Coating processes – Measuring – testing – or indicating
Patent
1997-01-15
1998-05-12
Pianalto, Bernard
Coating processes
Measuring, testing, or indicating
118 58, 118429, 118688, 118712, 422 62, 427258, 427288, 427391, 427508, 427558, 427559, 427595, B05D 136
Patent
active
057501866
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to a novel method for the deposition of aqueous coating compositions in printing processes including wet-trap, gravure, offset (waterless or using water), silk-screen, flexography, off-line dry-trap, and related printing processes. In addition, the present invention relates to a method for depositing barrier coatings on paperboard trays and related items for use in the food industry. These barrier coatings are particularly useful for influencing the moisture vapor transition rate (MVTR) and oil and water resistance in paperboard packing to be used to store moisture sensitive foods.
Use of the present invention allows the adaptation of an aqueous coating to virtually any printing method without changing the chemical content of that formulation. The present invention, in certain embodiments, utilizes exceptionally high levels of solids in printing coating compositions and unexpectedly obtains acceptable viscosity, flow characteristics and mechanical transfer for these compositions. In addition, the present invention is readily adaptable to virtually every type of coating process used to coat inked, uninked and related surfaces. The method according to the present invention may also be adapted for use in the food industry to deposit barrier coatings on paperboard for food storage in order to influence the MVTR and oil and water resistance of the underlying packing or storage material.
BACKGROUND OF THE INVENTION
Aqueous coating compositions of a resinous thermoplastic coating material (clearcoat) such as thermoplastic, (meth)acrylic or (meth)acrylic-styrene copolymer in the form of emulsions are well known in the printing industry and presently are being used to coat inked and uninked layers during wet-trap, off-line dry-trap, gravure, offset, silk-screen, flexography and related printing or coating processes using an aqueous coating composition.
In one aspect of the above-referenced printing processes, an ink layer is first put down on a substrate in the form of paper, cloth, fiberboard, corrugated box, etc. and depending upon the process, the ink layer is first allowed to dry before it is coated, or is coated wet. In other methods according to the present invention, the coating may simply be placed onto an uninked or ink-free substrate. The aqueous coating serves to provide certain film characteristics including gloss, mar resistance, oil and water resistance, MVTR, and protection of the inked, uninked or related surface, adhesion and other characteristics. These film characteristics are generally determined by the weight of the coating applied and the amount or percent of solids used in the coating composition.
The prior art materials used as coatings in combination with the current print coating techniques are grossly limited in the solid contents that may be uniformly deposited onto a substrate from a coating composition and the degree of gloss value that a coating may obtain. In addition, as presently employed, the formulation of one aqueous coating may only be used in one or perhaps two processes; it is virtually impossible using the present methods without the present invention to provide one formulation which may be readily adapted for use in wet-trap, off-line dry-trap, gravure, offset, silk-screen, flexography and other printing processes.
In wet-trap in-line printing processes an ink coating (usually a hydrophobic ink) is first deposited onto paper, fiberboard, cardboard, corrugated paper or similar material, as a wet ink and then an aqueous coating is deposited onto the wet ink layer such that the ink is "trapped" under the aqueous coating to provide adequate film characteristics. In dry-trap off-line printing processes the ink is first dried before an aqueous coating is deposited onto the ink layer.
Gravure and flexography printing processes employ plates or etched cylinders (generally containing inverted pyramids) to deposit the ink layer (usually a water-based or solvent-based ink) which is generally dried before being coated by an aqueo
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Coleman Henry D.
Pianalto Bernard
Sudol R. Neil
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