Patent Application
20080057232
As indicated above, one aspect of the present invention is directed to a method of making a porous swellable inkjet recording element comprising coating a first aqueous composition, comprising particles and a polymeric binder, onto a support to form at least one porous underlying layer when dried, then coating above the underlying layer a second aqueous composition comprising a hydrophilic polymeric binder and a dispersion of water-insoluble polymeric latex to form a non-porous upper layer when dried, and finally, after drying the coated compositions to form a porous underlying layer and a non-porous upper layer, applying solvent for the water-insoluble polymeric latex to the coated layers to transport a substantial portion of the water-insoluble polymeric latex from the non-porous upper layer, thereby forming an image-receiving layer comprising a porous water-swellable polymeric matrix.
Various methods may be used for applying solvent to the coated material. For example, one embodiment involves applying, to the upper surface of the coated support, an amount of solvent not exceeding an amount that would run off the surface of the coated support. Accordingly, the amount of solvent would be more than an amount that would completely saturate the intermediate material. The solvent can be applied to the coated support by contact with another solvent-containing material, by spraying a solvent, by immersion in a solvent, etc. In one particular embodiment, solvent causes sufficient water-insoluble polymeric latex to migrate to the underlying porous layer to render the non-porous layer effectively porous, thereby not removing the water-insoluble latex from the final inkjet recording element. In contrast, when the water-insoluble polymer latex is removed from the image-receiving layer by immersion of the coated support in solvent, water-insoluble polymeric latex is removed from the inkjet recording element altogether.
In still another embodiment, the solvent for removing water-insoluble polymer latex can be applied onto a coated support that is facing downwards, such that gravity facilitates the fall or removal of solvent containing dissolved water-insoluble latex from the coated support. For example, during manufacture, the coated support can be a continuous web in which the top of the coated support is facing substantially downwards while a spray means positioned beneath the continuous web impinges solvent onto the surface of the coated support.
A homogeneous aqueous coating composition for the image-receiving layer comprising the water-swellable polymer and a latex polymer can be made optionally comprising one or more pigments, surfactants, cross-linking agents, plasticizers, fillers. After the coating for the image-receiving layer is applied and dried over the support, the latex is extracted from its original location by treatment with an organic-containing solvent, that is, a solvent primarily comprising one or more organic-solvent compounds, optionally with a minor amount of water, preferably less than 10 percent by weight water. The organic solvent (comprising one or more organic compounds) can be any suitable solvent, which can dissolve the latex and has a boiling point preferably below 120° C. for easy drying. Preferably the solvent will not appreciably swell the water-soluble binder. Depending on the latex polymer, one can use very non-polar solvents like hexane or pentane, or less non-polar solvents such as ethyl acetate. Preferably solvents such as 2-butanone, acetone, ethyl acetate, or toluene or the like are used. Solvent mixtures can be used to tailor the properties of the overall solvent. These organic solvents can comprise agents to adjust the subtractive power and/or to modify the pore formation of the image-receiving layer.
In the case of transporting the latex from its original location to a different location in the inkjet recording element, the organic solvent will thereafter evaporate. Optionally, the coated material can be heated and/or subjected to reduced pressure to facilitate evaporation of the organic solvent. In any case, the voids left by the removal of the latex by the solvent provide for the porous structure of the upper layer of the present invention.
The hydrophilic polymer used in the above-mentioned method comprises a polymer that is soluble in water, at least before optional crosslinking in the image-receiving layer. Water-soluble polymers suitable for this purpose include, but are not limited to, homopolymers and copolymers such as hydrophilic organic polymers and lightly crosslinked hydrogels, for example, polyvinylpyrrolidone and vinylpyrrolidone-containing copolymers, polyethyloxazoline and oxazoline-containing copolymers, imidazole-containing polymers, polyacrylamides and acrylamide-containing copolymers, poly(vinyl alcohol) and vinyl-alcohol-containing copolymers, poly(vinyl methyl ether), poly(vinyl ethyl ether), poly(alkylene oxide), gelatin and derivatives thereof, cellulose ethers, poly(vinylacetamides), partially hydrolyzed poly(vinyl acetate/vinyl alcohol), poly(acrylic acid), sulfonated or phosphated polyesters and polystyrenes, casein, albumin, chitin, chitosan, dextran, pectin, collagen derivatives, collodian, agar-agar, arrowroot, guar, carrageenan, tragacanth, xanthan, rhamsan and the like, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, and poly(alkylene oxide). Mixtures of the above listed hydrophilic polymers can be used.
The hydrophilic polymer in the image-receiving layer is preferably selected from the group consisting of gelatin, polyvinylpyrrolidinone (PVP), and poly(vinyl alcohol), and derivatives and copolymers of the foregoing and combinations thereof. Poly(vinyl alcohol) derivatives and copolymers include, for example, copolymers of poly(ethylene oxide) and poly(vinyl alcohol) (PEO-PVA) and copolymers of poly(ethylene vinyl alcohol) and poly(vinyl alcohol). Derivitized poly(vinyl alcohol) includes, for example, polymers having at least one hydroxyl group replaced by ether or ester groups, which may be used in the invention, for example an acetoacetylated poly(vinyl alcohol). Another copolymer of poly(vinyl alcohol), for example, is carboxylated PVA in which the acid group is present in a comonomer.
There are a variety of gelatins or modified gelatins, which can be used. For example: alkali-treated gelatin (cattle bone or hide gelatin) or acid-treated gelatin (pigskin gelatin), gelatin derivatives such as acetylated gelatin, phthalate gelatin and the like.
Preferred poly(vinyl alcohol) polymers and copolymers thereof have a degree of hydrolysis of preferably at least about 75%, more preferably at least 88 percent. Commercial embodiments of such poly(vinyl alcohol) and copolymers are readily available from various suppliers. Suitable PVA copolymers may, for example, have a degree of polymerization of at least 500, preferably less than 5000.
The water-soluble polymers in the porous water-swellable ink receiving layer(s) are preferably used in a total amount of from 1 to 30 g/m2, and more preferably from 2 to 20 g/m2.
If desired, the water-soluble hydrophilic polymers can be cross-linked in the inkjet recording elements of the present invention in order to impart mechanical strength to the layer. Any suitable cross-linking agent known in the art can be employed. Such an additive can improve the adhesion of a layer to the substrate as well as contribute to the cohesive strength and water resistance of the layer. Cross-linkers such as carbodiimides, polyfunctional aziridines, melamine formaldehydes, isocyanates, epoxides, and the like may be used. Other crosslinkers include, for example, borax, tetraethyl orthosilicate, 2,3-dihydroxy-1,4-dioxane (DHD) or any other suitable crosslinker may be added to the polymer to provide an amount of crosslinking to the polymeric layer.
Preferably, the at least one hydrophilic polymer is inherently capable of gaining greater than 30 w % by weight of water by absorption over 24 hours at 25° C.
The water-insoluble polymer latex is selected so that it is effectively soluble in the solvent used for its removal from the image-receiving layer. For example, the weight average molecular weight of water-insoluble polymer latex is sufficiently low to allow a substantial portion to be effectively solubilized and transported by the solvent from the non-porous upper layer. A suitable weight average molecular weight may therefore depend on the composition and structure of the latex and the choice of solvent. In general, the weight average molecular weight of water-insoluble polymer latex is preferably less than 250,000, more preferably less than 100,000. However, when the water-insoluble polymer latex is polystyrene or a copolymer thereof, the weight average molecular weight is preferably less than 25,000, more preferably less than 16,000. On the other hand, a more polar latex material such as PMMA may have a higher preferred molecular weight.
In a preferred embodiment, the water-insoluble latex is essentially non-crosslinked, a linear or branched polymer.
The water-insoluble latex has a median particle size in dispersion of less than 1 micrometer, preferably less than 500 nm, and more preferably less than 250 nm. Any suitable hydrophobic, water-insoluble latex can be employed. Lattices are addition polymers made from ethylenically unsaturated monomers, in one embodiment preferably from styrene homopolymers or copolymers and poly(methylmethacrylate) or copolymers are especially preferred. Thus, the water-insoluble latex is preferably a copolymer or polymer comprising monomeric units that are the reaction product of monomers selected from the group consisting of acrylic, methacrylic, or styrenic monomers. Alternately, N-alkyl or N-aryl acrylamides or methacrylamides can be used provided that they contain hydrophobic substituents which are of sufficient size as to impart organic solubility to the latex. Alternate monomers may include unsaturated hydrocarbons (such as butadiene or isoprene), vinyl halides, vinyl esters, or vinyl ethers. However, other lattices can be used which are insoluble in water but which are capable of being extracted in an organic solvent.
The latex material may be considered to serve as a template material for the voids formed in the image-receiving layer. When this latex material has been removed, by suitable solvent, from the water-swellable polymeric matrix, then a plurality of voids remain in their desired number, shape and dimensions. In a preferred embodiment, the weight ratio of water-insoluble polymeric latex to hydrophilic binder is from 10:1 to 1:1, more preferably from 6:1 to 2:1.
The solvent used in the present method is capable of effectively solubilizing the water-insoluble latex but effectively not solubilizing the hydrophilic binder, which is optionally crosslinked. The solvent comprises at least one organic compound. Preferably the organic compound is a solvent that is not of greater polarity than acetone according to conventional solubility parameter measurements. The solvent can be miscible in water, for example THF or acetone, or can be immiscible in water. If miscible, the solvent may include a minor amount of water.
The organic solvent solution used in the present invention is used to extract the latex from its original location in the coated layer for the IRL. After extraction by the solvent, the latex will leave voids, creating a porous structure. In one embodiment, the organic solvent comprises one or more organic compounds, preferably all organic compounds, having a boiling point less than 120° C., preferably a boiling point between 40° C. and 110° C.
Examples of suitable solvents include, but are not limited to, acetone, 2-butanone, ethyl acetate, propyl acetate, THF, heptane, hexane, methylene chloride, chloroform, toluene, and the like and mixtures of these solvents.
Another aspect of the present invention is directed to an inkjet recording element comprising a support and, coated over the support, in order:
(a) an underlying porous layer comprising less than 35 percent by weight of a polymeric binder, greater than 65 percent by weight of particles and, interstitially located in the pores formed by the particles, water-insoluble polymer latex;
(b) a porous water-swellable image-receiving layer comprising at least one water-swellable hydrophilic polymer,
wherein there is a gradient of said water-insoluble polymer latex in the underlying porous layer that decreases in the direction of the support, resulting from diffusion of said water-insoluble polymer latex when organic solvent was applied to the upper surface of the coated material during the manufacture of the inkjet recording element.
For example, a common gradient would be such that the porous water-swellable image-receiving layer comprises less water-insoluble polymer latex in the top half of the upper layer, and the underlying porous layer comprises more water-insoluble polymer latex in the top half of the layer.
A dye mordant can be employed in any of the ink-retaining layers, but usually at least the image-receiving upper layer and optionally also the underlying layer. The mordant can be any material that is substantive to the inkjet dyes. Examples of such mordants include cationic lattices such as disclosed in U.S. Pat. No. 6,297,296 and references cited therein, cationic polymers such as disclosed in U.S. Pat. No. 5,342,688, and multivalent ions as disclosed in U.S. Pat. No. 5,916,673, the disclosures of which are hereby incorporated by reference. Examples of these mordants include polymeric quaternary ammonium compounds, or basic polymers, such as poly(dimethylaminoethyl)-methacrylate, polyalkylenepolyamines, and products of the condensation thereof with dicyanodiamide, amine-epichlorohydrin polycondensates. Further, lecithins and phospholipid compounds can also be used. Specific examples of such mordants include the following: vinylbenzyl trimethyl ammonium chloride/ethylene glycol dimethacrylate; poly(diallyl dimethyl ammonium chloride); poly(2-N,N,N-trimethylammonium)ethyl methacrylate methosulfate; poly(3-N,N,N-trimethyl-ammonium)propyl methacrylate chloride; a copolymer of vinylpyrrolidinone and vinyl(N-methylimidazolium chloride; and hydroxyethylcellulose derivatized with 3-N,N,N-trimethylammonium)propyl chloride. In a preferred embodiment, the cationic mordant is a quaternary ammonium compound.
Alternately, mordants based on soft organic anions, such as sulfonates may be employed if an ink set comprising colorants with cationic moieties is used.
In order to be compatible with the mordant, both the binder and the polymer in the layer or layers in which it is contained should be either uncharged or the same charge as the mordant. Colloidal instability and unwanted aggregation could result if a polymer or the binder in the same layer had a charge opposite from that of the mordant.
In one embodiment, the porous upper image receiving-layer may independently comprise dye mordant in an amount ranging from about 2 parts to about 40 percent by weight of the layer, preferably 5 to 25 percent. The upper layer preferably is the layer containing substantially the highest concentration and amount of polymeric mordant.
In another embodiment, the inkjet recording element comprises, in the image-receiving layer, non-solvent-removable particles having a median particle size of 5 to 150 nm, to enhance voiding by reducing the degree of void collapse after removal of the water-insoluble polymer latex by solvent treatment during formation of the image-receiving layer. In one embodiment, particles of a hydrated or unhydrated metal oxide, for example, colloidal alumina hydrate, is used in an amount of between 5 to 30 weight percent. Similar effects were seen with fumed aluminas and fumed silicas used in combination with latex porogens of the invention.
Since the inkjet recording element may come in contact with other image recording articles or the drive or transport mechanisms of image-recording devices, additives such as surfactants, lubricants, matte particles and the like may be added to the inkjet recording element to the extent that they do not degrade the properties of interest.
The coating composition for the image-receiving layer may contain various particulate (i.e., pigments) to provide the medium with anti-blocking properties to prevent ink from transferring from one medium to an adjacent medium during imaging of the media. Further additives, such as white pigments, color pigments, fillers, especially absorptive fillers and pigments such as oxides, carbonates, silicates or sulfates of alkali metals, earth alkali metals such as silicic acid, aluminum oxide, barium sulfate, calcium carbonate and magnesium silicate, alumina, aluminum hydroxide, pseudoboehmite. Further additives such as color fixation agents, dispersing agents, softeners and optical brighteners can be contained in the polymer layer. Titanium dioxide can be used as a white pigment. Further fillers and pigments are calcium carbonate, magnesium carbonate, clay, zinc oxide, aluminum silicate, magnesium silicate, ultramarine, cobalt blue, and carbon black or mixtures of these materials. The fillers and/or pigments are used as additives in quantities of 0 to 20 wt. %. The quantities given are based on the mass of the polymer layer.
Further examples of inorganic and organic particulate include zinc oxide, tin oxide, silica-magnesia, bentonite, hectorite, poly(methyl methacrylate), and poly(tetrafluoroethylene). In order not to impair the gloss of the recording material, the pigment used within the image-receiving layer may be a finely divided inorganic pigment with a particle size of 0.01 to 1.0 μm, especially 0.02 to 0.5 μm. Especially preferred, however, is a particle size of 0.1 to 0.3 μm. Especially well suited are silicic acid and aluminum oxide with an average particle size of less than 0.3 μm. However, a mixture of silicic acid and aluminum oxide with an average particle size of less than 0.3 μm can also be employed.
Matte particles may be added to any or all of the layers described in order to provide enhanced printer transport, resistance to ink offset, or to change the appearance of the image-receiving layer to satin or matte finish. Typical additives can also include antioxidants, process stabilizers, UV absorbents, UV stabilizers, antistatic agents, anti-blocking agents, slip agents, colorants, foaming agents, plasticizers, optical brightening agents, flow agents, and the like.
Optional other layers, including subbing layers, overcoats, further underlying layers between the support and the upper image-receiving layer or layers, etc. may be coated by conventional coating means onto a support material commonly used in this art.
Coating compositions employed in the invention may be applied by any number of well known techniques, including dip-coating, wound-wire rod coating, doctor blade coating, gravure and reverse-roll coating, slide coating, bead coating, extrusion coating, curtain coating and the like. Known coating and drying methods are described in further detail in Research Disclosure no. 308119, published December 1989, pages 1007 to 1008. Some of these methods allow for simultaneous coatings of two or more layers, which is preferred from a manufacturing economic perspective. For example, slide coating may be used, in which the layers may be simultaneously applied. After coating, the layers are generally dried by simple evaporation, which may be accelerated by known techniques such as convection heating.
In the final product, the porous layers above the support contains interconnecting voids that can provide a pathway for the liquid components of applied ink to penetrate appreciably, thus allowing the one or more underlying layers to contribute to the dry time. A non-porous layer or a layer that contains closed cells would not allow underlying layers to contribute to the dry time.
In a preferred embodiment of the invention, the inkjet recording element further comprises, over the support, at least one porous ink-receiving underlying layer, optionally divided into one or more sub-layers, comprising greater than 50 percent, by weight of the layer, of particles of one or more second materials, wherein the average pore size of the layer is 10 to 1000 nm, preferably 20 to 500 nm, as measured by standard techniques such as mercury intrusion porosimetry or by nitrogen BET. Preferably the absorption capacity of the one or more underlying layers is in total at least 10 cc/m2, preferably at least 20 cc/mm2.
In a preferred embodiment, the underlying layer is made using a coating composition comprising inorganic particles, binder, and surfactant, wherein the underlying layer comprises greater than 50 percent by weight, preferably greater than 80 weight percent of the solids, of particles of one or more base-layer materials having an average particle size of under 5 micrometers.
In one embodiment, the inkjet recording element comprises more than one porous underlying layer, in which a latex-absorbing porous underlying layer is present for absorbing the water-insoluble latex polymer when organic-containing solvent is applied to the upper surface of the coated material during its manufacture. Such a latex-absorbing porous underlying layer is located between the image-receiving layer and a lower porous underlying layer. The latex-absorbing porous underlying layer is relatively thin and has a relatively larger average pore diameter compared to the lower porous underlying layer (for example, a base layer immediately adjacent the support), which larger average pore diameter can, for example, be obtained by including less binder or larger particles
Preferably, the one or more second materials in the ink-receiving underlying layer or layers comprise particles of hydrated or unhydrated metallic oxide or semi-metallic oxide such as silicon dioxide.
Metallic-oxide and semi-metallic oxide particles can be divided roughly into particles that are made by a wet process and particles made by a dry process (vapor phase process). The latter type of particles is also referred to as fumed or pyrogenic particles. In a vapor phase method, flame hydrolysis methods and arc methods have been commercially used. Fumed particles exhibit different properties than non-fumed or hydrated particles. In the case of fumed silica, this may be due to the difference in density of the silanol group on the surface. Fumed particles are suitable for forming a three-dimensional structure having high void ratio.
Fumed or pyrogenic particles are aggregates of smaller, primary particles. Although the primary particles are not porous, the aggregates contain a significant void volume, and hence are capable of rapid liquid absorption. These void-containing aggregates enable a coating to retain a significant capacity for liquid absorption even when the aggregate particles are densely packed, which minimizes the inter-particle void volume of the coating. For example, fumed alumina particles, for selective optional use in the present invention, are described in US20050170107 A1, hereby incorporated by reference.
More preferably, the underlying layer comprises substantially non-aggregated colloidal particles that comprise silica or hydrated or unhydrated alumina. Most preferably, the one or more materials comprise a hydrated alumina that is an aluminum oxyhydroxide material, for example, boehmite and the like.
The term “hydrated alumina” is herein defined by the following general formula:
Al2O3-n(OH)2nmMH2O
wherein n is an integer of 0 to 3, and m is a number of 0 to 10, preferably 0 to 5. In many cases, mH2O represents an aqueous phase, which does not participate in the formation of a crystal lattice, but is able to be eliminated. Therefore, m may take a value other than an integer. However, m and n are not 0 at the same time.
The term “unhydrated alumina” is herein defined by the above formula when m and n are both zero at the same time and includes fumed alumina, made in a dry phase process or anhydrous alumina Al2O3 made by calcining hydrated alumina. As used herein, such terms as unhydrated alumina apply to the dry materials used to make coating compositions during the manufacture of the inkjet recording element, notwithstanding any hydration that occurs after addition to water.
A crystal of the hydrated alumina showing a boehmite structure is generally a layered material the (020) plane of which forms a macro-plane, and shows a characteristic diffraction peak. Besides a perfect boehmite, a structure called pseudo-boehmite and containing excess water between layers of the (020) plane may be used. The X-ray diffraction pattern of this pseudo-boehmite shows a diffraction peak broader than that of the perfect boehmite. Since perfect boehmite and pseudo-boehmite may not be clearly distinguished from each other, so the term “boehmite” or “boehmite structure” is herein used to include both unless indicated otherwise by the context. For the purposes of this specification, the term “boehmite” implies boehmite and/or pseudoboehmite.
Boehmite and pseudoboehmite are aluminum oxyhydroxides, which is herein defined by the general formula γ-AlO(OH) xH2O, wherein x is 0 to 1. When x=0 the material is specifically boehmite as compared to pseudo-boehmite; when x>0 and the materials incorporate water into their crystalline structure, they are known as pseudoboehmite. Boehmite and pseudoboehmite are also described as Al2O3.zH2O where, when z=1 the material is boehmite and when 1<z<2 the material is pseudoboehmite. The above materials are differentiated from the aluminum hydroxides (e.g. Al(OH)3, bayerite and gibbsite) and diaspore (α-AlO(OOH) by their compositions and crystal structures. As indicated above, boehmite is usually well crystallized and, in one embodiment, has a structure in accordance with the x-ray diffraction pattern given in the JCPDS-ICDD powder diffraction file 21-1307, whereas pseudoboehmite is less well crystallized and generally presents an XRD pattern with relatively broadened peaks with lower intensities.
The term “aluminum oxyhydroxide” is herein defined to be broadly construed to include any material whose surface is or can be processed to form a shell or layer of the general formula γ-AlO(OH) xH2O (preferably boehmite), such materials including aluminum metal, aluminum nitride, aluminum oxynitride (AlON), α-Al2O3, γ-Al2O3, transitional aluminas of general formula Al2O3, boehmite (γ-AlO(OH)), pseudoboehmite ((γ-AlO(OH)).x H2O where 0<x<1), diaspore (α-AlO(OH)), and the aluminum hydroxides (Al(OH)3) of bayerite and gibbsite. Thus, aluminum oxyhydroxide particles include any finely divided materials with at least a surface shell comprising aluminum oxyhydroxide. In the most preferred embodiment, the core and shell of the particles are both of the same material comprises boehmite with a BET surface area of over 100 m2/g.
The underlying layer can also or alternatively comprise other inorganic particles, for example, calcium carbonate, magnesium carbonate, insoluble sulfates (for example, barium or calcium sulfate), hydrous silica or silica gel, silicates (for example aluminosilicates), titanium dioxide, talc, and clay or constituents thereof (for example, kaolin or kaolinite). Admixtures of two different precipitated calcium carbonate particles, of different morphologies, can be employed.
Examples of organic particles that may be used in the underlying layer include polymer beads or particles, for example, crosslinked styrenic particles, not softened by the solvent/drying operation. Hollow styrene beads may be preferred organic particles for certain applications.
Other examples of organic particles, which may be used, include core/shell particles such as those disclosed in U.S. Pat. No. 6,492,006 and homogeneous particles such as those disclosed in U.S. Pat. No. 6,475,602, the disclosures of which are hereby incorporated by reference.
In one particular preferred embodiment of the invention, the underlying layer comprises between 75% by weight and 98% by weight of particles and between about 2% and 25% by weight of a polymeric binder, preferably from about 82% by weight to about 96% by weight of particles and from about 18% by weight to about 4% by weight of a polymeric binder, most preferably about 4 to 10% by weight of binder.
As mentioned above, the amount of binder is desirably limited, because when ink is applied to inkjet media, the (typically aqueous) liquid carrier tends to swell the binder and close the pores and may cause bleeding or other problems. Preferably, therefore, the underlying layer comprises less than 25 weight percent of binder, to maintain porosity, although higher levels of binder may be used in some cases to prevent cracking.
Any suitable polymeric binder may be used in the underlying layer of the inkjet recording element employed in the invention. In a preferred embodiment, the polymeric binder may be a compatible, preferably hydrophilic polymer such as poly(vinyl alcohol), poly(vinyl pyrrolidone), gelatin, cellulose ethers, poly(oxazolines), poly(vinylacetamides), partially hydrolyzed poly(vinyl acetate/vinyl alcohol), poly(acrylic acid), poly(acrylamide), poly(alkylene oxide), sulfonated or phosphated polyesters and polystyrenes, casein, zein, albumin, chitin, chitosan, dextran, pectin, collagen derivatives, collodian, agar-agar, arrowroot, guar, carrageenan, tragacanth, xanthan, rhamsan and the like. Preferably, the hydrophilic polymer is poly(vinyl alcohol), hydroxypropyl cellulose, hydroxypropyl methylcellulose, a poly(alkylene oxide), poly(vinyl pyrrolidinone), poly(vinyl acetate) or copolymers thereof or gelatin. In general, good results are also obtained with polyurethanes, vinyl acetate-ethylene copolymers, ethylene-vinyl chloride copolymers, vinyl acetate-vinyl chloride-ethylene terpolymers, acrylic polymers, or derivatives thereof. Preferably, the binder is a water-soluble hydrophilic polymer, most preferably polyvinyl alcohol or the like.
Other binders can also be used such as hydrophobic materials provided that they are not soluble or appreciably swellable in the organic solvent. Such binders may include, for example, poly(styrene-co-butadiene), polyurethane latex, polyester latex, poly(n-butyl acrylate), poly(n-butyl methacrylate), poly(2-ethylhexyl acrylate), copolymers of n-butylacrylate and ethylacrylate, copolymers of vinylacetate and n-butylacrylate, and the like. Mixtures of hydrophilic and latex binders are useful.
In order to impart mechanical durability to the underlying layer, crosslinkers that act upon the binder may be added in small quantities. Such an additive improves the cohesive strength of the layer. Crosslinkers such as carbodiimides, polyfunctional aziridines, aldehydes, isocyanates, epoxides, polyvalent metal cations, vinyl sulfones, pyridinium, pyridylium dication ether, methoxyalkyl melamines, triazines, dioxane derivatives, chrom alum, zirconium sulfate, boric acid or a borate salt and the like may be used. As indicated below, other conventional additives may be included in the underlying layer, which may depend on the particular use for the recording element. The underlying layer typically does not need a mordant.
As mentioned above, the porous underlying layer is located under the image-receiving layer and absorbs a substantial amount of the liquid carrier applied to the inkjet recording element, but substantially less dye or colored pigment than the overlying layer or layers.
In another embodiment of the invention, a filled layer containing light-scattering particles such as titania may be situated between a clear support material and the ink-receiving or hydrophilic absorbing layers described herein. Such a combination may be effectively used as a backlit material for signage applications. Yet another embodiment which yields an ink receiver with appropriate properties for backlit display applications results from selection of a partially voided or filled poly(ethylene terephthalate) film as a support material, in which the voids or fillers in the support material supply sufficient light scattering to diffuse light sources situated behind the image.
The support for the inkjet recording element used in the invention can be any of those usually used for inkjet receivers, such as resin-coated paper, paper, polyesters, or microporous materials such as polyethylene polymer-containing material sold by PPG Industries, Inc., Pittsburgh, Pa. under the trade name of TESLIN, TYVEK synthetic paper (DuPont Corp.), and OPPALYTE films (Mobil Chemical Co.) and other composite films listed in U.S. Pat. No. 5,244,861. Opaque supports include plain paper, coated paper, synthetic paper, photographic paper support, melt-extrusion-coated paper, and laminated paper, such as biaxially oriented support laminates. Biaxially oriented support laminates are described in U.S. Pat. Nos. 5,853,965; 5,866,282; 5,874,205; 5,888,643; 5,888,681; 5,888,683; and 5,888,714. These biaxially oriented supports include a paper base and a biaxially oriented polyolefin sheet, typically polypropylene, laminated to one or both sides of the paper base. Transparent supports include glass, cellulose derivatives, e.g., a cellulose ester, cellulose triacetate, cellulose diacetate, cellulose acetate propionate, cellulose acetate butyrate; polyesters, such as poly(ethylene terephthalate), poly(ethylene naphthalate), poly(1,4-cyclohexanedimethylene terephthalate), poly(butylene terephthalate), and copolymers thereof, polyimides; polyamides; polycarbonates; polystyrene; polyolefins, such as polyethylene or polypropylene; polysulfones; polyacrylates; polyetherimides; and mixtures thereof. The papers listed above include a broad range of papers, from high end papers, such as photographic paper to low end papers, such as newsprint. In a preferred embodiment, polyethylene-coated or poly(ethylene terephthalate) paper is employed.
In principal, any raw paper can be used as support material. Preferably, surface sized, calendared or non-calendared or heavily sized raw paper products are used. The paper can be sized to be acidic or neutral. The raw paper should have a high dimensional stability and should be able to absorb the liquid contained in the ink without curl formation. Paper products with high dimensional stability of cellulose mixtures of coniferous cellulose and eucalyptus cellulose are especially suitable. Reference is made in this context to the disclosure of DE 196 02 793 B1, which describes a raw paper as an ink-jet recording material. The raw paper can have further additives conventionally used in the paper industry and additives such as dyes, optical brighteners or defoaming agents. Also, the use of waste cellulose and recycled paper is possible. However, it is also possible to use paper coated on one side or both sides with polyolefins, especially with polyethylene, as a support material.
The support used in the invention may have a thickness of from 50 to 500 μm, preferably from 75 to 300 μm. Antioxidants, antistatic agents, plasticizers and other known additives may be incorporated into the support, if desired.
In order to improve the adhesion of the tie layer or, in the absence of a tie layer, the ink-receiving layer, to the support, the surface of the support may be subjected to a corona-discharge treatment prior to applying a subsequent layer. The adhesion of the ink-recording layer to the support may also be improved by coating a subbing layer or glue on the support. Examples of materials useful in a subbing layer include halogenated phenols and partially hydrolyzed vinyl chloride-co-vinyl acetate polymer.
Optionally, an additional backing layer or coating may be applied to the backside of a support (i.e., the side of the support opposite the side on which the image-recording layers are coated) for the purposes of improving the machine-handling properties and curl of the recording element, controlling the friction and resistivity thereof, and the like.
Typically, the backing layer may comprise a binder and filler. Typical fillers include amorphous and crystalline silicas, poly(methyl methacrylate), hollow sphere polystyrene beads, micro-crystalline cellulose, zinc oxide, talc, and the like. The filler loaded in the backing layer is generally less than 5 percent by weight of the binder component and the average particle size of the filler material is in the range of 5 to 30 μm. Typical binders used in the backing layer are polymers such as polyacrylates, gelatin, polymethacrylates, polystyrenes, polyacrylamides, vinyl chloride-vinyl acetate copolymers, poly(vinyl alcohol), cellulose derivatives, and the like. Additionally, an antistatic agent also can be included in the backing layer to prevent static hindrance of the recording element. Particularly suitable antistatic agents are compounds such as dodecylbenzenesulfonate sodium salt, octylsulfonate potassium salt, oligostyrenesulfonate sodium salt, laurylsulfosuccinate sodium salt, and the like. The antistatic agent may be added to the binder composition in an amount of 0.1 to 15 percent by weight, based on the weight of the binder. An ink-retaining layer may also be coated on the backside, if desired.
Although the recording elements disclosed herein have been referred to primarily as being useful for inkjet printers, they also can be used as recording media for pen plotter assemblies. Pen plotters operate by writing directly on the surface of a recording medium using a pen consisting of a bundle of capillary tubes in contact with an ink reservoir.
Another aspect of the invention relates to an inkjet printing method comprising the steps of: (a) providing an inkjet printer that is responsive to digital data signals; (b) loading the inkjet printer with the inkjet recording element described above; (c) loading the inkjet printer with a pigmented inkjet ink; and (d) printing on the inkjet recording element using the inkjet ink in response to the digital data signals.
Inkjet inks used to image the recording elements of the present invention are well known in the art. The ink compositions used in inkjet printing typically are liquid compositions comprising a solvent or carrier liquid, dyes or pigments, humectants, organic solvents, detergents, thickeners, preservatives, and the like. The solvent or carrier liquid can be solely water or can be water mixed with other water-miscible solvents such as polyhydric alcohols. Inks in which organic materials such as polyhydric alcohols are the predominant carrier or solvent liquid may also be used. Particularly useful are mixed solvents of water and polyhydric alcohols. If dyes are used in such compositions, they are typically water-soluble direct or acid type dyes. Such liquid compositions have been described extensively in the prior art including, for example, U.S. Pat. Nos. 4,381,946; 4,239,543; and 4,781,758.
Typically the colorants used in inkjet printing are anionic in character. In dye-based printing systems, the dye molecules contain anionic moieties. In pigment based printing systems, the dispersed pigments are functionalized with anionic moieties. Colorants must be fixed near the surface of the inkjet receiver in order to provide the maximum image density. In the case of pigment based printing systems, the inkjet receiver is designed with the optimum pore size in the top layer to provide effective trapping of ink pigment particles near the surface. Dye-based printing systems require a fixative or mordant in the top layer of the receiver. Polyvalent metal ions and insoluble cationic polymeric latex particles provide effective mordants for anionic dyes. Both pigment and dye based printing systems are widely available. For the convenience of the user, a universal porous inkjet receiver will comprise a dye fixative in the topmost layer.
The following examples are provided to further explain the invention.
The following polymeric latex beads are used in the examples shown below to demonstrate the properties of the invention.
Styrene (3125 g), deionized water (9375 g), tert-dodecanethiol (187.5 g), cetylpyridinium chloride (12.5 g), were combined in an appropriately sized three-neck round bottom flask such that approximately half the volume was filled (22 L in this case). The contents were bubble degassed with nitrogen for 20 minutes and placed in a thermostatted water bath at 70° C. The paddle stirrer was adjusted to a depth of approximately midway between the surface and the bottom in order to avoid immobilization by coagulum accumulation. When the temperature of the flask contents had equilibrated at 70° C., azobis(methylpropionamidine) hydrochloride (31.25 g) was added all at once. The reaction was stirred at about 100 RPM overnight, cooled to room temperature, and filtered through a milk filter. A latex (12,264 g, 24.42% solids) was obtained. The volume average particle size was measured by quasi-elastic light scattering using a MICROTRAC UPA instrument. The molecular weights were determined by size exclusion chromatography in tetrahydrofuran against poly(methylmethacrylate) standards. The characterization data is given in Table 1.
Polymeric Latex L-2 was prepared by the same procedure described in Preparative Example 1. The following reagents were used: Styrene (375.0 g), deionized water (1125.0 g), tert-dodecanethiol (22.5 g), cetylpyridinium chloride (7.5 g), and azobis(methylpropionamidine) hydrochloride (3.75 g). 1185 g of a latex of 24.71% solids was obtained. The characterization data is given in Table 1.
Polymeric Latex L-3 was prepared by the same procedure described in Preparative Example 1 except that an additional monomer (vinylbenzyl trimethylammonium chloride) was used. The following reagents were used: Styrene (371.25 g), vinylbenzyl trimethylammonium chloride (3.75 g), deionized water (1125.0 g), tert-dodecanethiol (22.5 g), cetylpyridinium chloride (7.5 g), and azobis(methylpropionamidine) hydrochloride (3.75 g). 1263 g of latex of 25.08% solids was obtained. The characterization data is given in Table 1.
Polymeric Latex L-4 was prepared by the same procedure described in Preparative Example 3. The following reagents were used: Styrene (367.5 g), vinylbenzyl trimethylammonium chloride (7.50 g), deionized water (1125.0 g), tert-dodecanethiol (22.5 g), cetylpyridinium chloride (15.00 g), and azobis(methylpropionamidine) hydrochloride (3.75 g). Latex L-4 (1465 g, 25.65% solids) was obtained. The characterization data is given in Table 1.
Polymeric Latex L-5 was prepared by the same procedure described in Preparative Example 1. The following reagents were used: Styrene (312.5 g), deionized water (937.5 g), tert-dodecanethiol (12.5 g), cetylpyridinium chloride (1.25 g), and azobis(methylpropionamidine) hydrochloride (3.13 g). Latex L-5 (1128 g, 23.40% solids) was obtained. The characterization data is given in Table 1.
Polymeric Latex L-6 was prepared by the same procedure described in Preparative Example 1. The following reagents were used: Styrene (312.5 g), deionized water (937.5 g), tert-dodecanethiol (6.25 g), cetylpyridinium chloride (1.25 g), and azobis(methylpropionamidine) hydrochloride (3.13 g). Latex L-6 (1145 g, 23.98% solids) was obtained. The characterization data is given in Table 1.
Polymeric Latex L-7 was prepared by the same procedure described in Preparative Example 1 except that no tert-dodecanethiol was used. The following reagents were used: Styrene (187.5 g), deionized water (1062.5 g), cetylpyridinium chloride (3.75 g), and azobis(methylpropionamidine) hydrochloride (1.88 g). Latex L-7 (1162 g, 13.81% solids) was obtained. The characterization data is given in Table 1.
Polymeric Latex L-8 was prepared by the same procedure described in Preparative Example 1 except that no tert-dodecanethiol was used. The following reagents were used: Methyl methacrylate (312.5 g), deionized water (937.5 g), cetylpyridinium chloride (1.25 g), and azobis(methylpropionamidine) hydrochloride (3.13 g). Latex L-8 (1156 g, 23.97% solids) was obtained. The characterization data is given in Table 1.
A coating solution was prepared by dispersing 6.1 kg of CATAPAL 200 (100% solids, colloidal alumina, Sasol) in 11.76 kg of water and then slowly adding 0.255 kg of GOHSENOL GH-23 (100% solids, polyvinyl alcohol, Nippon Goshei) over 1 hour to the prop stirred mixture. The mixture heated to 90° C. for 1 hour, cooled to room temperature and 0.064 kg of 2,3-dihydroxy-1,4-dioxane (40% solids, blocked glyoxal cross-linker, Aldrich) added. Additional water was added to dilute the solution to 30% solids.
Coating Solution A was coated at room temperature via a slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element C-1 comprising a liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage.
A coating solution was prepared at room temperature by dilution of 236.7 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 150 g of water, followed by addition of 290.8 g of Polymeric Latex 1 (24.4% solids), 18.9 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, from Aldrich) and 37.9 g of ZONYL FSN (40% solids, fluorosurfactant, Dupont). The final solids of the solution was adjusted to 12.5% with 15.6 g of water.
Coating Solution B was coated at room temperature via slot hopper onto Element C-1 and after drying gave Element C-2 at 4.26 g/m2 dry coverage.
The Polystyrene Polymeric Latex L-1 particles were removed by immersing Element C-2 for 1 minute in 1 L of 2-butanone with gentle agitation followed by air drying to give porous Element E-1.
A continuous web of Element B was overcoated with a total of 104 g/m2 of 2-butanone in three passes, allowing to air dry between each pass to give porous Element E-2.
Ink Capacity Target: Test images were printed using a CANON i960 printer with a set of pigmented inks using an ink capacity target that was designed to print cyan, magenta, yellow and black inks in 10 equal increments such that at 100% ink laydown an optical density of about 1.0 was obtained. Similarly, red, green and blue patches were obtained by overprinting the appropriate process colors together (200% in laydown). A process black was obtained by overprinting cyan, magenta and yellow inks (300% ink laydown). As the target was exiting the printer, the last step of the black only channel that was apparently dry was noted and this is referred to as the Puddling Point. In addition, a visual assessment as to the Degree of Coalescence was made. For this assessment, a rating of 1 indicates little to no coalescence was observed in the 200% & 300% RGBK patches, a rating of 2 indicates moderate coalescence, while a rating of 3 indicates severe coalescence. The results are shown in Table 2.
The data in Table 2 clearly shows an increase in the porosity of the image-receiving layer of the invention since both the Puddling Point increased and the Degree of Coalescence decreased. While an image printed on the porous underlying layer alone (Element C-1) showed a high Puddling Point and low Degree of Coalescence, the gloss of the element was undesirably low. Further, without the image-receiving layer acting as a top protective layer, the durability of the element is also compromised.
Test images of a colorful portrait scene were printed using a CANON i960 printer with the standard CANON i960 dye-based ink set. An assessment of the degree of ink coalescence and color to color bleed was made and is shown in Table 3. For this assessment, coalescence was rated as described above. A color to color bleed a rating of 1 indicates little to no color to color bleed was observed in RGBK patches, a rating of 2 indicates moderate color to color bleed, while a rating of 3 indicates severe color to color bleed.
The data in Table 3 shows that the elements of the invention also show similar improvement when printed with a dye-based ink set.
Samples were printed using an EPSON R300 printer and inks to give a target that had cyan (C), magenta (M), yellow (Y), black (K) and CMY process black patches with an optical density of about 1.0. The samples were faded in an environmental chamber that was charged with 5 ppm ozone and the results are shown in Table 4.
The data in Table 4 clearly demonstrates the reduced sensitivity to environmental ozone for the inventive elements that would translate into increased print life.
A coating solution was prepared by dispersing 5.7 kg of CATAPAL 200 (100% solids, colloidal alumina, Sasol) in 12.024 kg of water and then slowly adding 0.253 kg of GOHSENOL GH-23 (100% solids, polyvinyl alcohol, Nippon Goshei) over 1 hour to the prop stirred mixture. The mixture heated to 90° C. for 1 hour, cooled to room temperature and 0.036 kg of CARTABOND GHF (40% glyoxal in water, Clariant Corporation). To aid coating, surfactant OLIN 10G (10% solids, p-nonylphenoxypolyglycidol, Olin Corporation) was added at 0.1% of the total solids and additional water was added to dilute the solution to 28% solids just prior to coating.
A coating solution was prepared at room temperature by dilution of 50 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 90 g of water, followed by addition of 4.0 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich) and 0.25 g of ZONYL FSN (40% solids, fluorosurfactant, Dupont). The final solids of the solution was adjusted to 3% with 5.75 g of water.
Coating Solutions C and D were coated in a two-pass operation at room temperature via slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed after each pass by convective drying to give Element C-3 with a liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage and a top coat at 0.97 g/m2 dry coverage.
A coating solution was prepared at room temperature by dilution of 47.35 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 25 g of water, followed by addition of 58.17 g of Polymeric Latex 1 (24.4% solids), 3.79 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich) and 7.58 g of ZONYL FSN (40% solids, fluorosurfactant, Dupont). The final solids of the solution was adjusted to 12.5% with 8.1 g of water.
Coating Solutions C and E were coated in a two-pass operation at room temperature via slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed after each pass by convective drying to give Element E-3 with a liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage and a image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution E, except that Polymeric Latex L-2 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 8%.
Coating Solutions C and F were coated in a two-pass operation at room temperature via slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed after each pass by convective drying to give Element E-4 with bottom liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution E, except that Polymeric Latex L-3 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 7%.
Coating Solutions C and G were coated in a two-pass operation at room temperature via slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed after each pass by convective drying to give Element E-5 with bottom liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution E, except that Polymeric Latex L-4 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 7%.
Coating Solutions C and H were coated in a two-pass operation at room temperature via slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed after each pass by convective drying to give Element E-6 with bottom liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage and an image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared at room temperature by dilution of 34.09 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 60 g of water, followed by addition of 39.89 g of Polymeric Latex 1 (25.64% solids), 2.73 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich) and 0.0.68 g of ZONYL FSN (40% solids, fluorosurfactant, Dupont). The final solids of the solution was adjusted to 9% with 12.61 g of water.
Coating Solutions C and I were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element E-7 with a liquid-absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution I, except that Polymeric Latex L-5 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 9%.
Coating Solutions C and J were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element E-8 with a liquid-absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution I, except that Polymeric Latex L-6 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 8%.
Coating Solutions C and K were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element E-9 with a liquid-absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution I, except that Polymeric Latex L-7 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 7%.
Coating Solutions C and L were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element C-4 with a liquid-absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared as described for Coating Solution I, except that Polymeric Latex L-8 was used in place of Polymeric Latex L-1 and the final solids was adjusted to 7%.
Coating Solutions C and M were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element E-10 with a liquid absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
Elements C-3, C-4 and E-3 to E-10 were washed for 1 minute in 1 L of 2-butanone with gentle agitation followed by air drying. Test images were printed using a CANON i960 printer with a set of pigmented inks using an ink capacity target as is described in Example 4 and the Puddling Point and Degree of Coalescence is shown for the Elements in Table 5.
As is seen in the above table, elements of the invention show advantaged image characteristics that are indicative of a more porous structure. For example, Elements E-3 to E-10 show less ink coalescence when compared to Element C-3 and Element C-4.
A coating solution was prepared as described for Coating Solution C except that the final solids of the solution was adjusted to 26% with water. Coating Solution O for Control Image-Receiving Layer
A coating solution was prepared at room temperature by dilution of 50 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 90 g of water, followed by addition of 4.0 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich) and 0.25 g of ZONYL FSN (40% solids, fluorosurfactant, Dupont). The final solids of the solution was adjusted to 3% with 5.75 g of water.
Coating Solutions N and O were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element C-5 with a liquid-absorbing underlying porous layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 0.97 g/m2 dry coverage.
A coating solution was prepared at room temperature by dilution of 37.88 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 50 g of water, followed by addition of 46.53 g of Polymeric Latex L-1 (25.64% solids), 3.03 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich) and 0.76 g of ZONYL FSN (40% solids, fluorosurfactant, from Dupont). The final solids of the solution was adjusted to 10% with 11.8 g of water.
Coating Solutions N and P were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element E-11 with a liquid-absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared at room temperature by dilution of 27.47 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 60 g of water, followed by addition of 11.91 g of CATAPAL 200 (34.6% solids, colloidal alumina, Sasol), 33.75 g of Polymeric Latex L-1 (24.42% solids), 2.20 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich) and 0.55 g of ZONYL FSN (40% solids, fluorosurfactant, Dupont). The final solids of the solution was adjusted to 10% with 14.1 g of water.
Coating Solutions N and Q were simultaneously coated at room temperature via a slide hopper onto a moving web of photographic quality, non-polyethylene coated paper support. Water was removed by convective drying to give Element E-12 with a liquid-absorbing porous underlying layer at 27.1 g/m2 dry coverage and a top image-receiving layer at 5.88 g/m2 dry coverage.
Elements C-5 and E-11 to E-12 were washed for 1 minute in 1 L of 2-butanone with gentle agitation followed by air drying. A test target that contained cyan, magenta, yellow and black patches were printed using a CANON i960 printer with the standard CANON i960 dye-based ink set. The optical density of the patches were measured using a GretagMacbeth SPECTROLINO Model No. 36.55.52 calorimeter and are recorded in Table 6.
As is seen in the above Table 6, the optical density of the magenta, yellow and black patches were increased when colloidal alumina filler was included in the top layer. Similar effects were seen with fumed aluminas and fumed silicas used in combination with the latex porogens of the invention.
Element E-13 was produced as is described for Element E-3 in Example 6 to give a liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage and a top image-receiving layer at 4.26 g/m2 dry coverage.
A coating solution was prepared at room temperature by dilution of 8.45 g of GOHSEFIMER K-210 (8% solids, cationically modified polyvinyl alcohol, Nippon Goshei) with 100 g of water, followed by addition of 0.84 g of CARTACOAT S2 (100% solids, amorphous silica, Clariant), 18.34 g of CARTACOAT K 302 C (32.24% solids, cationized colloidal silica, Clariant) and 0.68 g of 2,3-dihydroxy-1,4-dioxane (10% solids, blocked glyoxal cross-linker, Aldrich). The final solids of the solution was adjusted to 5% with 21.7 g of water.
Coating Solutions C (bottom), R (middle) and E (top) were sequentially coated at room temperature via a slot hopper onto a moving web of photographic quality, non-polyethylene coated paper support. After each pass, water was removed by convective drying to give Element E-14 with a bottom liquid-absorbing porous underlying layer at 25.8 g/m2 dry coverage, a supplemental (middle) porous underlying layer at 2.39 g/m2 dry coverage and a image-receiving layer at 4.26 g/m2 dry coverage.
Elements E-14 and E-15 were washed for 1 minute in 1 L of 2-butanone with gentle agitation followed by air drying. Test images were then printed with either the Ink Capacity Target using a CANON i960 printer and a pigmented ink set or the Image Quality Target using a CANON i960 printer and the standard CANON i960 dye-based ink set, as is described in Example 4. The degree of coalescence was then evaluated as previously described and the results are shown in Table 7.
As is seen above, use of the interlayer (supplemental/middle porous underlying layer) led to even greater reduced coalescence for both pigmented and dye-based ink sets. Similar results would be expected with interlayers formulated with other fillers.
The invention has been described with reference to a preferred embodiment. However, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention.
