Low energy thermal transfer formulation

Abstract: A coating formulation which provides a thermal transfer layer of a thermal transfer medium which softens and flows at a temperature below 250°C, characterized by comprising a solid thermoplastic resin having a melting/softening point in the range of 50°C to 300°C, an active plasticizer with either a boiling pointin the range of 100°C to 250°C, unsaturated carbon atoms which react at a temperature in the range of 60°C to 250°C or both, a wax and a sensible material.

Description: The present invention relates to thermal transfer printing wherein images are formed on a receiving substrate by heating extremely precise areas of a print ribbon with thin film resistors. This heating of the localized area causes transfer of ink or other sensible material from the ribbon to the receiving substrate. The sensible material is typically a pigment or dye which can be detected optically or magnetically. Thermal transfer printing has displaced impact printing in many applications due to advantages such as the relatively low noise levels which are attained during the printing operation. Thermal transfer printing is widely used in special applications such as in the printing of machine readable bar codes and magnetic alpha-numeric characters. The thermal transfer process provides great flexibility in generating images and allows for broad variations in style, size and color of the printed image. Representative documentation in the area of thermal transfer printing includes the following patents. U.S. Patent No. 3,663,278, issued to J. H. Blose et al. on May 16, 1972, discloses a thermal transfer medium having a coating composition of cellulosic polymer, thermoplastic resin, plasticizer and a "sensible" material such as a dye or pigment. U.S. Patent No. 4,315,643, issued to Y. Tokunaga et al. on February 16, 1982, discloses a thermal transfer element comprising a foundation, a color developing layer and a hot melt ink layer. The ink layer includes heat conductive material and a solid wax as a binder material. U.S. Patent No. 4,403,224, issued to R. C. Winowski on September 6, 1983, discloses a surface recording layer comprising a resin binder, a pigment dispersed in the binder, and a smudge inhibitor incorporated into and dispersed throughout the surface recording layer, or applied to the surface recording layer as a separate coating. U.S. Patent No. 4,463,034, issued to Y. Tokunaga et al. on July 31, 1984, discloses a heat-sensitive magnetic transfer element having a hot melt or a solvent coating. U.S. Patent No. 4,510,206, issued to Shuman on April 9, 1985, discloses a thermal transfer formulation that includes a wax binder comprising a paraffin wax and a microcrystalline wax; a resin binder; and a coloring agent comprising a dye dispersed in an unsaturated fatty acid having a carbon content between about C 10 to C 20 . U.S. Patent No. 4,523,207, issued to M. W. Lewis et al. on June 11, 1985, discloses a multiple copy thermal record sheet which uses crystal violet lactone and a phenolic resin. U.S. Patent No. 4,628,000, issued to S. G. Talvalkar et al. on December 9, 1986, discloses a thermal transfer formulation that includes an adhesive-plasticizer or sucrose benzoate transfer agent and a coloring material or pigment. U.S. Patent No. 4,687,701, issued to K. Knirsch et al. on August 18, 1987, discloses a heat sensitive inked element using a blend of thermoplastic resins and waxes. U.S. Patent No. 4,698,268, issued to S. Ueyama on October 6, 1987, discloses a heat resistant substrate and a heat-sensitive transferring ink layer. An overcoat layer may be formed on the ink layer. U.S. Patent No. 4,707,395, issued to S. Ueyama et al. on November 17, 1987, discloses a substrate, a heat-sensitive releasing layer, a coloring agent layer, and a heat-sensitive cohesive layer. U.S. Patent No. 4,777,079, issued to M. Nagamoto et al. on October 11, 1988, discloses an image transfer type thermosensitive recording medium using thermosoftening resins and a coloring agent. U.S. Patent No. 4,778,729, issued to A. Mizobuchi on October 18, 1988, discloses a heat transfer sheet comprising a hot melt ink layer on one surface of a film and a filling layer laminated on the ink layer. U.S. Patent No. 4,869,941, issued to Ohki on September 26, 1989, discloses an imaged substrate with a protective layer laminated on the imaged surface. U.S. Patent No. 4,923,749, issued to Talvalkar on May 8, 1990, discloses a thermal transfer ribbon which comprises two layers, a thermal sensitive layer and a protective layer, both of which are water based. U.S. Patent No. 4,975,332, issued to Shini et al. on December 4, 1990, discloses a recording medium for transfer printing comprising a base film, an adhesiveness improving layer, an electrically resistant layer and a heat sensitive transfer ink layer. U.S. Patent No. 4,983,446, issued to Taniguchi et al. on January 8, 1991, describes a thermal image transfer recording medium which comprises as a main component, a saturated linear polyester resin. U.S. Patent No. 4,988,563, issued to Wehr on January 29, 1991, discloses a thermal transfer ribbon having a thermal sensitive coating and a protective coating. The protective coating is a wax-copolymer mixture which reduces ribbon offset. U.S. Patent Nos. 5,128,308 and 5,248,652, issued to Talvalkar each disclose a thermal transfer ribbon having a reactive dye which generates color when exposed to heat from a thermal transfer printer. And, U.S. Patent No. 5,240,781, issued to Obatta et al. discloses an ink ribbon for thermal transfer printers having a thermal transfer layer comprising a wax-like substance as a main component and a thermoplastic adhesive layer having a film forming property. There are some limitations on the applications for thermal transfer printing. For example, the properties of the thermal transfer formulation which permit transfer from a carrier to a receiving substrate can place limitations on the permanency of the printed matter. Printed matter from conventional processes can smear or smudge, especially when subjected to a subsequent sorting operation. Additionally, where the surface of a receiving substrate is subject to scratching, the problem is compounded. This smearing can make character recognition such as optical character recognition or magnetic ink character recognition difficult and sometimes impossible. In extreme cases, smearing can make it difficult to read bar codes. Many attempts have been made to provide high integrity thermal transfer printing which is resistant to scratching and smearing, some of which are described above. For example, Talvalkar provides print with improved smear resistance from a thermal transfer formulation which contains thermally reactive materials in U.S. Patent Nos. 5,128,308 and 5,248,652. For non-reactive thermal transfer formulations, it is generally known to those skilled in the art that higher melting resins and/or waxes can provide a higher degree of scratch and smear resistance. However, higher print head energies are necessary to achieve the desired flow to promote transfer and adhesion to a receiving substrate. An alternative thermal transfer formulation which provides printed images with high scratch and smear resistance and which can be employed using low print head energies is desired. It is the object of the present invention to provide a thermal transfer formulation which provides printed images which are resistant to scratching and smearing. According to the invention there is provided a coating formulation which provides a thermal transfer layer of a thermal transfer medium which softens and flows at a temperature below 250°C, characterized by comprising a solid thermoplastic resin having a melting/softening point above the softening point of the thermal transfer layer and in the range of 150°C to 300°C, an active plasticizer with either a boiling point in the range of 100°C to 250°C, unsaturated carbon atoms which react at a temperature in the range of 60°C to 250°C or both, a wax and a sensible material. Also according to the invention a thermal transfer ribbon comprising a flexible substrate and a thermal transfer layer which has a softening point below 250°C, characterized in that said thermal transfer material comprising a solid thermoplastic resin having a melting/softening point above the softening point of the thermal transfer layer and in the range of 150°C to 300°C, a sensible material, a wax and an active plasticizer with either a boiling point in the range of 100°C to 250°C, unsaturated carbon atoms which react at a temperature in the range of 60°C to 250°C or both. The invention will now be described by way of example only with reference to the accompanying drawings in which:- Figure 1 illustrates a thermal transfer medium of the present invention in a printing operation prior to thermal transfer; Figure 2 illustrates a thermal transfer medium of the present invention in a printing operation after thermal transfer; and Figure 3 illustrates a thermal transfer medium of the present invention in a printing operation wherein thermal transfer is taking place. Thermal transfer ribbon 20, as illustrated in Figures 1-3, comprises substrate 22 of a flexible material which is preferably a thin smooth paper or plastic-like material. Tissue type paper materials such as 30-40 gauge capacitor tissue, manufactured by Glatz and polyester-type plastic materials such as 14-35 gauge polyester film manufactured by Dupont under the trademark Mylar® are suitable. Polyethylene napthalate films, polyamide films such as nylon, polyolefin films such as polypropylene film, cellulose films such as triacetate film and polycarbonate films are also suitable. The substrates should have high tensile strength to provide ease in handling and coating and preferably provide these properties at minimum thickness and low heat resistance to prolong the life of heating elements within thermal print heads. The thickness is preferably 3 to 50 µm. Positioned on substrate 22 is thermal transfer layer 24. Typically, thermal transfer layers have a softening point below 250°C, preferably below 200°C and most preferably from 50°C to 150°C. Softening temperatures within this range enable the thermal transfer medium to be used in conventional thermal transfer printers, which typically have print heads which operate at temperatures in the range of 100°C to 250°C, more typically, temperatures in the range of 150°C to 200°C. The thermal transfer layer comprises a thermoplastic resin which has a melting softening point above the softening point of the thermal transfer layer and in the range of 150°C to 300°C. Thermoplastic resins with melting points in the range of 150°C to 225°C are most preferred. Examples of suitable thermoplastic resins are polyvinyl chloride, polyvinyl acetate, vinyl chloride-vinyl acetate copolymers, polyethylene, polypropylene, polyacetal, ethylene-vinyl acetate copolymers, ethylene alkyl (meth)acrylate copolymers, ethylene-ethyl acetate copolymer, polystyrene, styrene copolymers, polyamide, ethylcellulose, epoxy resin, xylene resin, ketone resin, petroleum resin, rosin or its derivatives, terpene resin, polyurethane resin, polyvinyl butyryl, synthetic rubber such as styrene-butadine rubber, nitrile rubber, acrylic rubber and ethylene-propylene rubber. Also suitable are polyvinyl alcohol, ethylene alkyl (meth)acrylate copolymers, styrene-alkyl (meth) acrylate copolymer, saturated polyesters and the like. Suitable saturated polyesters are described in U.S. Patent No. 4,983,446. It is recognized that mixtures of the above-identified resins can be used. In the viewpoint of transfer sensitivity, it is desirable for the thermoplastic rubbers to have a low softening temperature. From the viewpoint of image integrity, it is desirable for these resins to have a high softening temperature. The thermoplastic resin is preferably used in an amount of about 5 to 40 weight percent, particularly 10 to 20 weight percent based on the weight of total dry ingredients of the coating formulation which forms the thermal transfer layer. The thermal transfer layer also contains a wax. Suitable wax substances include natural waxes such as whale wax, bees wax, lanolin, carnauba wax, rice wax candelilla wax, montan wax and ceresine wax; petroleum waxes such as paraffin wax and microcrystalline waxes, synthetic waxes such as oxidized wax, ester wax, low molecular weight polyethylene and Fisher-Tropsch wax; higher fatty acids such as lauric acid, myristic acid, palmitic acid, stearic acid and behenic acid; higher aliphatic alcohol such stearyl alcohol; ester such as sucrose fatty acid esters, sorbitan fatty acid esters and amides. The wax substances may be used singly or in admixture. The melting points of preferred waxes used in conventional thermal transfer layers range from 75 °C to 175 °C, more preferably 100°C to 150°C. The preferred wax substances used in the thermal transfer layer have melting points at the high end of these ranges to aid the integrity of the printed image. As with thermoplastic resins, higher melting points tend to enhance the integrity of the image obtained, but transfer sensitivity tends to be decreased. Another component of the thermal transfer layer (24) is a sensible material which is capable of being sensed visually, by optical means, by magnetic means, by electroconductive means or by photoelectric means. The sensible material is typically a coloring agent such as a dye or pigment or magnetic particles. Any coloring agent used in conventional ink ribbons is suitable, including carbon black and a variety of organic and inorganic coloring pigments and dyes, examples of which include phthalocyanine dyes, fluorescent naphthalimide dyes and others such as cadmium, primrose, chrome yellow, ultra marine blue, titanium dioxide, zinc oxide, iron oxide, cobalt oxide, nickel oxide, etc. In the case of the magnetic thermal printing, the thermal transfer coating includes a magnetic pigment or particles for use in imaging or in coating operations to enable optical, human or machine reading of the characters. The magnetic thermal transfer ribbon 20 provides the advantages of thermal printing while encoding or imaging the substrate with a magnetic signal inducible ink. The sensible material is typically used in an amount from about 5 to 80 parts by weight of the total dry ingredients for the coating formulation which provides the thermal transfer layer. The thermal transfer layer 24 has as a key component an active plasticizer with a boiling point in the range of 150°C to 250°C, preferably below 230°C and most preferably below the print head temperature of the thermal printers employed in generating images and/or unsaturated groups which react at a temperature in the range of 60°C to 250°C. These plasticizers reduce the softening point of the thermal transfer layer and enable larger amounts of thermoplastic polymer with high melting points to be used. Active plasticizers with a low boiling point can be volatilized during printing which effectively increases the softening temperature of the thermal transfer layer once transferred. Active plasticizers with unsaturated groups which react at temperatures in the range of 60°C to 250°C also increase the softening temperature of the thermal transfer layer once reacted. Any plasticizer which is volatile at a temperature in the range given above, which is compatible with the thermoplastic resin and wax, and which can be retained in the thermal transfer layer until use, is suitable. Suitable plasticizers include low molecular weight (less than 25 carbon atoms), organic acids such as unsaturated fatty acids which are preferably liquid at room temperature. Particular examples include linoleic acid and linolenic acid. To incorporate such plasticizers into the thermal transfer layer, it is necessary that its boiling point be above the processing temperatures used in mixing and depositing the thermal transfer on a substrate layer. The coating formulations are typically heated and dried once applied to a substrate at a temperature in the range of 50°C to 150°C. Lower processing temperatures are preferred so as to prevent the loss of the volatile plasticizer. Active plasticizers with unsaturated groups which react at temperatures in the range of 60°C to 250°C either self-polymerize in the thermal transfer layer react with other components or absorb ambient oxygen. This effectively increases the molecular weight of the components within the thermal transfer layer and raises the softening point of the thermal transfer layer. Active plasticizer with reactive unsaturated groups include linoleic acid and linolenic acid described above. These monomers are preferred in that they can increase the softening point of the thermal transfer layer by volatilization and reaction of their unsaturated groups. To provide for reaction of temperatures in the range of 100°C to 250°C, the thermal transfer layer may have incorporated therein a conventional addition polymerization catalyst which is compatible with the thermal transfer resin. The thermal transfer layer 24 may contain plasticizers, other than those which are volatile at the softening point, to aid in processing of the thermal transfer layer. Suitable plasticizers used are adipic acid esters, phthalic acid esters, ricinoleic acid esters sebasic acid esters, succinic acid esters, chlorinated diphenyls, citrates, epoxides, glycerols, glycols, hydrocarbons, chlorinated hydrocarbons, phosphates, and the like. The plasticizer provides low temperature sensitivity and flexibility to the thermal transfer layer so as not to flake off the substrate. The thermal transfer layer may contain other additives including flexibilizers such as oil, weatherability improvers such a UV light absorbers, and fillers. The thermal transfer layer can be applied to the substrate 22 by conventional coating techniques such as a Meyer Rod or like wire-round doctor bar set up on a typical solvent coating machine to provide a coating thickness in the range of 2.54 x 10 -6 to 10.16 x 10 -6 m (0.0001 to 0.0004 inches). This coating thickness equates to a coating weight of between 0.15 and 0.62 mg per square centimetre (4 and 16 milligrams per four square inches). Suitable thermal transfer layers are derived from coating formulations having approximately 10 to 55 percent dry ingredients. A temperature of approximately 38°C to 66°C (100°F to 150°F) is maintained during the entire coating process. After the coating is applied to the substrate, the substrate is passed through a dryer at an elevated temperature but below the boiling point of the volatile plasticizer to ensure drying and adherence of the coating 24 onto the substrate 22 in making the transfer ribbon 20. The above-mentioned coating weight as applied by the Meyer Rod onto a preferred 3 to 12 mm thick substrate translates to a total thickness of 6 to 15 mm. The thermal transfer layer can be fully transferred onto a receiving substrate at a temperature in the range of 75°C to 200°C. If desired, the substrate or base film may be provided with a backcoating on the surface opposite the thermal transfer layer 24. The thermal transfer ribbon 20 provides the advantages of thermal printing. When the thermal transfer layer 24 is exposed to the heating elements (thin film resistor) of the thermal print head, the thermal transfer layer is transferred from the ribbon to the receiving substrate 28 in a manner to produce precisely defined characters 32 on the document for recognition by the reader. In the case of non-magnetic thermal printing, the image transferred to document 28 defines characters or codes for optical recognition by a machine or human. Figures 1-3 show use of the thermal transfer ribbon of the present invention in a printing operation. Figure 3 more particularly shows the heating of thermal transfer ribbon 20 by print head 30 where volatilization of plasticizer takes place during transfer of thermal transfer layer 24 onto receiving substrate 28. The heat from the print head 30 softens a portion of the thermal transfer layer 24 resulting transferred portion 40. Loss of the volatile plasticizer from transferred portion 40 results in image 32. The coating formulation of this invention contains the above-identified solid materials, in the proportions described, in a solution, dispersion or emulsion. Preferably, the solution, dispersion or emulsion is water-rich comprising primarily water and alkanols such as propanol. However, organic solvent based formulations, such as those comprising mineral spirits with a boiling point in the range of 150 C to 190°C also suitable. The coating formulation typically contains the solids in an amount in the range of about 10 to 50 weight percent. Preferably, the coating formulation contains about 30 percent solids. To prepare the coating formulation of the present invention, the ingredients are typically combined as an aqueous emulsion in a ball mill or similar conventional grinding equipment and agitated. Typically, the solids are added as dispersions at about 30 weight percent solids. The wax emulsion is typically the initial material and the remaining components added thereto with minor heating. The composition of the coating formulation and the thermal transfer layer can be controlled so as to adjust the temperature at which the coating is transferred to the receiving substrate. The images obtained from the coating formulations and thermal transfer layers of the present invention incorporate a higher proportion of high melting thermoplastic resin and therefore, show greater smear and scratch resistance.

Claims: A coating formulation which provides a thermal transfer layer of a thermal transfer medium which softens and flows at a temperature below 250°C, characterized by comprising a solid thermoplastic resin having a melting/softening point above the softening point of the thermal transfer layer and in the range of 150°C to 300°C, an active plasticizer with either a boiling point in the range of 100°C to 250°C, unsaturated carbon atoms which react at a temperature in the range of 60°C to 250°C or both, a wax and a sensible material. A formulation according to claim 1, characterized in that the thermoplastic resin has a melting point in the range of 150°C to 225°C. A coating formulation according to claim 1, characterized in that the thermoplastic resin is used in an amount of from 10 to 70 weight percent, based on the total dry ingredients. A coating formulation according to claim 1, characterized in that the active plasticizer has a boiling point below 230°C. A coating formulation according to claim 1, characterized in that the active plasticizer has a boiling point below 250°C and unsaturated carbon atoms which react at a temperature in the range of 60°C to 250°C. A coating formulation according to claim 5, characterized in that the active plasticizer is selected from the group consisting of low molecular weight unsaturated fatty acids with less than 25 carbon atoms. A coating formulation according to claim 1, characterized in that the active plasticizer is selected from linoleic acid and linolenic acid. A thermal transfer ribbon comprising a flexible substrate (22) and a thermal transfer layer (24) which has a softening point below 250°C, characterized in that said thermal transfer material comprising a solid thermoplastic resin having a melting/softening point above the softening point of the thermal transfer layer and in the range of 150°C to 300°C, a sensible material, a wax and an active plasticizer with either a boiling point in the range of 100°C to 250°C, unsaturated carbon atoms which react at a temperature in the range of 60°C to 250°C or both.

Inventors: KENNY FRANK J, LEWIS MONICA N, LORENZ MICHAEL A, KENNY, FRANK J., LEWIS, MONICA N., LORENZ, MICHAEL A.
Applicants: NCR INT INC, NCR INTERNATIONAL INC.
Application year: 1996
Main classification: B41M5
IPC codes: B41J31, B41M5, C08K5, B32B9, B32B27