Silica Pigments for Use in Commercial Color Inkjet, High-Volume, On-Demand Printing Systems

Transcription

1 Silica Pigments for Use in Commercial Color Inkjet, High-Volume, On-Demand Printing Systems Demetrius Michos, W. R. Grace & Co. Natalia Krupkin, W. R. Grace & Co.

2 TRENDS IN DIGITAL MEDIA WORLD New installations of high volume production IJ printers are increasing Digital printing is replacing traditional technologies High speed printing represents fastest growth opportunity: ability to print variable data personalize content and print short color runs (for example TransPromo) # Printed Sheets [billions] Printed Sheets Per Year WW Top 2 Fast IJ Printing Categories Based on the IMI Worldwide Digital Printing Market Report, 2009 Current research indicates that consumers in Western Europe spend an average of three to four minutes reviewing transaction documents, making them an optimal communications vehicle to facilitate additional customer messaging CapVentures InfoTrends Light Production IJ High Volume Production IJ RAPID GROWTH OVER NEXT 3 YEARS!

3 Materials Technology for IJ Coatings Amorphous Inorganic Pigments Silica Silica / Alumina Submicron Micron. Silica Colloidal Precipitated Sodium Magnesium Aluminum Silicate Particle Size Surface Area Pore Size Concentration Particle Size Surface Area Pore Size Surface Chemistry Particle Size Surface Chemistry Concentration Particle Size Surface Area Pore Size Key Properties Particle Size Surface Area Pore Size Color Smooth surface Ink Capacity Dye fixation Optical Density Matte finish Ink Capacity Dye fixation Optical Density Surface Modification Coating Film primer Protective Topcoats Gloss enhancement Low cost matte Targeted Applications TiO2 Extender Base paper Opacity Strike-thru Dispersions Micronized Powder Dispersions Micronized Powder Manufacturing Technologies Micronized Powder

4 Porous Silica Introduction in Paper Coatings Experimental Factors: Keep total pigment concentration constant. Maintain the same weight ratio of GCC to Clay Introduce two types of micronized silicas: Particle size of 6 microns & Pore volume of 1.1cc/g Particle size of 5 microns & Pore volume of 2.0cc/g Investigate the effect of partial replacement of starch with PVOH Coat weight: 6 gsm

5 Effects of Silica on Ink Absorption Ref 14% Substitution of [GCC + Clay] with Silica (PV=1.1cc/g) A D PV=1.1 cc/g 20% Substitution of [GCC + Clay] with Silica E PV=2.0 cc/g SUBSTRATE: 65gsm base paper PRINTER: Epson Stylus Photo 870

6 Effects of Silica and PVOH on Ink Absorption Ref 14% Substitution of [GCC + Clay] with Silica (PV=1.1cc/g) A B C PV=1.1 cc/g 14% Substitution of [GCC + Clay] with Silica 50% Substitution of Starch with PVOH PV=2.0 cc/g SUBSTRATE: 65gsm base paper PRINTER: Epson Stylus Photo 870

7 Porous Silica Introduction in Paper Coatings Experimental Factors: Formulation: Pigment/PVOH/Latex = 80/4.4/15.6 Keep total pigment [Calcium Carbonate + Silica] concentration constant Replace 25% of the calcium carbonate with various silicas: Introduce silicas with different particle sizes and pore volumes: Particle size of 0.4 to 9 microns Pore volumes of 0.9 to 2.0cc/g Apply the formulations on two substrates and print with two types of printers Coat weight: 6 gsm

8 Effect of Porous Silica Introduction in the Coating 25% Substitution of Calcium Carbonate with Silica SUBSTRATE: 65gsm base paper PRINTER: Epson Stylus Photo R200

9 Addition of Porous Silica POWDERS in the Coating 25% Substitution of GCC with Silica SUBSTRATE: Glossy (148gsm) PRINTER: Epson Stylus Photo R200

10 Addition of Porous Silica DISPERSIONS in the Coating 25% Substitution of GCC with Silica SUBSTRATE: Glossy (148gsm) PRINTER: Epson Stylus Photo R200

11 Surface SEM Images of the Coatings Calcium Carbonate (CC) Only Coating 25% Substitution of CC with 0.4 micron Silica PARTIAL SUBSTITUTION OF CALCIUM CARBONATE WITH SILICA CREATES HIGHER LEVEL OF COATING POROSITY TO IMPROVE INK ABSORPTION CAPACITY SUBSTRATE: Glossy (148gsm)

12 Surface SEM Images of the Coatings 25% Substitution of CC with 1.0 micron Silica 25% Substitution of CC with 4 micron Silica PARTIAL SUBSTITUTION OF CALCIUM CARBONATE WITH SILICA CREATES HIGHER LEVEL OF COATING POROSITY TO IMPROVE INK ABSORPTION CAPACITY SUBSTRATE: Glossy (148gsm)

13 Titration of Porous Silica in the Coating SUBSTRATE: 65gsm base paper PRINTER: Epson Stylus Photo R200

14 Conclusions Partial substitution of coating pigments with porous silicas (Powders or Dispersions) can improve the overall porosity of the coating. This extra porosity can allow for: - Faster drying - Less bleeding - Upgrade the paper to meet the high speed ink-jet printing requirements Silica improves the mechanical properties of the coating - Dry and wet mar resistance - Changes coefficient of friction GRACE and GRACE DAVISON are trademarks, registered in the United States and/or other countries, of W. R. Grace & Co.-Conn. EPSON STYLUS is a trademark, registered in the United States and/or other countries, of Seiko Epson Kabushiki Kaisha TA Seiko Epson Corp. This presentation is an independent publication and is not affiliated with, nor has it been authorized, sponsored, or otherwise approved by the aforesaid company. This trademark list has been compiled using available published information as of the publication date of this presentation and may not accurately reflect current trademark ownership. Copyright 2010 W. R. Grace & Co.-Conn. All rights reserved.