Inkjet printing media

Abstract

A printing medium comprising a substrate having at least one surface and a coating on the surface wherein the coating comprises: (a) binder comprising: (1) organic polymer which is substantially free of onium groups, and (2) onium addition polymer consisting essentially of onium-containing mer units derived from addition monomer and onium-free mer units derived from addition monomer of which from 20 to 100 percent by weight is hydrophobic addition monomer, wherein the binder constitutes from 20 to 90 percent by weight of the coating; and (b) finely divided substantially water-insoluble pseudoboehmite particles which have a maximum dimension of less than 500 nanometers, are distributed throughout the binder, and constitute from 10 to 80 percent by weight of the coating.

Description

When substrates coated with an ink-receiving coating are printed with inkjet printing inks and dried, the inks often later migrate from their original locations on the coated substrate, thereby resulting in unsatisfactory images. Such migration is known as "bleed" or "bloom" and is especially prevalent under conditions of high temperature and high humidity such as for example, 35.degree. C. and 80 percent relative humidity.

It has now been found that bleed can be substantially reduced or even eliminated if the coating contains both organic polymer which is substantially free of onium groups and addition polymer which contains onium containing mer units if the latter polymer also contains onium-free mer units derived from a large proportion of hydrophobic addition monomer.

Accordingly, one embodiment of the invention is a coating composition comprising: (a) a volatile aqueous liquid medium; and (b) binder dissolved or dispersed in the volatile aqueous liquid medium, the binder comprising: (1) water-soluble film-forming organic polymer which is substantially free of onium groups, and (2) water-soluble or water-dispersible onium addition polymer consisting essentially of onium-containing mer units derived from addition monomer and onium-free mer units derived from addition monomer of which from 20 to 100 percent by weight is hydrophobic addition monomer, wherein the binder constitutes from 20 to 90 percent by weight of the solids of the coating composition; and (c) finely divided substantially water-insoluble pseudoboehmite particles which have a maximum dimension of less than 500 nanometers and constitute from 10 to 80 percent by weight of the solids of the coating composition.

Another embodiment of the invention is a printing medium comprising a substrate having at least one surface and a coating on the surface wherein the coating comprises: (a) binder comprising: (1) organic polymer which is substantially free of onium groups, and (2) onium addition polymer consisting essentially of onium-containing mer units derived from addition monomer and onium-free mer units derived from addition monomer of which from 20 to 100 by weight is hydrophobic addition monomer, wherein the binder constitutes from 20 to 90 percent by weight of the coating; and (b) finely divided substantially water-insoluble pseudoboehmite particles which have a maximum dimension of less than 500 nanometers, are distributed throughout the binder, and constitute from 10 to 80 percent by weight of the coating.

Yet another embodiment of the invention is a printing process which comprises applying liquid ink droplets to the printing medium of the second embodiment.

The printing media of the invention may be made by coating a surface of a substrate with the coating composition of the invention and thereafter substantially removing the aqueous liquid medium.

The coating composition can be in the form of an aqueous solution in which case the volatile aqueous liquid medium is a volatile aqueous solvent for the polymer of the binder, or the coating composition can be in the form of an aqueous dispersion in which instance the volatile aqueous liquid medium is a volatile aqueous dispersion liquid for at least some of the polymer of the binder.

The volatile aqueous liquid medium is predominately water. Small amounts of low boiling volatile water-miscible organic liquids may be intentionally added for particular purposes. Examples of such low boiling volatile water-miscible organic liquids solvents include methanol �CAS 67-56-1!, ethanol �CAS 64-17-5!, 1-propanol, �CAS 71-23-8!, 2-propanol �CAS 67-63-0!, 2-butanol �CAS 78-92-2!, 2-methyl-2-propanol �CAS 75-65-0!, 2-propanone �CAS 67-64-1!, and 2-butanone �CAS 78-93-3!. The listing of such liquids is by no means exhaustive.

Similarly, water-miscible organic liquids which themselves are of low, moderate, or even negligible volatility may be intentionally added for particular purposes, such as for example, retardation of evaporation. Examples of such organic liquids include 2-methyl-1-propanol �CAS 78-83-1!, 1-butanol �CAS 71-36-3!, 1,2-ethanediol �CAS 107-21-1!, and 1,2,3-propanetriol �CAS 56-81-5!. The listing of such liquids is by no means exhaustive.

Those materials which, although not intentionally added for any particular purpose, are normally present as impurities in one or more of the components of the coating compositions of the invention and which become components of the volatile aqueous liquid medium, may be present at low concentrations.

In most instances water constitutes at least 60 percent by weight of the volatile aqueous liquid medium. Often water constitutes at least 80 percent by weight of the volatile aqueous liquid medium. Preferably water constitutes substantially all of the volatile aqueous liquid medium.

The amount of volatile aqueous liquid medium present in the coating composition may vary widely. The minimum amount is that which will produce a coating composition having a viscosity low enough to apply as a coating. The maximum amount is not governed by any theory, but by practical considerations such as the cost of the liquid medium, the minimum desired thickness of the coating to be deposited, and the cost and time required to remove the volatile aqueous liquid medium from the applied wet coating. Usually, however, the volatile aqueous liquid medium constitutes from 60 to 98 percent by weight of the coating composition. In many cases the volatile aqueous liquid medium constitutes from 70 to 96 percent by weight of the coating composition. Often the volatile aqueous liquid medium constitutes from 75 to 95 percent by weight of the coating composition. Preferably the volatile aqueous liquid medium constitutes from 80 to 95 percent by weight of the composition.

The water-soluble film-forming organic polymers which are substantially free of onium groups and which may be used in the present invention are numerous and widely varied. Examples include poly(ethylene oxide), poly(vinyl alcohol), poly(vinyl pyrrolidone), water-soluble cellulosic organic polymer, or a mixture of two or more thereof.

Water-soluble poly(ethylene oxide) is known. Such materials are ordinarily formed by polymerizing ethylene oxide �CAS 75-21-8!, usually in the presence of a small amount of an initiator such as low molecular weight glycol or triol. Examples of such initiators include ethylene glycol �CAS 107-21-1!, diethylene glycol �CAS 111-46-6!, triethylene glycol �CAS 112-27-6!, tetraethylene glycol �CAS 112-60-7!, propylene glycol �CAS 57-55-6!, trimethylene glycol �CAS 504-63-2!, dipropylene glycol �CAS 110-98-5!, glycerol �CAS 56-81-5!, trimethylolpropane �CAS 77-99-6!, and .alpha.,.omega.-diaminopoly(propylene glycol) �CAS 9046-10-0!. One or more other lower alkylene oxides such as propylene oxide �CAS 75-56-9! and trimethylene oxide �CAS 503-30-0! may also be employed as comonomer with the ethylene oxide, whether to form random polymers or block polymers, but they should be used only in those small amounts as will not render the resulting polymer both water-insoluble and nondispersible in water. As used herein and in the claims, the term "poly(ethylene oxide)" is intended to include the foregoing copolymers of ethylene oxide with small amounts of lower alkylene oxide, as well as homopolymers of ethylene oxide. The configuration of the poly(ethylene oxide) can be linear, branched, comb, or star-shaped. The preferred terminal groups of the poly(ethylene oxide) are hydroxyl groups, but terminal lower alkoxy groups such as methoxy groups may be present provided their types and numbers do not render the poly(ethylene oxide) polymer unsuitable for its purpose. In most cases the poly(ethylene oxide) is water-soluble. The preferred poly(ethylene oxide) is a water-soluble homopolymer of ethylene oxide produced using a small amount of ethylene glycol as an initiator.

The weight average molecular weight of the water-soluble poly(ethylene oxide) may vary widely. Usually it is in the range of from 100,000 to 3,000,000 although a weight average molecular weights somewhat below 100,000 or somewhat above 3,000,000 may be used. Often the weight average molecular weight of the water-soluble poly(ethylene oxide) is in the range of from 150,000 to 1,000,000. Frequently the weight average molecular weight of the water-soluble poly(ethylene oxide) is in the range of from 200,000 to 1,000,000. From 300,000 to 700,000 is preferred.

When used, poly(ethylene oxide) having a weight average molecular weight in the range of from 100,000 to 3,000,000 generally constitutes from 10 to 100 percent by weight of the water-soluble film-forming organic polymer which is substantially free of onium groups.

Water-soluble poly(vinyl alcohol) may be broadly classified as one of two types. The first type is fully hydrolyzed water-soluble poly(vinyl alcohol) in which less than 1.5 mole percent acetate groups are left on the molecule. The second type is partially hydrolyzed water-soluble poly(vinyl alcohol) in which from 1.5 to as much as 20 mole percent acetate groups are left on the molecule. The water-soluble organic polymer may comprise either type or a mixture of both. The weight average molecular weight of the water-soluble poly(vinyl alcohol) may vary considerably, but often it is in the range of from 100,000 to 400,000. In many cases the weight average molecular weight is in the range of from 110,000 to 300,000. From 120,000 to 200,000 is preferred.

Water-soluble poly(vinylpyrrolidone) is a known material and may be used. Usually, but not necessarily, the weight average molecular weight of the poly(vinylpyrrolidone) is in the range of from 10,000 to 3,000,000. From 50,000 to 1,000,000 is preferred.

There are many widely varying types of water-soluble cellulosic organic polymers which may be employed in the present invention. Of these, the water-soluble cellulose ethers are preferred water-soluble cellulosic organic polymers. Many of the water-soluble cellulose ethers are also excellent water retention agents. Examples of the water-soluble cellulose ethers include water-soluble methylcellulose �CAS 9004-67-5!, water-soluble carboxyrmethylcellulose, water-soluble sodium carboxyrnethylcellulose �CAS 9004-32-4!, water-soluble ethylmethylcellulose, water-soluble hydroxyethylmethylcellulose �CAS 9032-42-2!, water-soluble hydroxypropylmethylcellulose �CAS 9004-65-3!, water-soluble hydroxyethylcellulose �CAS 9004-62-0!, water-soluble ethylhydroxyethylcellulose, water-soluble sodium carboxymethylhydroxyethylcellulose, water-soluble hydroxypropylcellulose �CAS 9004-64-2!, water-soluble hydroxybutylcellulose �CAS 37208-08-5!, water-soluble hydroxybutylmethylcellulose �CAS 9041-56-9! and water-soluble cellulose sulfate sodium salt �CAS 9005-22-5!. Water-soluble hydroxypropylcellulose is preferred.

Water-soluble hydroxypropylcellulose is a known material and is available commercially in several different weight average molecular weights. The weight average molecular weight of the water-soluble hydroxypropylcellulose used in the present invention can vary widely, but usually it is in the range of from 100,000 to 1,000,000. Often the weight average molecular weight is in the range of from 100,000 to 500,000. From 200,000 to 400,000 is preferred. Two or more water-soluble hydroxypropylcelluloses having different weight average molecular weights may be admixed to obtain a water-soluble hydroxypropyl cellulose having a differing weight average molecular weight.

Similarly, there are many widely varying kinds of other water-soluble polymers which may be employed in the present invention. Examples include water-soluble poly(vinylpyridine), water-soluble poly(ethylenimine), water-soluble ethoxylated poly(ethylenimine), water-soluble poly(ethylenimine)-epichlorohydrin, water-soluble polyacrylate, water-soluble sodium polyacrylate, water-soluble poly(acrylamide), water-soluble carboxy modified poly(vinyl alcohol), water-soluble poly(2-acrylamido-2-methylpropane sulfonic acid), water-soluble poly(styrene sulfonate), water-soluble vinyl methyl ether/maleic acid copolymer, water-soluble styrene-maleic anhydride copolymer, water-soluble ethylene-maleic anhydride copolymer, water-soluble acrylamide/acrylic acid copolymer, water-soluble poly(diethylene triamine-co-adipic acid), water-soluble poly�(dimethylamino)ethyl methacrylate hydrochloride!, water-soluble quaternized poly(imidazoline), water-soluble poly(N,N-dimethyl-3,5-dimethylene piperidinium chloride), water-soluble poly(vinylpyridinium halide), water-soluble starch, water-soluble oxidized starch, water-soluble casein, water-soluble gelatin, water-soluble sodium alginate, water-soluble carrageenan, water-soluble dextran, water-soluble gum arabic, water-soluble pectin, water-soluble albumin, and water-soluble agar-agar.

As a component of the binder of the coating or coating composition as the case may be, the amount of organic polymer which is substantially free of onium groups, may vary considerably. Usually the organic polymer which is substantially free of onium groups constitutes from 5 to 95 percent by weight of the binder. Often the film-forming organic polymer which is substantially free of onium groups constitutes from 15 to 80 percent by weight of the binder. From 20 to 60 percent by weight of the binder is preferred.

The water-soluble or water-dispersible onium addition polymer consists essentially of onium-containing mer units derived from addition monomer and onium-free mer units derived from addition monomer of which from 20 to 100 percent by weight is hydrophobic addition monomer. In many cases the onium-free mer units are derived from addition monomer of which from 40 to 100 percent by weight is hydrophobic addition monomer. In other instances the onium-free mer units are derived from addition monomer of which from 60 to 100 percent by weight is hydrophobic addition monomer. Often the onium-free mer units are derived from addition monomer of which from 80 to 100 percent by weight is hydrophobic addition monomer. In some instances the onium-free mer units are derived from addition monomer of which from 95 to 100 percent by weight is hydrophobic addition monomer. Preferably all of the onium-free mer units are derived from hydrophobic addition monomer.

As used herein and in the claims, the phrase "hydrophobic addition monomer" means addition monomer, the homopolymer of which (weight average molecular weight at least 1000) is water insoluble. In most cases the hydrophobic addition monomer contains no hydrophilic groups such as hydroxyl, carboxyl, primary amino, secondary amino, tertiary amino, or the like. Examples of hydrophobic addition monomers which are devoid of aromatic hydrocarbon groups include methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, tert-butyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, and tert-butyl methacrylate. Usually at least 5 percent by weight of the hydrophobic addition monomers employed contain at least one aromatic hydrocarbon group. Often at least 10 percent by weight of the hydrophobic addition monomers employed contain at least one aromatic hydrocarbon group. Preferably at least 15 percent by weight of the hydrophobic addition monomers employed contain at least one aromatic hydrocarbon group. Examples of such aromatic-containing addition monomers include styrene, phenyl methacrylate, o-tolyl methacrylate, m-tolyl methacrylate, p-tolyl methacrylate, and benzyl methacrylate. Styrene is the preferred aromatic-containing addition monomer.

The onium-containing mer units are derived from addition monomer which contains at least one onium group before polymerization, or it is derived from addition monomer which contains at least one group that can be converted to an onium group after polymerization by conventional methods. The counter ion can be any of those commonly employed such as for example chloride, bromide, nitrate, hydrogen sulfate, methylsulfate, sulfonate, acetate, and the like, and are hereinafter and in the claims generically referred to as "salt". The onium may be primary ammonium, secondary ammonium, tertiary ammonium, quaternary ammonium, phosphomium, or sulfonium. Secondary ammonium, tertiary ammonium, or quaternary ammonium is preferred. Quaternary ammonium is especially preferred.

Examples of addition monomer which contains at least one onium group include:

Primary Ammonium 2-(methacryloylamino)ethylammonium salt, 2-(acryloylamino)ethylammonium salt, 3-(methacryloylamino)propylammonium salt, 3-(acryloylamino)propylammonium salt, p-vinylbenzylammonium salt, m-vinylbenzylammonium salt, p-vinylbenzylammonium salt, Secondary Ammonium methyl-2-(methacryloyloxy)ethylammonium salt, ethyl-2-(methacryloyloxy)ethylammonium salt, n-propyl-2-(methacryloyloxy)ethylammonium salt, isopropyl-2-(methacryloyloxy)ethylammonium salt, n-butyl-2-(methacryloyloxy)ethylammonium salt, sec-butyl-2-(methacryloyloxy)ethylammonium salt, isobutyl-2-(methacryloyloxy)ethylammonium salt, tert-butyl-2-(methacryloyloxy)ethylammonium salt, methyl-2-(acryloyloxy) ethylammonium salt, ethyl-2-(acryloyloxy) ethylammonium salt, n-propyl-2-(acryloyloxy)ethylammonium salt, isopropyl-2-(acryloyloxy)ethylammonium salt, n-butyl-2-(acryloyloxy)ethylammonium salt, sec-butyl-2-(acryloyloxy)ethylammonium salt, isobutyl-2-(acryloyloxy)ethylammonium salt, tert-butyl-2-(acryloyloxy)ethylammonium salt, methyl-3-(methacryloyloxy)propylammonium salt, ethyl-3-(methacryloyloxy)propylammonium salt, n-propyl-3-(methacryloyloxy)propylammonium salt, methyl-3-(acryloyloxy)propylammonium salt, ethyl-3-(acryloyloxy)propylammonium salt, n-propyl-3-(acryloyloxy)propylammonium salt, methyl-2-(acryloylamino)ethylammonium salt, ethyl-2-(methacryloylamino)ethylammonium salt, n-propyl-2-(methacryloylamino)ethylammonium salt, isopropyl-2-(methacryloylamino)ethylammonium salt, n-butyl-2-(methacryloylamino)ethylammonium salt, sec-butyl-2-(methacryloylamino)ethylammonium salt, isobutyl-2-(methacryloylamino)ethylammonium salt, isobutyl-2-(methacryloylamino)ethylammonium salt, tert-butyl-2-(methacryloylamino)ethylammonium salt, methyl-2-(acryloylamino)ethylammonium salt, m-ethyl-2-(acryloylamino)ethylammonium salt, n-propyl-2-(acryloylamino)ethylammonium salt, isopropyl-2-(acryloylamino)ethylammonium salt, n-butyl-2-(acryloylamino)ethylammonium salt, sec-butyl-2-(acryloylamino)ethylammonium salt, isobutyl-2-(acryloylamino)ethylammonium salt, tert-butyl-2-(acryloylamino)ethylammonium salt, methyl-3-(methacryloylamino)propylammonium salt, ethyl-3-(methacryloylamino) propylammonium salt, n-propyl-3-(methacryloylamino)propylammonium salt, methyl-3-(acryloylamino)propylammonium salt, ethyl-3-(acryloylamino) propylammonium salt, n-propyl-3-(acryloylamino)propylammonium salt, methyl-p-vinylbenzylammonium salt, methyl-m-vinylbenzylammonium salt, ethyl-p-vinylbenzylammonium salt, ethyl-m-vinylbenzylammonium salt, Tertiary Ammonium dimethyl-2-(methacryloyloxy)ethylammonium salt, diethyl-2-(methacryloyloxy)ethylammonium salt, dimethyl-2-(acryloyloxy)ethylammonium salt, diethyl-2-(acryloyloxy)ethylammonium salt, dimethyl-3-(methacryloyloxy)propylammonium salt, diethyl-3-(methacryloyloxy)propylammonium salt, dimethyl-2-(methacryloylamino)ethylammonium salt, diethyl-2-(methacryloylamino)ethylammonium salt, dimethyl-2-(acryloylamino)ethylammonium salt, diethyl-2-(acryloylamino)ethylammonium salt, dimethyl-3-(methacryloylamino)propylammonium salt, diethyl-3-(methacryloylamino)propylammonium salt, dimethyl-3-(acryloylamino)propylammonium salt, diethyl-3-(acryloylamino)propylammonium salt, N-ethyl-N-ethyl-2-(methacryloyloxy)ethylammonium salt, N-ethyl-N-methyl-2-(methacryloyloxy)ethylammonium salt, N-methyl-N-ethyl-3-(acryloylamino)propylammonium salt, dimethyl-p-vinylbenzylammonium salt, dimethyl-m-vinylbenzylammonium salt, diethyl-p-vinylbenzylammonium salt, diethyl-m-vinylbenzylammonium salt, N-methyl-N-ethyl-p-vinylbenzylammonium salt, N-methyl-N-ethyl-p-vinylbenzylammonium salt, Quaternary Ammonium trimethyl-2-(methacryloyloxy)ethylammonium salt, triethyl-2-(methacryloyloxy)ethylammonium salt, trimethyl-2-(acryloyloxy)ethylammonium salt, triethyl-2-(acryloyloxy)ethylammonium salt, trimethyl-3-(methacryloyloxy)propylammonium salt, triethyl-3-(methacryloyloxy)propylammonium salt, trimethyl-2-(methacryloylamino)ethylammonium salt, triethyl-2-(methacryloylamino)ethylammonium salt, trimethyl-2-(acryloylamino)ethylammonium salt, triethyl-2-(acryloylamino) ethylammonium salt, trimethyl-3-(methacryloylamino)propylammonium salt, triethyl-3-(methacryloylamino)propylammonium salt, trimethyl-3-(acryloylamino)propylammonium salt, triethyl-3-(acryloylamino)propylammonium salt, N,N-dimethyl-N-ethyl-2-(methacryloyloxy)ethylammonium salt, N,N-diethyl-N-methyl-2-(methacryloyloxy)ethylammonium salt, N,N-dimethyl-N-ethyl-3-(acryloylamino)propylammonium salt, trimethyl-p-vinylbenzylammonium salt, trimethyl-m-vinylbenzylammonium salt, triethyl-p-vinylbenzylammonium salt, triethyl-m-vinylbenzylammonium salt, N,N-dimethyl-N-ethyl-p-vinylbenzylammonium salt, N,N-diethyl-N-methyl-p-vinylbenzylammonium salt, Phosphonium vinylbenzyltributylphosphonium salt, Sulfonium dimethylvinylsulfonium salt, and dimethylallylsulfonium salt.

Examples of addition monomer which contains at least one group that can be converted to an onium group after polymerization include:

Primary Amine N-(2-aminoethyl) methacrylamide, N-(2-aminoethyl) acrylamide, N-(3-aminopropyl) methacrylamide, N-(3-aminopropyl) acrylamide, p-vinylbenzylamine, m-vinylbenzylamine, Secondary Amine methylaminoethyl methacrylate, ethylaminoethyl methacrylate, n-propylaminoethyl methacrylate, isopropylaminoethyl methacrylate, n-butylaminoethyl methacrylate, sec-butylaminoethyl methacrylate, isobutylaminoethyl methacrylate, tert-butylaminoethyl methacrylate, methylaminoethyl acrylate, ethylaminoethyl acrylate, n-propylaminoethyl acrylate, isopropylaminoethyl acrylate, n-butylaminoethyl acrylate, sec-butylaminoethyl acrylate, isobutylaminoethyl acrylate, tert-butylaminoethyl acrylate, methylaminopropyl methacrylate, ethylaminopropyl methacrylate, n-propylaminopropyl methacrylate, isopropylaminopropyl methacrylate, n-butylaminopropyl methacrylate, sec-butylaminopropyl methacrylate, isobutylaminopropyl methacrylate, tert-butylaminopropyl methacrylate, methylaminopropyl acrylate, ethylaminopropyl acrylate, n-propylaminpropyl acrylate, isopropylaminopropyl acrylate, n-butylaminopropyl acrylate, sec-butylaminopropyl acrylate, isobutylaminopropyl acrylate, tert-butylaminopropyl acrylate, N-(methbylaminoethyl) methacrylamide N-(ethylaminoethyl) methacrylamide N-(methylaminoethyl) acrylamide N-(ethylaminoethyl) acrylamide N-(methylaminopropyl) methacrylamide N-(ethylaminopropyl) methacrylamide N-(methylaminopropyl) acrylamide N-(ethylaminopropyl) acrylamide N-methyl-N-(methylaminoethyl) methacrylamide N-methyl-N-(methylaminoethyl) acrylamide N-methyl-N-(p-vinylbenzyl)amine, N-methyl-N-(m-vinylbenzyl)amine, N-ethyl-N-(p-vinylbenzyl)amine, N-ethyl-N-(m-vinylbenzyl)amine, Tertiary Amine dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate, dimethylaminoethyl acrylate, diethylaminoethyl acrylate, dimethylaminopropyl methacrylate, diethylaminopropyl methacrylate, N-(dimethylaminoethyl) methacrylamide N-(diethylaminoethyl) methacrylamide N-(dimethylaminoethyl) acrylamide N-(diethylaminoethyl) acrylamide N-(dimethylaminopropyl) methacrylamide N-(diethylaminopropyl) methacrylamide N-(dimethylaminopropyl) acrylamide N-(diethylaminopropyl) acrylamide N-ethyl-N-methylaminoethyl methacrylate, N-ethyl-N-methylaminopropyl acrylate, N,N-dimethyl-N-(p-vinylbenzyl)amine, N,N-dimethyl-N-(m-vinylbenzyl)amine, N,N-diethyl-N-(p-vinylbenzyl)amine, N,N-diethyl-N-(m-vinylbenzyl)amine, and N-ethyl-N-methyl-N-(p-vinylbenzyl)amine.

The onium-containing mer units generally constitute from 5 to 90 weight percent of the onium addition polymer. Often the onium-containing mer units constitute from 5 to 75 weight percent of the onium addition polymer. From 10 to 65 weight percent is preferred.

Onium-free mer units generally constitute from 5 to 95 weight percent of the onium addition polymer. Often the onium-free mer units constitute from 25 to 95 weight percent of the onium addition polymer. From 35 to 90 weight percent is preferred.

The onium addition polymer may be formed by free-radical addition polymerization in accordance with well known, conventional procedures. The polymerization may be a solution polymerization conducted in organic solvent, or it may be a dispersion polymerization.

The amount of onium addition polymer in the binder of the coating or coating composition as the case may be, may vary widely. Usually the onium addition polymer constitutes from 5 to 75 percent by weight of the binder. Often the onium addition polymer constitutes from 5 to 65 percent by weight of the binder. From 5 to 55 percent by weight of the binder is preferred.

The binder constitutes from 20 to 90 percent by weight of the solids of the coating composition. In many cases the binder constitutes from 25 to 75 percent by weight of the solids of the coating composition. From 35 to 70 percent by weight is preferred.

Similarly, the binder constitutes from 20 to 90 percent by weight of the dry coating. Often the binder constitutes from 25 to 75 percent by weight of the dry coating. From 35 to 70 percent by weight is preferred.

Polymer constituting some or all of the binder of the coating may or may not be insolubilized after application of the coating composition to the substrate. As used herein and in the claims, insolubilized organic polymer is organic polymer which is water-soluble or water-dispersed when applied to the substrate and which is completely or partially insolubilized after such application. Insolubilization may be accomplished through use of insolubilizer. Insolubilizers generally function as crosslinking agents. Preferably the insolubilizer reacts with functional groups of at least a portion of the organic polymer to provide the desired degree of insolubilization to the total organic polymer of the coating.

There are many available insolubilizers which may optionally be used. Examples of suitable insolubilizers include, but are not limited to, Curesan.RTM. 199 insolubilizer (PPG Industries, Inc., Pittsburgh, Pa.), Curesan.RTM. 200 insolubilizer (PPG Industries, Inc.), Sequarez.RTM. 700C insolubilizer (Sequa Chemicals, Inc., Chester, S.C.), Sequarez.RTM. 700M insolubilizer (Sequa Chemicals, Inc.), Sequarez.RTM. 755 insolubilizer (Sequa Chemicals, Inc.), Sequarez.RTM. 770 insolubilizer (Sequa Chemicals, Inc.), Berset.RTM. 39 insolubilizer (Bercen Inc., Cranston, R.I.), Berset.RTM. 47 insolubilizer (Bercen Inc.), Berset.RTM. 2185 insolubilizer (Bercen Inc.), and Berset.RTM. 2586 insolubilizer (Bercen Inc.).

When used, the amount of insolubilizer present in the binder of the coating composition may vary considerably. In such instances the weight ratio of the insolubilizer to the polymer of the binder is usually in the range of from 0.05:100 to 15:100. Often the weight ratio is in the range of from 1:100 to 10:100. From 2:100 to 5:100 is preferred. These ratios are on the basis of insolubilizer dry solids and polymer dry solids.

Finely divided substantially water-insoluble pseudoboehmite particles and their preparation are known. The preparation and properties of pseudoboehmite are described by B. E. Yoldas in The American Ceramic Society Bulletin, Vol. 54, No. 3, (March 1975), pages 289-290, in Journal of Applied Chemical Biotechnology, Vol. 23 (1973), pages 803-809, and in Journal of Materials Science, Vol. 10 (1975), pages 1856-1860. Briefly, aluminum isopropoxide or aluminum secondary-butoxide are hydrolyzed in an excess of water with vigorous agitation at from 75.degree. C. to 80.degree. C. to form a slurry of aluminum monohydroxide. The aluminum monohydroxide is then peptized at temperatures of at least 80.degree. C. with an acid to form a clear pseudoboehmite sol which exhibits the Tyndall effect when illuminated with a narrow beam of light. Since the pseudoboehmite of the sol is neither white nor colored, it is not a pigment and does not function as a pigment in the present invention. The acid employed is noncomplexing with aluminum, and it has sufficient strength to produce the required charge effect at low concentration. Nitric acid, hydrochloric acid, perchloric acid, acetic acid, chloroacetic acid, and formic acid meet these requirements. The acid concentration is usually in the range of from 0.03 to 0.1 mole of acid per mole of aluminum alkoxide. In most instances the pseudoboehmite is transparent and colorless.

The pseudoboehmite particles have a maximum dimension of less than 500 nanometers. Often the pseudoboehmite particles have a maximum dimension of less than 100 nanometers. Frequently the maximum dimension is less than 50 nanometers. Preferably the maximum dimension is less than 20 nanometers.

As used herein and in the claims the maximum dimension of the pseudoboehmite particles is determined by transmission electron microscopy.

The amount of the finely divided substantially water-insoluble pseudoboehmite particles in the coating or in the solids of the coating composition, as the case may be, may vary widely. The finely divided substantially water-insoluble pseudoboehmite particles constitute from 10 to 80 percent by weight of the coating or of the solids of the coating composition. In many cases the finely divided substantially water-insoluble pseudoboehmite particles constitute from 25 to 75 percent by weight of the coating or of the solids of the coating composition. From 30 to 65 percent by weight is preferred. As used herein and in the claims, "solids of the coating composition" is the residue remaining after the solvent and any other volatile materials have been substantially removed from the coating composition by drying to form a coating in accordance with good coatings practice.

The finely divided substantially water-insoluble pseudoboehmite particles having a maximum dimension of less than 500 nanometers and the binder together usually constitute from 2 to 40 percent by weight of the coating composition. Frequently such particles and the binder together constitute from 4 to 30 percent by weight of the coating composition. Often such particles and the binder together constitute from 5 to 25 percent by weight of the coating composition. Preferably such particles and the binder together constitute from 5 to 20 percent by weight of the coating composition.

A material which may optionally be present in the coating composition is surfactant. For purposes of the present specification and claims surfactant is considered not to be a part of the binder. There are many available surfactants and combinations of surfactants which may be used. Examples of suitable surfactants include, but are not limited to, Fluorad.RTM. FC-170-C surfactant (3M Company), and Triton.RTM. X-405 surfactant (Union Carbide Corporation).

When used, the amount of surfactant present in the coating composition may vary considerably. In such instances the weight ratio of the surfactant to the binder is usually in the range of from 0.01:100 to 10:100. In many instances the weight ratio is in the range of from 0.1:100 to 10:100. Often the weight ratio is in the range of from 0.2:100 to 5:100. From 0.5:100 to 2:100 is preferred. These ratios are on the basis of surfactant dry solids and binder dry solids.

There are many other conventional adjuvant materials which may optionally be present in the coating composition. These include such materials as lubricants, waxes, plasticizers, antioxidants, organic solvents, lakes, and pigments. The listing of such materials is by no means exhaustive. These and other ingredients may be employed in their customary amounts for their customary purposes so long as they do not seriously interfere with good coating composition formulating practice.

The pH of the coating composition may vary considerably. In most instances the pH is in the range of from 3 to 7. Often the pH is in the range of from 3.5 to 6.5.

The coating compositions are usually prepared by simply admixing the various ingredients. The ingredients may be mixed in any order. Although the mixing of liquid and solids is usually accomplished at room temperature, elevated temperatures are sometimes used. The maximum temperature which is usable depends upon the heat stability of the ingredients.

The coating compositions are generally applied to the surface of the substrate using any conventional technique known to the art. These include spraying, curtain coating, dipping, rod coating, blade coating, roller application, size press, printing, brushing, drawing, slot-die coating, and extrusion. The coating is then formed by removing the solvent from the applied coating composition. This may be accomplished by any conventional drying technique. Coating composition may be applied once or a multiplicity of times. When the coating composition is applied a multiplicity of times, the applied coating is usually but not necessarily dried, either partially or totally, between coating applications. Once the coating composition has been applied to the substrate, the solvent is substantially removed, usually by drying.

The substrate may be any substrate at least one surface of which is capable of bearing the coating discussed above. In most instances the substrate is in the form of an individual sheet or in the form of a roll, web, strip, film, or foil of material capable of being cut into sheets.

The substrate may be porous throughout, it may be nonporous throughout, or it may comprise both porous regions and nonporous regions.

Examples of porous substrates include paper, paperboard, wood, cloth, nonwoven fabric, felt, unglazed ceramic material, microporous polymer membranes, microporous membranes comprising both polymer and filler particles, porous foam, and microporous foam.

Examples of substrates which are substantially nonporous throughout include sheets or films of organic polymer such as poly(ethylene terephthalate), polyethylene, polypropylene, cellulose acetate, poly(vinyl chloride), and copolymers such as saran. The sheets or films may be filled or unfilled. The sheets or films may be metallized or unmetallized as desired. Additional examples include metal substrates including but not limited to metal foils such as aluminum foil and copper foil. Yet another example is a porous or microporous foam comprising thermoplastic organic polymer which foam has been compressed to such an extent that the resulting deformed material is substantially nonporous. Still another example is glass.

Base stocks which are normally porous such as for example paper, paperboard, wood, cloth, nonwoven fabric, felt, unglazed ceramic material, microporous polymer membranes, microporous membranes comprising both polymer and filler particles, porous foam, or microporous foam may be coated or laminated to render one or more surfaces substantially nonporous and thereby provide substrates having at least one substantially nonporous surface.

The substrate may be substantially transparent, it may be substantially opaque, or it may be of intermediate transparency. For some applications such as inkjet printed overhead slides, the substrate must be sufficiently transparent to be useful for that application. For other applications such as inkjet printed paper, transparency of the substrate is not so important.

The thickness of the coating may vary widely, but in most instances the thickness of the coating is in the range of from 1 to 40 .mu.m. In many cases the thickness of the coating is in the range of from 5 to 40 .mu.m. Often the thickness is in the range of from 8 to 30 .mu.m. From 12 to 18 .mu.m is preferred.

The coating may be substantially transparent, substantially opaque, or of intermediate transparency. It may be substantially colorless, it may be highly colored, or it may be of an intermediate degree of color. Usually the coating is substantially transparent and substantially colorless. As used herein and in the claims, a coating is substantially transparent if its luminous transmission in the visible region is at least 80 percent of the incident light. Often the luminous transmission of the coating is at least 85 percent of the incident light. Preferably the luminous transmission of the coating is at least 90 percent. Also as used herein and in the claims, a coating is substantially colorless if the luminous transmission is substantially the same for all wavelengths in the visible region, viz., 400 to 800 nanometers.

Optionally the above-described coatings may be overlaid with an overcoating comprising ink-receptive organic film-forming polymer. The overcoating may be formed by applying an overcoating composition comprising a liquid medium and ink-receptive organic film-forming polymer dissolved or dispersed in the liquid medium and removing the liquid medium, as for example, by drying. Preferably the liquid medium is an aqueous solvent and the ink-receptive organic film-forming polymer is water-soluble poly(ethylene oxide) having a weight average molecular weight in the range of from 100,000 to 3,000,000, both of which have been described above in respect of earlier described embodiments of the invention. Water is an especially preferred aqueous solvent.

The relative proportions of liquid medium and organic film-forming polymer present in the overcoating composition may vary widely. The minimum proportion is that which will produce an overcoating composition having a viscosity low enough to apply as an overcoating. The maximum proportion is not governed by any theory, but by practical considerations such as the cost of the liquid medium and the cost and time required to remove the liquid medium from the applied wet overcoating. Usually, however, the weight ratio of liquid medium to film-forming organic polymer is from 18:1 to 50:1. Often the weight ratio is from 19:1 to 40:1. Preferably weight ratio is from 19:1 to 24:1.

Optional ingredients such as those discussed above may be present in the overcoating composition when desired.

The overcoating composition may be prepared by admixing the ingredients. It may be applied and dried using any of the coating and drying techniques discussed above. When an overcoating composition is to be applied, it may be applied once or a multiplicity of times.

Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about".

The invention is further described in conjunction with the following example which is to be considered illustrative rather than limiting, and in which all parts are parts by weight and all percentages are percentages by weight unless otherwise specified.

EXAMPLE

With stirring 22.35 kg. of aluminum tri-secondary butoxide �CAS 2269-22-9! was charged with stirring into a reactor containing 75 kg of water at about 78.degree. C. Four hundred twenty grams of 70% nitric acid was diluted in 1110 grams of water and added into the same reactor immediately after the charging of aluminum tri-secondary butoxide. The system was closed when the reactor was heated to about 120.degree. C. gaining pressure to about 276 kilopascals, gauge. The reactor was held at this temperature for 5 hours then cooled to 70.degree. C. and opened. Then the reactor was heated to boil off the alcohol and water-alcohol azeotrope of the hydrolysis reaction until the concentration of the alumina monohydroxide sol reached about 10 weight percent AlO(OH), about 54 kg. total, having a pH of 3.8-4.0 and a turbidity of 112.

The following initial charge and feeds shown in Table 1 were used in the preparation of aqueous acrylic polymer.

TABLE 1______________________________________Ingredients Weight grams______________________________________Initial ChargeIsopropanol 130.0Feed 1Isopropanol 113.0n-Butyl acrylate 69.2Methyl methacrylate 153.02-(tert-Butylamino)ethyl methacrylate 73.0�CAS 3775-90-4!Styrene 69.2VAZO .RTM. 67 Initiator.sup.1 18.2Feed 2Glacial acetic acid 17.7Feed 3Deionized water 1085.0______________________________________ .sup.1 2,2Azobis(2-methylbutanenitrile) initiator commercially available from E. I. du Pont de Nemours and Company, Wilmington, Delaware.

The initial charge was heated in a reactor with agitation to reflux temperature (80.degree. C.). Then Feed 1 was added in a continuous manner over a period of 3 hours. At the completion of Feed 1 addition, the reaction mixture was held at reflux for 3 hours. The resultant acrylic polymer solution had a total solids content of 61.7 percent (determined by weight difference of a sample before and after heating at 110.degree. C. for one hour) and number average molecular weight of 4792 as determined by gel permeation chromatography using polystyrene as the standard. Thereafter, Feed 2 was added over five minutes at room temperature with agitation. After the completion of the addition of Feed 2, Feed 3 was added over 30 minutes while the reaction mixture was heated for azeotropic distillation of isopropanol. When the distillation temperature reached 99.degree. C., the distillation was continued about one more hour and then the reaction mixture was cooled to room temperature. The total distillate collected was 550.6 grams. The product, which was a cationic acrylic polymer aqueous product, had a solids content of 32.6 percent by weight (determined by weight difference of a sample before and after heating at 110.degree. C. for one hour), and a pH of 5.25.

The following initial charge and feeds shown in Table 2 were used in the preparation of a quaternary ammonium addition polymer.

TABLE 2______________________________________Ingredients Weight, grams______________________________________Initial ChargeIsopropanol 100.0Feed 1Isopropanol 106.5VAZO .RTM. 67 Initiator.sup.1 18.2Feed 2Isopropanol 205.7Styrene 182.575% aqueous solution of 243.3trimethyl-2-(methacrylyloyloxy)-ethylammonium chlorideFeed 3Deionized water 787.0______________________________________ .sup.1 2,2Azobis(2-methylbutanenitrile) initiator commercially available from E. I. du Pont de Nemours and Company, Wilmington, Delaware.

The Initial Charge was charged to a reactor and heated with agitation to reflux temperature (77.degree.-80.degree. C.). At reflux Feed 1 was added continuously over a period of three hours. Fifteen minutes after beginning addition of Feed 1, the addition of Feed 2 was begun. Feed 2 was added continuously over a period of three hours. After completion of both additions, the reaction mixture was held at reflux for 4 hours. Upon completion of the holding period, the reactor was set for total distillation. About 297 grams of Feed 3 was added to the reactor, the jacket temperature was reduced, and vacuum was applied slowly. Vacuum distillation was begun and 491 grams of distillate was collected. The remaining Feed 3 was charged and distillation under vacuum was continued. After most distillate was removed, the percent solids was ascertained and the solution was adjusted to 31.8 weight percent solids and filtered through a 5-micrometer glass fiber filter. The product was a quaternary ammonium addition polymer product.

A polymer composition was prepared by admixing 174.3 grams of a 6 percent by weight poly(ethylene oxide) aqueous solution, 39.48 grams of a cationic acrylic polymer aqueous product prepared similarly to that described and above, 39.48 grams of the quaternary ammonium addition polymer aqueous product described above. An intermediate composition was formed by admixing with the polymer compositions 81.7 grams of a pseudoboehmite sol containing 12.9 percent solids by weight which was prepared similarly to that described above. A coating composition was prepared by admixing with the intermediate composition 90 milligrams of Fluorad.RTM. FC-170-C surfactant (3M Company) and 60 milligrams of Macol.RTM. OP-40 surfactant (PPG Industries, Inc.).

The coating composition was applied to poly(ethylene terphthalate) substrates with a Meyer rod #120 and allowed to dry in an air-blown oven at 105.degree. C. for 4.5 minutes. The dry coating was about 15 micrometers thick and it was very clear. The coated substrates were then printed on the coated side with a Hewlett-Packard 870 Inkjet Printer or a Hewlett-Packard 1600c Inkjet Printer. The printed sheets were placed in a humidity chamber (35.degree. C. and 80% relative humidity) for several days to ascertain bleed of printed image. The image maintained its acuity under those conditions.

Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except insofar as they are included in the accompanying claims.

Claims

1. A coating composition comprising:

(a) a volatile aqueous liquid medium; and

(b) binder dissolved or dispersed in the volatile aqueous liquid medium, the binder comprising:

(1) water-soluble film-forming organic polymer which is substantially free of onium groups, and

(2) water-soluble or water-dispersible onium addition polymer consisting essentially of onium-containing mer units derived from addition monomer and onium-free mer units derived from addition monomer of which from 20 to 100 percent by weight is hydrophobic addition monomer,

wherein the binder constitutes from 20 to 90 percent by weight of the solids of the coating composition; and

(c) finely divided substantially water-insoluble pseudoboehmite particles which have a maximum dimension of less than 500 nanometers and constitute from 10 to 80 percent by weight of the solids of the coating composition.

2. The coating composition of claim 1 wherein the onium polymer contains primary ammonium groups, secondary ammonium groups, tertiary ammonium groups, quaternary ammonium groups, phosphonium groups, sulfonium groups, or two or more thereof.

3. The coating composition of claim 1 wherein:

(a) the onium polymer is water-soluble onium polymer, and

(b) both the water-soluble film-forming organic polymer which is substantially free of onium groups and the onium polymer are dissolved in the volatile aqueous liquid medium.

4. The coating composition of claim 3 wherein substantially all of the onium-free mer units of the onium addition polymer are derived from hydrophobic addition monomer.

5. The coating composition of claim 3 wherein the onium polymer is quaternary ammonium polymer.

6. The coating composition of claim 3 wherein the hydrophobic addition monomer is styrene, alkyl acrylate wherein the alkyl group contains from 1 to 4 carbon atoms, alkyl methacrylate wherein the alkyl group contains from 1 to 4 carbon atoms, or a mixture of two or more thereof.

7. The coating composition of claim 3 wherein the water-soluble film-forming organic polymer which is substantially free of onium groups is polyethylene oxide), poly(vinyl alcohol), polyvinyl pyrrolidone), cellulosic organic polymer, or a mixture of two or more thereof.

8. The coating composition of claim 3 wherein poly(ethylene oxide) having a weight average molecular weight in the range of from 100,000 to 3,000,000 constitutes from 10 to 100 percent by weight of the water-soluble film-forming organic polymer which is substantially free of onium groups.

9. The coating composition of claim 3 wherein the pseudoboehmite particles have a maximum dimension of less than 100 nanometers.

10. The coating composition of claim 3 wherein the pseudoboehmite particles have a maximum dimension of less than 50 nanometers.

11. The coating composition of claim 3 wherein the pseudoboehmite particles constitute from 30 to 65 percent by weight of the solids of the coating composition.

12. The coating composition of claim 3 wherein the pseudoboehmite particles and the binder together constitute from 2 to 25 percent by weight of the coating composition.

13. The coating composition of claim 3 wherein the pseudoboehmite particles and the binder together constitute from 5 to 12 percent by weight of the coating composition.

14. The coating composition of claim 3 wherein water constitutes at least 80 percent by weight of the volatile aqueous liquid medium.

15. The coating composition of claim 3 wherein the volatile aqueous liquid medium constitutes from 75 to 98 percent by weight of the coating composition.

16. A printing medium comprising a substrate having at least one surface and a coating on the surface wherein the coating comprises:

(a) binder comprising:

(1) organic polymer which is substantially free of onium groups, and

(2) onium addition polymer consisting essentially of onium-containing mer units derived from addition monomer and onium-free mer units derived from addition monomer of which from 20 to 100 percent by weight is hydrophobic addition monomer,

wherein the binder constitutes from 20 to 90 percent by weight of the coating; and

(b) finely divided substantially water-insoluble pseudoboehmite particles which have a maximum dimension of less than 500 nanometers, are distributed throughout the binder, and constitute from 10 to 80 percent by weight of the coating.

17. The printing medium of claim 16 wherein the onium polymer contains primary ammonium groups, secondary ammonium groups, tertiary ammonium groups, quaternary ammonium groups, phosphonium groups, sulfonium groups, or two or more thereof.

18. The printing medium of claim 16 wherein substantially all of the onium-free mer units of the onium addition polymer are derived from hydrophobic addition monomer.

19. The printing medium of claim 16 wherein the onium polymer is quaternary ammonium polymer.

20. The printing medium of claim 16 wherein the hydrophobic addition monomer is styrene, alkyl acrylate wherein the alkyl group contains from 1 to 4 carbon atoms, alkyl methacrylate wherein the alkyl group contains from 1 to 4 carbon atoms, or a mixture of two or more thereof.

21. The printing medium of claim 16 wherein the organic polymer which is substantially free of onium groups is poly(ethylene oxide), poly(vinyl alcohol), poly(vinyl pyrrolidone), cellulosic organic polymer, or a mixture of two or more thereof.

22. The printing medium of claim 16 wherein poly(ethylene oxide) having a weight average molecular weight in the range of from 100,000 to 3,000,000 constitutes from 10 to 100 percent by weight of the organic polymer which is substantially free of onium groups.

23. The printing medium of claim 16 wherein the pseudoboehmite particles have a maximum dimension of less than 100 nanometers.

24. The printing medium of claim 16 wherein the pseudoboehmite particles have a maximum dimension of less than 50 nanometers.

25. The printing medium of claim 16 wherein the pseudoboehmite particles constitute from 30 to 65 percent by weight of the coating.

26. The printing medium of claim 16 wherein the coating is overlaid with an overcoating comprising ink-receptive organic polymer.

27. The printing medium of claim 16 wherein the thickness of the coating is in the range of from 5 to 40 micrometers.

28. A printing process which comprises applying liquid ink droplets to the printing medium of claim 16.