Patent Grant
7241333
1. Field of the Invention
The present invention relates to ink-jet recording, particularly to an ink-jet recording method capable of obtaining a high quality image on a recording medium mainly comprising plain paper, and to an ink-jet ink (abbreviated as “ink” hereinafter) used thereto. The invention further relates to an ink-jet recording unit, ink cartridge for ink-jet recording and ink-jet recording apparatus.
2. Description of the Related Art
The ink-jet recording method is the method of ejecting small droplets of ink by applying energy, and recording by landing droplets on a recording medium such as paper. Particularly, in the method using an electricity-heat conversion member as an ejection energy supply device for ejecting the droplets by allowing bubbles to be generated by applying heat energy to the ink, a recording head is readily made to have high density nozzles to enable high resolution quality images to be recorded in a high speed (see Japanese Patent Publication Nos. 61-59911, 61-59912 and 61-59914).
However, since the conventional ink used for ink-jet recording usually comprises water as a principal component with supplemented water-soluble high boiling point solvents, such as glycols for preventing drying and clogging, the ink permeates deep into the recording paper when images are recorded on plain paper using such ink. Consequently, sufficient image densities cannot be obtained, and the image densities become uneven probably due to uneven distribution of fillers and sizing agents on the surface of recording paper. Since a plurality of color inks are printed one after another before the precedent inks are fixed when a color image is printed, a satisfactory image cannot be obtained due to blur of colors and uneven mixing (referred to as “bleeding” hereinafter) at the boundaries of different colors.
For solving the above problems, an ink having a surface tension less than or equal to the critical surface tension of the recording medium is used, for example, by adding compounds capable of enhancing permeability of the ink, such as glycol ethers and surfactants (Japanese Patent Application Publication Nos. 60-34992 and 62-28828). However, although permeability of the ink into recording paper (recording medium) is improved suppress bleeding to a certain extent, the image density is decreased and clearness of the image is deteriorated because the ink permeates deep into recording paper together with colorants. This method is not preferable because the ink tends to be spread due to improved wettability of the surface of recording paper causing a decrease of resolution and blur. This problem is evident when black letters are printed.
On the other hand, when the surface tension of the ink is adjusted to be higher than the critical surface tension of the recording medium, fixing speed is impaired and bleeding performance becomes quite poor, although the problems of decreased image density and clearness and deteriorated quality of the black letters do not occur.
The present invention was made in view of the above-mentioned problems. The present invention can provide an ink-jet recording method in which a performance having a high fixing speed on a recording medium mainly comprising plain paper without causing bleeding and a performance capable of obtaining a high image density with an excellent clearness of the image are compatible with each other. The present invention can also provide an ink-jet ink, an ink-jet recording unit, an ink cartridge for ink-jet recording and an ink-jet printer used in the method.
A first aspect of the present invention is to provide an ink-jet recording method for forming an image by applying an ink to a recording medium, wherein the ink used comprises at least water, a colorant and a surfactant. The content of the surfactant is higher than or equal to the critical micelle concentration of the surfactant, and the surface tension of the ink used is lower than or equal to the critical surface tension of the recording medium. The ink is applied to the recording medium, and the surface tension of the ink is increased to a surface tension higher than the critical surface tension of the recording medium after contacting the recording medium.
According to the recording method of the present invention, the effect of the present invention becomes evident when the recording medium is plain paper, the colorant contained in the ink is pigment and the surfactant is an anionic surfactant, the critical micelle concentration of the anionic surfactant is lower than or equal to 0.0005 mol/L, and the increase of the surface tension of the ink after contacting the recording medium is due to a loss of surface activity of the surfactant caused by a pH change of the ink, and a loss of surface activity of the surfactant caused by a reaction between the ink in the surfactant and polyvalent metal ions.
A second aspect of the present invention is to provide an ink-jet ink comprising at least water, a colorant, and a surfactant at a concentration higher than or equal to the critical micelle concentration of the surfactant, wherein the surface tension of the ink is lower than or equal to the critical surface tension of a recording medium as an object for applying the ink, and the surface tension of the ink increases to a surface tension higher than the critical surface tension of the recording medium after contacting the recording medium.
According to the ink of the present invention, the effect of the invention becomes evident when the surfactant is an anionic surfactant, the anionic surfactant has a cyclic peptide in its molecular structure, the critical micelle concentration is lower than or equal to 0.0005 mol/L, and the pH of the ink is higher than or equal to 6.5 and lower than or equal to 7.5.
A third aspect of the present invention is to provide an ink-jet recording unit comprising a container for accommodating the ink-jet ink according to any one of the above aspects, and a head for ejecting the ink.
A fourth aspect of the present invention is to provide an ink cartridge for ink-jet recording comprising a container for accommodating the ink according to any one of the above aspects.
A fifth aspect of the present invention is to provide an ink-jet recording apparatus comprising the ink-jet recording unit.
The ink-jet recording apparatus may comprise the ink cartridge for ink-jet recording.
A sixth aspect of the present invention is to provide an ink-jet recording method in which a liquid containing one of an alkaline acidic substance and a polyvalent metal substance is applied to a recording medium. An ink having a surface tension lower than or equal to the critical surface tension of the recording medium is applied to the portions of the recording medium where the liquid was applied, and the surface tension of the ink is increased to a surface tension higher than the critical surface tension of the recording medium by an interaction of the liquid and the ink.
The present invention enables ink-jet recording in which a performance having a high fixing speed without causing bleeding and a performance capable of obtaining a high image density with an excellent clearness of the image are compatible with each other on a recording medium mainly comprising plain paper, which have been problems for many years.
Further objects, features and advantages of the present invention will become apparent from the following description of the preferred embodiments (with reference to the attached drawings).
The present invention will be described in more detail hereinafter with reference to preferred embodiments. It is important to control permeation of the ink into recording media (mainly comprising plain paper). For fixing on a recording medium mainly comprising plain paper in high speed, it is preferable to use an ink having a surface tension lower than or equal to the critical surface tension of the recording medium when the ink is applied to a recording medium. However, using an ultra-permeable ink at the next stage, which allows the colorant of the ink to permeate into the recording medium, is inappropriate from the view point of preventing the density from decreasing because the colorants in the ink also permeate into the recording medium to thereby cause a decrease of density. Based on the facts above, it is preferable for solving the problems above to allow the ink to function as an ultra-permeable ink when the ink has been applied to the recording medium, to permit the surface tension of the ink to be lower than or equal to the critical surface tension of the recording medium, and to suppress permeability of the ink by rapidly increasing the surface tension of the ink after application of the ink on the recording medium to increase the surface tension of the ink to be higher than the critical surface tension of the recording medium, in order to prevent bleeding and to prevent the image density from decreasing.
The change of the surface tension of the ink is preferably rapid, because the fixing of the ink is often completed before the change of the surface tension, since the ultra-permeable ink has a short fixing time. The inventors of the present invention have made intensive studies on the technology for rapidly increasing the surface tension after the ink has been applied to the recording medium in order to cope with this response speed, and have completed the present invention by finding that a remarkable result is obtained in the method taking advantage of a loss of surface activity of the surfactant contained in the ink.
The reason why the remarkably good results of preventing bleeding and preventing decreased image density were obtained in the method taking advantage of the loss of surface activity of a surfactant contained in the ink is considered as follows. While a rapid decrease of the surface tension is observed in the surfactant by slowly adding the surfactant in the ink until the concentration reaches a critical micelle concentration, the surface tension becomes substantially constant when the concentration exceeds the critical micelle concentration. Accordingly, a large change of the surface tension of the ink before and after adhesion on the recording medium, which is preferred in the present invention, is best achieved in a concentration range of lower than or equal to the critical micelle concentration. This means that the object of the present invention is to provide a recording medium, which is the object for applying the ink, having a critical surface tension within the range of the change in surface tension of the ink possible as a result of changes in a concentration within a range lower than or equal to the critical micelle concentration of the surfactant contained the ink. For example, the above-mentioned problem may be solved by precisely controlling the composition of the ink, which is combined with the recording medium having the critical surface tension as described above, so that surface activity of the surfactant in the ink is lost when the ink is applied to the recording medium.
Surface activity as used in the present invention means an effect of decreasing the surface tension in the presence of the surfactant.
The ink according to the present invention takes advantage of a phenomenon by which the concentration of the surfactant that has been initially higher than or equal to the critical micelle concentration changes to a concentration lower than the critical micelle concentration due to the loss of surface activity after adhesion on the recording medium. The preferred effect of the present invention is obtained when the critical surface tension of the recording medium lies between the surface tension levels that have changed as described above. Specific methods for allowing surface activity of the surfactant to be lost will be described below. The concentration of the surfactant in the ink is preferably controlled to be just above the critical micelle concentration. Since the surface tension is largely changed even by a small amount of loss of surface activity, it is advantageous to use a surfactant having a low critical micelle concentration. Particularly, the critical micelle concentration of the surfactant used is preferably smaller than or equal to 0.0005 mol/L.
Practical methods for changing the concentration of the surfactant below the critical micelle concentration by the loss of surface activity of the surfactant will be described below using an ink in which the concentration of the surfactant is controlled.
In a first method, an adsorption reaction of the surfactant in the ink with hydrophobic substances in the recording medium after adhesion of the ink on the recording medium is utilized. The concentration of the surfactant in the ink is decreased to be lower than the critical micelle concentration by adsorption of the surfactant causing an increase of the surface tension of the ink.
In a second method, surface activity is lost by a decrease of pH of the anionic surfactant to an acidic pH region or by forming insoluble salts with the polyvalent metal ions. This method takes advantage of a loss of a function of the surfactant by insolubilizing the surfactant in the ink as a result of forming an acid form and an insoluble salt by a chemical reaction of anionic groups in the surfactant. This method can be achieved by using acidic paper for the recording medium, or by coating paper with an acidic substance in advance of printing to facilitate the decrease of pH. When salts are formed with multivalent metal ions, paper is impregnated with a multivalent metal substance in a paper making process for producing the recording medium, or the recording medium is coated by the multivalent metal substance before printing. It is preferable to apply a larger quantity of the reactive substance than the number of water-soluble groups in the surfactant when a substance that reacts with the surfactant is coated on the recording medium in advance.
The reaction used above has a high reaction rate and is suitable for solving the problem. While these methods are not particularly restricted, the method taking advantage of pH changes of the anionic surfactant, and the method taking advantage of insolubilization of hydrophilic groups of the anionic surfactant with the multivalent metal ions are suitable.
<Recording Medium>
The recording medium used in the present invention will be described below. Various recording media have been known in ink-jet recording. The so-called ink-jet paper used for output of label printers and digital cameras usually comprises an ink-receiving layer. The ink-receiving layer has a void structure comprising an inorganic filler, such as silica and alumina, and a water-soluble resin, or is a swellable type comprising a water-soluble resin, such as gelatin. The ink-jet paper having such an ink-receiving layer is reliably wettable with an ink having a substantially high surface tension, for example with an ink prepared by dissolving a water-soluble dye in a solvent comprising 100% water, and its critical surface tension exceeds 70 mN/m in most cases. Since the surface tension of the ink is designed to be higher than the critical surface tension of the recording medium after contacting the recording medium, ink-jet paper having conventional ink-receiving layers is not preferred for use with the present invention.
Accordingly, the object of the invention is so-called plain paper mainly comprising cellulose and in which a sizing agent is added, or light-weight paper including an ink-receiving layer with a critical surface tension of preferably 26 to 44 mN/m, more preferably 27 to 40 nM/N, and even more preferably 28 to 36 mN/m. This range of the critical surface tension enables the change of the surface tension of the ink accompanying the loss of surface activity of the surfactant to be realized by precisely controlling the composition of the ink.
A general method for measuring the critical surface tension of the recording medium was proposed by Zisman. Usually, a contact angle θ of the recording medium is measured with respect to a series of saturated hydrocarbon liquids having different surface tension γ, and a plot of (cos θ−γ) of these measured values is extrapolated to cos θ=1 to obtain γ as the critical surface tension of the recording medium. However, since the critical surface tension is high in the recording medium mainly comprising plain paper, the method using the saturated hydrocarbon liquid as described above is inappropriate because it gives a measured value out of the desired range. Accordingly, the point where cos θ=1 is determined using solutions with a various mixing ratios of water and ethanol, and the critical surface tension of the recording medium is determined from the surface tension of a mixed solution.
The method for measuring the surface tension of the ink in the process of changing the surface tension after the ink has contacted the recording medium will be described below. Since actual ink droplets are so tiny, it is difficult to measure the surface tension by retrieving the ink after the contact. It is also difficult to determine an accurate surface tension after contact due to the effect of evaporation of water in the ink. Accordingly, such changes of the surface tension of the ink according to the invention were measured by the following method.
A contact volume between the ink in the recording medium, before the reaction for losing surface activity of the surfactant in the ink occurs by allowing ink droplets to collide with the recording medium, and the recording medium is important. In calculating the contact volume, it was assumed that perfectly spherical ink droplets have a perfect circular shape with a blur ratio of 2 on the surface of the recording medium in the finally fixed state of the ink, and the distribution of the ink formed by permeation of the ink is semi-spherically fixed. It was also assumed that the ink is spread to ¼ volume of the final distribution volume of the ink. The specific gravity of paper was assumed to be 0.8 relative to the specific gravity of the ink. On the basis of this assumption, the ink and the recording medium were mixed in a mass percent of 1/0.8, and the surface tension of the ink was measured by promptly retrieving the ink to define the measured value as the surface tension of the ink after contacting the recording medium.
Actually, since the initial surface tension of the ink is lower than or equal to the critical surface tension of the recording medium, the blur ratio is not 2 according to studies by the inventors of the present invention. Even by taking other conditions into consideration, the contact volume is certainly estimated to be smaller and the contact volume is larger in the actual system. Since the surface activity loss reaction is proportional to the contact volume, the surface tension change as a result of the reaction is actually larger than estimated. Accordingly, it is not a problem to discuss the surface tension of the ink based on the measurement as described above.
When surface activity of the surfactant in the ink is lost by contacting the recording medium as result of applying an acidic substance and a treating agent containing the multivalent metal ion on the recording medium in advance, these substances are preferably applied in mole ratios more than or equal to the number of anionic groups in the anionic surfactant present in the ink.
<Ink>
The ink according to the present invention will be described below. The ink according to the present invention comprises at least water, a colorant, and a surfactant. The content of the surfactant is higher than or equal to the critical micelle concentration, and the surface tension thereof is lower than or equal to the critical surface tension of the recording medium. These components will be described below.
(Aqueous Medium)
Although the ink according to the invention comprises water as an essential component, the content of water in the ink is preferably larger than or equal to 30 percent by mass and smaller than or equal to 95 percent by mass relative to the total mass of the ink.
An aqueous medium using water, water-soluble solvents and a substance together is often used. Examples of the components combined with water include alkyl alcohols with a carbon number of 1 to 5, such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, tert-butyl alcohol and n-pentyl alcohol; amides such as dimethylformamide and dimethylacetamide; ketones or ketoalcohols such as acetone and diacetone alcohol; ether such as tetrahydrofuran and dioxane; oxyethylene or oxypropylene polymers such as diethyleneglycol, triethyleneglycol, tetraethyleneglycol, dipropyleneglycol, tripropyleneglycol, polyethyleneglycol and polypropyleneglycol; alkyleneglycols in which the alkylene group contains 2 to 6 carbon atoms such as ethyleneglycol, propyleneglycol, trimethyleneglycol, 1,4-butanediol and 1,5-pentanediol; triols such as 1,2,6-hexnetriol, glycerin and trimethylol propane; lower alkylethers of glycols such as ethyleneglycol monomethyl(or ethyl) ether, diethyleneglycolmethyl(or ethyl)ether and triethyleneglycolmonomethyl(or ethyl or butyl)ether; lower dialkylethers of polyfunctional alcohols such as triethyleneglycoldimethyl(or ethyl or butyl)ether and tetraethyleneglycolmonomethyl(or ethyl)ether; alkanol amines such as monoethanolamine, diethanolamine and triethanolamine; sulfolane; N-methyl-2-pyrrolidone; 2-pyrrolidone; 1,3-dimethyl-2-imidazolydinone; urea; ethylene urea and bishydroxyethyl sulfone.
Ethyleneglycol, diethyleneglycol, triethyleneglycol, tetraethyleneglycol, polyethyleneglycol (average molecular weight of 200 to 1000), 2-pyrrolidone, glycerin, 1,2,6-hexanetriol, ethylene urea and trimethylol propane are preferably used among them, and glycerin is particularly suitable. While the kind and content of the water-soluble solvent to be used together with water are not particularly restricted, the content is preferably more than or equal to 3 percent by mass and lower than or equal to 60 percent by mass relative to the total mass of the ink.
(Surfactant)
While the ink according to the present invention essentially comprises an anionic surfactant, the surfactant preferred in the present invention will be described below. Examples of the surfactant include anionic surfactants such as fatty acid salts, sulfate ester salts of higher alcohols, alkylbenzene sulfonate salts, phosphate ester salts of higher alcohols, and carboxylate salts of cyclic peptides; cationic surfactants such as fatty amines and quaternary ammonium salts; nonionic surfactants such as higher alcohol ethyleneoxide adducts, alkylphenol ethyleneoxide adducts, fatty ethyleneoxide adducts, polyfunctional alcohol fatty acid ester ethyleneoxide adducts, higher alcohol ethyleneoxide adducts, fatty acid amide ethyleneoxide adducts, polypropyleneglycol ethyleneoxide adducts, higher alcohol fatty acid ester and alkanol amine fatty acid amide; and amphoteric surfactants of amino acids and betaine. These surfactants may be used alone or plurality of them are used together.
While the surfactant available in the present invention is not particularly restricted, use of at least one anionic surfactant is preferred. The surfactant having a cyclic peptide in its molecular structure with a critical micelle concentration of lower than or equal to 0.0005 mol/l is more preferable among them.
Specific examples of amino acids contained in the cyclic peptide include glycine, alanine, valine, norvaline, leucine, norleucine, isoleucine, phenylalanine, tyrosine, diiodotyrosine, surinamine, threonine, serine, proline, hydroxyproline, tryptophane, thyroxin, methionine, cystine, cysteine, α-aminobutyric acid, aspartic acid, glutamic acid, asparagine, glutamine, lysine, hydroxylysine, arginine and histidine.
While the amino acid contained in the surfactant having the cyclic peptide structure is not particularly restricted so long as the critical micelle concentration of the anionic surfactant is in the range of lowrr than or equal to 0.0005 mol/L, it may comprise a hydrophilic site comprising a cyclic peptide containing 5 to 10 amino acid residues and a branched structure, and a hydrophobic site having a long chain alkyl and/or long chain alkylphenyl site with a carbon number of the main chain of larger than or equal to 8 is preferable. The carboxylic group and salts thereof are suitable as the water-soluble group.
Although the anionic surfactant having the structure as described above with a critical micelle concentration of lower than or equal to 0.0005 mol/L may be synthesized by a conventional method, the surfactant having the following structure is preferable.
In the formula above, R1 denotes an amino acid residue represented by any one of CH(CH3)2, CH2CH(CH3)2 and CH(CH3)CH2CH3, and R2 denotes a long chain alkyl chain represented by any one of (CH2)6CH(CH3)2, (CH2)9CH(CH3)2 and (CH2)11CH3.
The commercially available substance having the structure above corresponds to Aminofect (trade name: manufactured by Showa Denko Co., critical micelle concentration 0.000003 mol/L, 7 amino acid residues, 2 carboxylic groups, 12 alkyl chain carbon atoms). For example, a substance having a structure in which R1 is CH2CH(CH2)2 and R2 is (CH2)9CH(CH3)2 is contained in Aminofect.
The content of the specified anionic surfactant having an extremely low critical micelle concentration and being used in the present invention is preferably 0.00001 to 3 percent by mass, more preferably 0.00005 to 2.5 percent by mass, and even more preferably 0.0001 to 2 percent by mass, in the total quantity of the ink.
A nonionic surfactant is preferably used together with the anionic surfactant as described above in order to obtain a good balance between ejection stability and printing durability. Concomitant use of the nonionic surfactant such as, for example, polyoxyethylene alkylether and ethyleneoxide adduct of acetyleneglycol is preferable. The HLB of this nonionic surfactant is preferably higher than or equal to 10, preferably higher than or equal to 13, and even more preferably higher than or equal to 15. The content of the nonionic surfactant is preferably 0.01 to 3 percent by mass, more preferably 0.05 to 2.5 percent by mass, and even more preferably 0.1 to 2 percent by mass in the ink when these nonionic surfactants are used together.
While the initial surface tension of the ink according to the present invention should be determined to be lower than or equal to the critical surface tension of the recording medium, the difference between the critical surface tension of the recording medium and the surface tension of the initial ink is preferably small from the view point of reaction speed. While the surface tension of the ink is basically adjusted by the surfactant as described above, the difference of the surface tension is preferably 0 to 10 mN/m, more preferably 0 to 8 mN/m, and even more preferably 0 to 5 mN/m relative to the critical surface tension of the recording medium.
(Additives)
Additives such as a pH control agents, viscosity controlling agents, defoaming agents, antiseptics, antifungal agents and antioxidants may be added in addition to the components described above to achieve desired physical properties. The pH is preferably higher than or equal to 6.5, and lower than or equal to 7.5.
(Colorant)
The colorant contained in the ink according to the invention will be described below. Either a dye or a pigment may be used as the colorant in the present invention. The amount of addition of the colorant in the ink is preferably 0.1 to 15 percent by mass, more preferably 0.2 to 12 percent by mass, and even more preferably 0.3 to 10 percent by mass, although it is not restricted to this range.
Almost all the dyes described in COLOR INDEX, such as water-soluble acid dyes, direct dyes, basic dyes and reactive dyes may be used as the dyes for the present invention.
Dyes not described in COLOR INDEX may be used provided that they are water-soluble dyes. However, it is more preferable to use pigments in order to more clearly realize the effect of the present invention described above.
Examples of the pigments available in the present invention will be described below. Carbon black is suitable as the pigment used in the black ink. Specific examples of the carbon black pigment include furnace black, lamp black, acetylene black and channel black. The preferably used carbon black pigment has a primary particle diameter of 15 to 40 nm, a specific surface area by the BET method of 50 to 300 m2/g, DBP oil absorption of 40 to 150 ml/100 g, and a content of volatile fractions of 0.5 to 10%.
The following organic pigments are favorably used as the pigment in the color ink. Specific examples include insoluble azo pigments such as toluidine red, toluidine marine, Hansa yellow, benzidine yellow and pyrazolon red; soluble azo pigments such as lithol red, helio Bordeaux, pigment scarlet and permanent red 2B; derivatives from vat dyes such as alizarin, indantron and thioindigo maloon; phthalocyanine pigments such as phthalocyanine blue and phthalocyanine green; quinacridone pigments such as quinacridone red and quinacridone magenta; perylene pigments such as perylene red and perylene scarlet; isoindolinone pigments such as isoindolinone yellow and isoindolinone orange; imidazolone pigments such as benzimidazolone yellow, benzimidazolone orange and benzimidazolone red; pyranthrone pigments such as pyranthrone red and pyranthrone orange; thioindigo pigments; condensed azo pigments; diketopyrrolopyrrole pigments; flavanthrone yellow; acylamide yellow; quinophthalone yellow; nickel azo yellow; copper azomethin yellow; perynone orange; anthrone orange; dianthraquinonyl red; and dioxadine violet.
Examples of the organic pigments represented by color indices (C.I.) numbers include C.I. pigment yellow-12, 13, 14, 17, 20, 24, 55, 74, 83, 86, 93, 97, 98, 109, 110, 117, 120, 125, 128, 137, 138, 139, 147, 148, 150, 151, 153, 154, 155, 166, 168, 180 and 195; C.I. pigment orange 16, 36, 43, 51, 55, 59, 61 and 71; C.I. pigment red 9, 48, 49, 52, 53, 57, 97, 122, 123, 149, 168, 175, 176, 177, 180, 192, 202, 209, 215, 216, 217, 220, 223, 224, 226, 227, 228, 238, 240, 254, 255 and 272; C.I. pigment violet 19, 23, 29, 30, 37, 40 and 50; C.I. pigment blue 15, 15:1, 15:3, 15:4, 15:6, 22, 60 and 63; C.I. pigment green 7 and 36; and C.I. pigment brown 23, 25 and 26. While pigments other than those described above may be used, C.I. pigment yellow 13, 17, 55, 74, 93, 97, 98, 110, 128, 139, 147, 150, 151, 154, 155, 180 and 185; C.I. pigment red 122, 202 and 209; and C.I. pigment blue 15:3 and 15:4 are more preferable among them.
(Dispersing Agent)
The preferred dispersing agents for dispersing the pigment when the pigments listed above are used will be described below. While the dispersing agent for dispersing the pigment in the present invention is not particularly restricted so long as it is soluble in water, specific examples thereof include block copolymers, random copolymers graft copolymers or derivatives thereof comprising at least two monomers (at least one of them is a hydrophilic monomer) selected from styrene, styrene derivatives, vinyl naphthalene, vinyl naphthalene derivatives, alcohol esters of ethylenic α,β-unsaturated carboxylic acid, acrylic acid, acrylic acid derivatives, maleic acid, maleic acid derivatives, itaconic acid, itaconic acid derivatives, fumaric acid, fumaric acid derivatives, vinyl acetate, vinyl pyrrolidone, acrylamide, and their derivatives. The block copolymer is the preferable dispersing agent for achieving the invention.
The block copolymer has a structure represented by AB, BAB and ABC. The block copolymer having hydrophobic blocks and hydrophilic blocks with a balanced block size for contributing to dispersion stability is particularly advantageous for achieving the present invention. Such block copolymer is able to integrate functional groups into the hydrophobic block (a block for binding the colorant), and specific interaction between the dispersing agent and pigment for improving dispersion stability may be further enhanced. Such block copolymer is more preferable due to its rheological compatibility when it is used for the ink-jet recording method taking advantage of a heat energy, particularly for the ink-jet recording head compatible with small droplets (with a volume of preferably 0.1 to 20 pl, more preferably 0.1 to 15 pl, and even more preferably 0.1 to 10 pl). The amount of the polymer in the ink depends on the structure, molecular weight and other characteristics of the polymer, and other components of the ink composition. The weight average molecular weight selected for achieving the present invention is preferably less than 30,000, more preferably less than 20,000, and even more preferably in the range of 2,000 to 10,000.
The method for manufacturing these polymers, and the method for dispersing the pigment are disclosed in detail in Japanese Patent Laid-Open Nos. 05-179183, 06-136311, 07-053841, 10-87768, 11-043639, 11-236502 and 11-269418.
While representative hydrophobic monomers available for the block copolymer are as follows, the present invention is not restricted to these monomers. Examples thereof include benzyl acrylate, benzyl methacrylate, methyl methacrylate (MMA), ethyl methacrylate (EMA), propyl methacrylate, n-butyl methacrylate (BMA or NBMA), hexyl methacrylate, 2-ethylhexyl methacrylate (EHMA), octyl methacrylate, lauryl methacrylate (LMA), stearyl methacrylate, phenyl methacrylate, hydroxyethyl methacrylate (HEMA), hydroxypropyl methacrylate, 2-ethoxyethyl methacrylate, methacrylonitrile, 2-trimehtylsiloxyethyl methacrylate, glycidyl methacrylate (GMA), p-tolyl methacrylate, sorbyl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, octyl acrylate, lauryl acrylate, stearyl acrylate, phenyl acrylate, 2-phenylethyl methacrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, acrylonitrile, 2-trimethylsiloxyethyl acrylate, glycidyl acrylate, p-tolyl acrylate and sorbyl acrylate. Preferable hydrophobic monomers are benzyl acrylate, benzyl methacrylate, 2-phenylethyl methacrylate, methyl methacrylate, butyl methacrylate and 2-ethylhexyl methacrylate. It is preferable to produce homopolymers and copolymers, for example block copolymers, using a copolymer of methyl methacrylate and butyl methacrylate.
While representative hydrophilic monomers available for the block copolymer are as follows, the present invention is not restricted thereto. Examples include methacrylic acid (MMA), acrylic acid, dimethylaminoethyl methacrylate (DMAEMA), diethylaminoethyl methacrylate, t-butylaminoethyl methacrylate, dimethylaminoethyl acrylate, diethylaminoethyl acrylate, dimethylaminopropyl methacrylamide, methacrylamide, acrylamide and dimethyl acrylamide. The block copolymer is preferably produced using a homopolymer or copolymer of methacrylic acid, acrylic acid or dimethylaminoethyl methacrylate.
Polymers containing acids may be directly produced, or produced from blocked monomers having blocking groups that are eliminated after polymerization. Examples of the blocked monomer that generates acrylic acid or methacrylic acid after eliminating the blocking group include trimethylsilyl methacrylate (TMS-MMA), trimethylsilyl acrylate, 1-butoxyethyl methacrylate, 1-ethoxyethyl methacrylate, 1-butoxyethyl acrylate, 1-ethoxyethyl acrylate, 2-tetrahydropyranyl acrylate and 2-tetrahydropyranyl methacrylate.
Allowing the block copolymers as described above to be contained in the ink according to the present invention permits ink ejection stability to be more evidently improved, particularly when the ink-jet recording head using the thermal energy is actuated at a high frequency, for example, at a frequency higher than or equal to 5 kHz.
The content of the dispersing agent as described above in the ink is preferably 0.5 to 10 percent by mass, more preferably 0.8 to 8 percent by mass, and even more preferably 1 to 6 percent by mass. It is difficult to obtain a desired viscosity of the ink when the content of the pigment dispersing agent in the ink is higher than the above range.
While the components constituting the ink of the present invention have been described above, the average particle diameter of the pigment in the pigment dispersion as the ink of the present invention is preferably in the range of 50 to 200 nm. The average particle diameter can be measured using ELS-8000 (trade name, manufactured by Otsuka Electronics Co.) or Micro Track UPA 150 (trade name, manufactured by Nikkiso Co.)
<Ink-Jet Recording Method and Recording Apparatus>
The ink-jet recording method and recording apparatus using the ink according to the present invention will be described below. The following construction of the printer is not necessary when acidic paper or processed paper, in which polyvalent metal ions are added in the paper making process, is used as the recording medium. On the contrary, the following construction of the printer is preferred when the recording medium, such as recording paper, is coated with a liquid (named as a first liquid hereinafter) containing an acidic substance and a polyvalent metal substance prior to printing. When the first liquid containing the acidic substance and polyvalent metal substance and the ink according to the present invention are used, the first liquid is applied to the recording paper prior to the ink. Then, the ink according to the present invention is applied on the portions where the first liquid has been applied basically without heating or forced drying to obtain a recorded image. The recording paper may be subjected to forced drying, such as heat-drying, after the first liquid has been applied on recording paper, if necessary.
While the first liquid may be applied on the entire surface of the recording medium using a spray or roller, it is preferable to use an ink-jet method by which the first liquid is selectively and uniformly applied on the portion where the ink is applied thereafter. When the first liquid is applied by the ink jet method, the first liquid should be previously applied on the portion where the ink is to be applied. While the size of one droplet of the first liquid and ink, or the dot diameter formed on recording paper is not particularly restricted, a desired effect may be obtained when the dot diameter of the first liquid is larger than the dot diameter of the recording ink.
The recording apparatus used in the present invention will be described below. The ink-jet method by which a recording signal is applied to a recording head to eject the droplets by generated heat energy is favorably used in the present invention. The construction of the recording head as a major part of the recording apparatus is shown in
A head 13 is obtained by bonding a thermal head 15 (the head is not restricted to that shown in the drawing) having a resistor used for thermal recording to a glass, ceramic or plastic member in which the ink flow passageway 14 were formed. The thermal head 15 comprises a protective film 16 composed of silicon oxide, aluminum electrodes 17-1 and 17-2, a heating resistor layer 18 composed of nichrome etc., an oven layer 19 and a substrate 20 made of a radiator such as alumina etc.
The ink 21 reaches an ejection orifice 22, and forms a meniscus 23 by receiving a pressure P. When an electric signal is applied to the electrodes 17-1 and 17-2, the region of the thermal head 15 denoted by “n” is rapidly heated, and bubbles are formed in the ink 21 in contact with the head. The meniscus is formed by the pressure of the bubbles to form recording droplets 24 from the nozzle, and the droplets fly toward the recording medium 25.
The reference numeral 65 denotes a recording head having an ejection energy generating device for recording by ejecting the ink onto the recording medium opposed to an ejection port face having ejection ports. The reference numeral 66 denotes a carriage for allowing the recording head 65 to travel by mounting the recording head 65 thereto. The carriage 66 is slidably engaged with a guide shaft 67, and a part of the carriage 66 is connected to a belt 69 driven with a motor 68. The carriage 66 is movable along the guide shaft 67, or is movable in the recording region and adjoining regions for the recording head.
The reference numeral 51 denotes a paper feed part for inserting the recording medium, and the reference numeral 52 denotes a paper feed roller driven with a motor (not shown). Such construction permits the recording medium to be fed to a position opposed to the ejection port face of the recording head, and the recording medium is discharged to a discharge part comprising a discharge roller 53 in accordance with recording.
While the cap 62 of the ejection recovery part 64 is shunted from the travel passageway of the recording head 65 when the recording head returns to a home position after recording, the blade 61 remains to be protruded in the travel passageway. Consequently, the ejection port face of the recording head 65 is wiped with the blade. When the cap 62 is capped in contact with the ejection port face, the cap 62 travels so as to protrude in the travel passageway of the recording head.
The cap 62 and blade 61 stay at the same position as the position for wiping when the recording head 65 travels from the home position to the recording start position. Consequently, the ejection port face of the recording head is wiped during the movement.
The recording head moves not only to the home position at the end of recording and during recovery of ejection, but also to a home position adjacent to the recording region with a given interval when the recording head moves to the recording region for recording, and the ejection port face is also wiped during this movement.
In
A recording apparatus having five heads, as shown in
A recording apparatus having four recording heads arranged on the carriage is used when the first liquid is not used.
The present invention will be described in detail with reference to examples and comparative examples. “Parts” and “%” in the descriptions are based on mass unless otherwise mentioned. Inks 1 to 8 were prepared as follows.
<Ink 1>
(Preparation of Pigment Dispersion Solution 1)
A block polymer of AB type with an acid value of 250 and weight average molecular weight of 3,000 was prepared by a conventional method using benzyl methacrylate and methacrylic acid as starting materials. The product was neutralized with an aqueous potassium hydroxide solution to prepare a uniform aqueous polymer solution with a concentration of 50% by diluting with ion-exchange water. The aqueous polymer solution (180 g) obtained and C.I. pigment blue 15:3 (100 g) were mixed with 220 g of ion-exchange water, and the solution was mechanically stirred for 0.5 hours. Then, the mixture was treated by passing through an interaction chamber five times under a hydraulic pressure of about 10,000 psi (about 70 MPa) using a microfluidizer. Cyan color pigment dispersion solution 1 was prepared by removing non-dispersed substances including coarse particles by centrifuging (12,000 rpm, 20 minutes) the dispersion solution obtained above. The pigment dispersion solution 1 had a pigment concentration of 10% and dispersing agent concentration of 10%.
(Preparation of Ink 1)
Cyan color pigment dispersion solution 1 obtained above was used for preparing ink 1. The following components were added to the dispersion solution in prescribed concentrations (adjusted to 100 parts in total by adding ion-exchange water), and after thoroughly mixing these components, the solution was filtered by pressurizing using a micro-filter (manufactured by Fuji Film Co.) with a pore size of 2.5 μm to prepare ink 1 with a pigment concentration of 2% and dispersing agent concentration of 2%. Aminofect (trade name, manufactured by Showa Denko Co., critical micelle concentration=0.000003 mol/L, molecular weight=1036), as an anionic surfactant having a cyclic peptide structure, was added to ink 1 as shown below. Polyoxyethylene cetylether and ethyleneoxide adduct of and acetyleneglycol as a nonionic surfactant were also added.
<Ink 2>
Ink 2 was prepared by the same method as ink 1, except that the content of the anionic surfactant having the cyclic peptide structure in the composition of ink 1 was changed to 0.1 parts.
<Ink 3>
Ink 3 was prepared by the same method as ink 1, except that the content of the anionic surfactant having the cyclic peptide structure in the composition of ink 1 was changed to 0.001 parts.
<Ink 4>
(Preparation of Pigment Dispersion Solution 2)
The same polymer solution (100 g) used in the preparation of pigment dispersion solution 1, C.I. pigment red 122 (100 g) and ion-exchange water (300 g) were mixed and mechanically stirred for 0.5 hours. Then, the mixture was treated by passing through an interaction chamber five times under a hydraulic pressure of about 10,000 psi (about 70 MPa) using a microfluidizer. Magenta color pigment dispersion solution 2 was prepared by removing non-dispersed substances including coarse particles by centrifuging (12,000 rpm, 20 minutes) the dispersion solution obtained. The pigment dispersion solution 2 had a pigment concentration of 10% and dispersing agent concentration of 5%.
(Preparation of Ink 4)
Magenta color pigment dispersion solution 2 obtained above was used for preparing ink 4. The following components were added to the dispersion solution in prescribed concentrations (adjusted to 100 parts in total by adding ion-exchange water), and after thoroughly mixing these components, the solution was filtered by pressurizing using a micro-filter (manufactured by Fuji Film Co.) with a pore size of 2.5 μm to prepare ink 4 with a pigment concentration of 4% and dispersing agent concentration of 2%. Aminofect (trade name, manufactured by Showa Denko Co., critical micelle concentration=0.000003 mol/L, molecular weight=1036), as an anionic surfactant having a cyclic peptide structure, was added to ink 4 as shown below. Polyoxyethylene cetylether and ethyleneoxide adduct of acetyleneglycol, as a nonionic surfactant, were also added.
<Ink 5>
(Preparation of Dispersion Solution 3)
A block polymer of AB type with an acid value of 300 and weight average molecular weight of 4,000 was prepared by a conventional method using benzyl acrylate and methacrylic acid as starting materials. The product was neutralized with an aqueous potassium hydroxide solution to prepare a uniform aqueous polymer solution with a concentration of 50% by diluting with ion-exchange water. The aqueous polymer solution (110 g) obtained and C.I. pigment yellow 128 (100 g) were mixed with 290 g of ion-exchange water, and the solution was mechanically stirred for 0.5 hours. Then, the mixture was treated by passing through an interaction chamber five times under a hydraulic pressure of about 10,000 psi (about 70 MPa) using a microfluidizer. Yellow color pigment dispersion solution 3 was prepared by removing non-dispersed substances including coarse particles by centrifuging (12,000 rpm, 20 minutes) the dispersion solution obtained above. The pigment dispersion solution 3 had a pigment concentration of 10% and dispersing agent concentration of 6%.
(Preparation of Ink 5)
Yellow color pigment dispersion solution 3 obtained above was used for preparing ink 5. The following components were added to the dispersion solution in prescribed concentrations (adjusted to 100 parts in total by adding ion-exchange water), and after thoroughly mixing these components, the solution was filtered by pressurizing using a micro-filter (manufactured by Fuji Film Co.) with a pore size of 2.5 μm to prepare ink 5 with a pigment concentration of 5% and dispersing agent concentration of 3%. Monosodium lauroyl glutamate (critical micelle concentration=0.0003 mol/L), as an anionic surfactant, was added to ink 6 as shown below. Polyoxyethylene cetylether and ethyleneoxide adduct of acetyleneglycol, as a nonionic surfactant, were also added.
<Preparation of Ink 6>
(Preparation of Pigment Dispersion Solution 4)
A block polymer of ABC type with an acid value of 350 and weight average molecular weight of 5,000 was prepared by a conventional method using benzyl methacrylate, methacrylic acid and 2-ethoxyethyl methacrylate as starting materials. The product was neutralized with an aqueous potassium hydroxide solution to prepare a uniform aqueous polymer solution with a concentration of 50% by diluting with ion-exchange water. The aqueous polymer solution (60 g), and carbon black (100 g) were mixed with 340 g of ion-exchange water, and the solution was mechanically stirred for 0.5 hours. Then, the mixture was treated by passing through an interaction chamber five times under a hydraulic pressure of about 10,000 psi (about 70 MPa) using a microfluidizer. Black color pigment dispersion solution 4 was prepared by removing non-dispersed substances including coarse particles by centrifuging (12,000 rpm, 20 minutes) the dispersion solution obtained above. The pigment dispersion solution 4 had a pigment concentration of 10% and dispersing agent concentration of 3.5%.
(Preparation of Ink 6)
Black color pigment dispersion solution 4 obtained above was used for preparing ink 6. The following components were added to the dispersion solution in prescribed concentrations (adjusted to 100 parts in total by adding ion-exchange water), and after thoroughly mixing these components, the solution was filtered by pressurizing using a micro-filter (manufactured by Fuji Film Co.) with a pore size of 2.5 μm to prepare ink 6 with a pigment concentration of 3% and dispersing agent concentration of 1.05%. Aminofect (trade name, manufactured by Showa Denko Co., critical micelle concentration=0.000003 mol/L, molecular weight=1036), as an anionic surfactant having a cyclic peptide structure, was added to ink 6 as shown below. An ethyleneoxide adduct of acetyleneglycol, as a nonionic surfactant, was also added.
<Ink 7>
Ink 7 was prepared by the same method as in ink 6, except that the content of the anionic surfactant having the cyclic peptide structure in the composition of ink 6 was changed to 0.001 parts.
<Ink 8>
The following components were adding in prescribed concentrations (adjusted to 100 parts in total by adding ion-exchange water), and after thoroughly mixing these components, the solution was filtered by pressurizing using a micro-filter (manufactured by Fuji Film Co.) with a pore size of 0.45 μm to prepare ink 8 with a dye concentration of 2%. Aminofect (trade name, manufactured by Showa Denko Co., critical micelle concentration=0.000003 mol/L, molecular weight=1036), as an anionic surfactant having a cyclic peptide structure, was added to ink 8 as shown below.
The surface tension of and pH of inks 1 to 0.8 are shown in Table 1 below.
<Liquid I for Reaction>
The following components were added in prescribed concentrations (adjusted to 100 parts in total by adding ion-exchange water), and after thoroughly mixing these components, the solution was filtered by pressurizing using a micro-filter (manufactured by Fuji Film Co.) with a pore size of 0.45 μm to prepare first liquid I. The pH of liquid I was 2.5.
<First Liquid II for Reaction>
First liquid II was prepared by the same method as in first liquid I, except that 0.5 parts of citric acid in first liquid I was changed to 0.5 parts of calcium chloride.
<Standard Ink for Evaluating Recording Density>
The standard ink 8 was prepared by the same method as in inks 1 to 8, except that the content of ethyleneoxide adduct of acetyleneglycol in the compositions of inks 1 to 8 was changed to 1.5 parts (adjusted to 100 parts in total by adding ion-exchange water). No changes of the surface tension were observed in any of the standard inks before and after contacting the recording medium.
<Ink for Evaluation of Bleeding>
A red dye ink as a standard for evaluating bleeding was prepared by the same method as in first liquid I, except that 0.5 parts of citric acid in first liquid I prepared above was changed to 0.5 parts of acid dye C.I. acid red 35.
Images were recorded on commercially available copy paper, bond paper and light coat paper having the characteristics shown in Table 2 using inks 1 to 8 obtained above. The critical surface tension of each recording medium is shown in Table 2.
Color images were formed using the ink-jet recording apparatus shown in
Images were formed by the combinations selected from inks 1 to 8 and papers A to F shown in Table 3, and were evaluated by the following evaluation methods and evaluation criteria.
(Recording Density)
Inks 1 to 8 as evaluation object, and the standard inks prepared for evaluating the recording density were used. After printing solid images using the compositions of ink and paper shown in Table 3, the recording density was measured with Macbeth RD 915 (trade name, manufactured by Macbeth Co.) after allowing the images to sit for 1 hour. A ratio of (recording density of evaluation ink)/(recording density of standard ink) was determined, and the measured value was evaluated relative to the image density of the standard ink. The results were evaluated by the following criteria, and the results are shown in Table 3.
A: recording density ratio was larger than or equal to 1.10.
B: recording density ratio was larger than or equal to 1.40 and less than 1.10.
C: recording density ratio was less than 1.40.
(Bleeding)
Inks 1 to 8 as evaluation objects and the red dye standard ink prepared for evaluating bleeding were used. After printing solid images using the compositions of ink and paper shown in Table 3, the images obtained were observed with respect to blur of the color and uneven mixing at the boundaries. The results were evaluated by the following criteria, and the results are shown in Table 3.
A: no blur or uneven mixing of the color were observed.
B: blur and uneven mixing of the color were partly observed.
C: the color was blurred and unevenly mixed.
In the combination of ink 1 and paper C in Comparative Example 3, images were formed after forming a solid recording of first liquid I using a separate recording head mounted on the recording apparatus. The image was evaluated by the same method as in Comparative Example 3. The results are shown in Table 4.
In the combination of ink 5 and paper E in Comparative Example 9, images were formed after forming a solid recording of first liquid II using a separate recording head mounted on the recording apparatus. The image was evaluated by the same method as in Comparative Example 9. The results are shown in Table 4.
Since the surface tension of the ink increases from a lower side to a higher side of the critical surface tension of the recording medium before and after contacting the recording medium, permeability is initially high to suppress bleeding. Since permeability of the ink rapidly decreases during permeation of the ink into the recording medium in the second stage, the recording density becomes high by permitting the ink to stay at the upper layer of the recording medium. Consequently, compatibility between recording without bleeding and high density recording, which has been difficult before, can be attained.
While the present invention has been described with reference to what are presently considered to be the preferred embodiments, it is to be understood that the present invention is not limited to the disclosed embodiments. On the contrary, the present invention is intended to overcome various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encourage all such modifications and equivalent structures and functions.
This application claims priority from Japanese Patent Application No. 2003-415799 filed Dec. 12, 2003, which is incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003-415799 | Dec 2003 | JP | national |
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