are also obtained by an ink receptive coating for an ink receiving sheet, comprising 1) at least one layer comprising a water-soluble component, and 2) particulates dispersed therein having an average particle size of from 15 µm to about 50 µm, a particle size span is equal to or smaller than 1.0 and a refractive index of from 1.2 to about 2.4, wherein this coating is present in an amount of from 2 g/m 2 to 30 g/m 2 . Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while they may indicated preferred embodiments of the invention, are given by way of illustration only. Detailed description of the invention Examples of suitable substrate for the ink receiving sheet include transparent plastics, such as poly(ethylene terephthalate), polycarbonate, polystyrene, cellulose esters, poly(vinyl acetate), and others. The thickness of the substrate is not particularly restricted, but should be in the range of about (1.5 to about 10 mils), 0.038-0.254 mm preferably about 0.051-0.127 mm (2.0 to about 5.0 mils). The substrates may be pretreated to enhance adhesion of the coatings thereto. The ink receptive coating, which is disposed on at least one side of the polymer substrate, contains at least one layer comprising at least one water-soluble component. The ink receptive coating may have a single layer structure, or may have multiple layers. When multiple layers are present, the particulates can reside in any of these layers, as long as the particulates are exposed on the surface of the ink receptive coating. The ink receptive coating may contain both water-soluble and water-insoluble components, as long as the ink receptive coating functions to receive ink. Examples of water-soluble components include poly(vinyl alcohol), poly(vinyl acetate), poly(vinyl pyrrolidone), poly(acrylic acid), cellulose esters, gelatins, proteins, poly(ethylene oxide), alginates, poly(ethylene glycol) and water-soluble gums. Examples of water-insoluble components include methyl methacrylate, styrene, urethane, butadiene, 2-hydroxyethyl acrylate, ethyl acrylate, N-hydroxyethyl acrylamide, N-hydroxymethyl acrylamide, and ethylene terephthalate. These water-soluble and water-insoluble components may be incorporated as the component of a homopolymer, a copolymer, or a polymer blend. The coating weight of the ink receptive coating is from about 2 g/m 2 to about 30 g/m 2 and preferably, from about 4 g/m 2 to about 20 g/m 2 . The particulates disclosed in this invention have an average particle size of from 15 µm to about 50 µm, preferably from about 20 µm to about 40 µm; a particle size span equal to or smaller than 1.0, preferably < 0.8; and a refractive index of from about 1.2 to about 2.4. Examples of the particulates include glass beads, poly(methyl methacrylate), polystyrene, starch, silica, polyurethane, calcium carbonate and other organic and inorganic particles specified particle size, particle size span and refractive index. The concentration of the particulates in the ink receiving sheet may be from about 0.5% to about 10% (weight percentage based on coating solid content), depending on the particle size, the particle size distribution and ink laydown. Usually, low concentration is required when large particulates having small particle size span are used. The smoothness of the ink receiving sheet disclosed in this invention may be from about 200 to about 400 Sheffield units, preferably from about 240 to about 360 Sheffield units. The haze of the ink receiving sheet is < 8%. The Sheffield smoothness was measured on Paper Smoothness Tester, model 538 (Hagerty Technologies). The haze was measured on Haze Guard System, XL-211 (BKY Gardner). The average particle size and the particle size distribution ware measured on MasterSizer, MS-20 (Malvern Instruments). The average particle size is defined by the mean particle size or D50. The particle size distribution is expressed by the particle size span, which is defined as: Particle Size Span = (D90-D10)/(D50) where D90 is the 90th percentile diameter, D10 is the 10th percentile diameter, and D50 is the 50th percentile diameter. When the ink receptive coating is one side of the substrate, the side of the substrate which is not covered with ink receptive coating may to a backing material in order to reduce electrostatic charge and to reduce sheet-to-sheet friction and sticking. The backing material may be either a polymer coating, an ink receptive coating, a polymer film, or paper, in accordance with what is known in the art, and is not particularly limited. To prevent stacking blocking, the particulates disclosed in this invention can also be added in the backing materials. Any of a number of art recognized coating methods may be employed to coat the ink receptive coating onto the polymer substrate, such as roller coating, wire-bar coating, dip coating, extrusion coating, air knife coating, curtain coating, slide coating, doctor coating, or gravure coating. Such techniques are well known in the art. The following examples are merely illustrative of the invention and are not to be construed as limiting the invention. Example 1 Underlayer PVP-K90 12.0 parts Copolymer A 7.5 parts Particulate I 0.3 parts Dowanol PM ® 17.3 parts MEK 61.4 parts Surface layer Hydroxyethyl cellulose 1.8 parts Water 97.7 parts The underlayer coating was coated on the polyester base using a No. 36 Meyer rod. After drying the underlayer coating at 120°C for about 2 minutes, the surface layer coating was coated using No. 8 Meyer rod under the same conditions. The dry coat weight of the ink receptive coating is about 10 g/m 2 . Example 2 Underlayer PVP-K90 9.6 parts Copolymer A 6.0 parts Quaternary copolymer 8.6 parts Particulate I 0.3 parts Dowanol PM® 16.3 parts MEK 57.7 parts Surface layer Hydroxyethyl cellulose 1.8 parts Water 97.7 parts The underlayer coating was coated on the polyester baseusing a No. 36 Meyer rod. After drying the underlayer coating at 120°C for about 2 minutes, the surface layer coating was coated using a No. 8 Meyer rod under the same conditions. The dry coat weight of the ink receptive coating is about 10 g/m 2 . Example 3 Underlayer PVP-K90 12.0 parts Copolymer A 7.5 parts Particulate II 0.3 parts Dowanol PM® 17.3 parts MEK 61.4 parts Surface layer Hydroxyethyl cellulose 1.8 parts Water 97.7 parts The underlayer coating was coated on the polyester base using No. 38 Meyer rod. After drying the underlayer coating at 120°C for about 2 minutes, the surface layer coating was coated using a No. 8 Meyer rod under the same conditions. The dry coat weight of the ink receptive coating is about 10 g/m 2 . Example 4 Underlayer PVP-K90 8.4 parts Copolymer B 8.4 parts Quaternary copolymer 9.8 parts Particulate III 0.2 parts Dowanol PM® 13.5 parts MEK 58.1 parts Surface layer Hydroxyethyl cellulose 1.8 parts Water 97.7 parts The underlayer coating was coated on the polyester base using a No. 46 Meyer rod. After drying the underlayer coating at 120°C for about 2 minutes, the surface layer coating was coated using No. 8 Meyer rod under the same conditions. The dry coat weight of the ink receptive coating is about 10 g/m 2 . Comparative Example 1 Underlayer PVP-K90 8.67 parts Copolymer A 5.42 parts Quaternary copolymer 10.1 parts Dowanol PM® 20.7 parts MEK 53.5 parts Surface layer Hydroxyethyl cellulose 0.5 parts Particulate IV 0.14 parts Water 98.4 parts 1 Poly(methyl methacrylate), the average particle size is about 18 µm, the particle size span is about 1.19 and the refractive index is about 1.49. The underlayer coating was coated on the polyester base using a No. 46 Meyer rod. After drying the underlayer coating at 120°C for about 2 minutes, the surface layer coating was coated using a No. 16 Meyer rod under the same conditions. The dry coat weight of the ink receptive coating is about 10 g/m 2 . Comparative Example 2 Underlayer PVP-K90 8.7 parts Copolymer B 8.7 parts Quaternary copolymer 10.1 parts Particulate V 0.4 parts Dowanol PM ® 20.7 parts MEK 50.0 parts Surface layer Hydroxyethyl cellulose 1.8 parts Water 97.7 parts The underlayer coating was coated on the polyester base using a No. 46 Meyer rod. After drying the underlayer coating at 120°C for about 2 minutes, the surface layer coating was coated using a No. 8 Meyer rod under the same conditions. The dry coat weight of the ink receptive coating is about 10 g/m 2 . Samples prepared according to the above examples and comparative examples were printed on a Hewlett-Packard ink jet printer with a color ink cartridge at 50% RH and 22°C. The samples were allowed to dry for about 15 minutes and then were placed in a plastic sleeve. The samples were stored in the plastic sleeve at 80% RH and 30°C for 72 hours. Blocking was judged by examining the size of the contact areas between the image and the sleeve and assigning a scaled score thereto (a score of 5 being the best and a score of 0 being the worst). The results are summarized in Table 1. Performance comparisons Haze (%) Smoothness (Sheffield Units) Blocking Example 1 2.5 336 5 Example 2 2.7 341 5 Example 3 3.7 330 5 Example 4 1.7 373 5 Comparative Example 1 10.5 273 3 Comparative Example 2 8.9 193 0

Claims: A transparent ink-receiving sheet having anti-blocking properties, comprising: (a) a polymer substrate; (b) an ink-receptive coating disposed on at least one side of said substrate, comprising at least one layer which comprises a water-soluble component; and (c) particulates dispersed in said ink-receptive coating, having an average particle size of from 15 µm to 50 µm, a particle size span equal to or smaller than 1.0 and a refractive index of from 1.2 to 2.4; provided that the ink receptive coating is present in an amount of from 2g/m 2 to 30 g/m 2 ; the average particle size and particle size span being determined on Master Sizer, MS-20, the average particle size being defined by the mean particle size or D50, the particle size span being defined as (D90-D10)/D50, wherein D90 is the 90 th percentile diameter, D10 is the 10 th percentile diameter and D50 is the 50 th percentile diameter. The ink receiving sheet according to claim 1, characterized in that the ink receptive coating is present in an amount of from 4 g/m 2 to 20 g/m 2 . The ink receiving sheet according to claim 1, characterized in that the ink receptive coating has a Sheffield smoothness of from 200 to 400. The ink receiving sheet according to claim 3, characterized in that the Sheffield smoothness is from 240 to 360. The ink receiving sheet according to claim 1, characterized in that the ink receiving sheet has a haze of less than 8%. The ink receiving sheet according to claim 1, characterized in that the ink receptive coating comprises multiple layers. The ink receiving sheet according to claim 1, characterized in that the water-soluble component is selected from the group consisting to poly(vinyl alcohol), poly(vinyl pyrrolidone), gelatin, poly(vinyl acetate), cellulose ester, poly(acrylic acid), alginate, protein, poly(ethylene oxide), poly(ethyleneglycol), water soluble gum, and mixtures thereof. The ink receiving sheet according to claim 1, characterized in that the particulates are selected from the group consisting of glass beads, silica, polyolefins, polystyrene, poly(methyl methacrylate), starch and calcium carbonate. The ink receiving sheet according to claim 1, characterized in that the concentration of particulates is 0.5 weight % to 10 weight % based on total solids weight of the coating. The ink receiving sheet according to claim 1, characterized in that the substrate has a thickness of 0.038 to 0.127 mm. The ink receiving according to claim 10, characterized in that the thickness is 0.051 to 0.127 mm. The ink receiving sheet according to claim 1, characterized in that the substrate is a transparent plastic selected from the group consisting of polyester, polycarbonate, polystyrene, cellulose ester, poly(vinyl acetate), and mixtures thereof. A process for ink jet printing, comprising applying liquid ink to the ink receptive coating of the ink receiving sheet according to claim 1. A transparent ink receiving sheet as recited in claim 1, characterized in that the particulates comprise poly(methylmethacrylate). A transparent ink receiving sheet as recited in claim 1, characterized in that the particulates comprise glass beads. A transparent ink receiving sheet having anti-blocking properties, comprising: (a) a polymer substrate; (b) an ink-receptive coating disposed on at least one side of said substrate, comprising at least one layer which comprises a water-soluble component; and (c) organic particulates dispersed in said ink-receptive coating, having an average particle size of from 15 µm to 50 µm, a particle size span equal to or smaller than 1.0 and a refractive index of from 1.2 to 2.4; provided that the ink receptive coating is present in an amount of from 2g/m 2 to 30 g/m 2 ; the average particle size and particle size span being determined on Master Sizer, MS 20, the average particle size being defined by the mean particle size or D50, the particle size span being defined as (D90-D10)/D50 wherein D90 is the 90 th percentile diameter, D10 is the 10 th percentile diameter and D50 is the 50 th percentile diameter.

Inventors: ATHERTON DAVID, HUANG MIAOLING, SARGEANT STEVEN J, SUN KANG, YANG SEN, ATHERTON, DAVID, HUANG, MIAOLING, SARGEANT, STEVEN J., SUN, KANG, YANG, SEN
Applicants: ARKWRIGHT INC, ARKWRIGHT INC.
Application year: 1995
Main classification: B41M5
IPC codes: B41J2, B41M5