a new mechanism for enhancing adhesion of ...results: 3-star qualification • no runnability issues...
TRANSCRIPT
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Dr. Daniel F. VarnellResearch FellowSolenis LLC
A New Mechanism for Enhancing Adhesion of Electroreprographic Printing with Liquid Toner
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2 Confidential and proprietary.
Overview Liquid Toner Digital Printing
• Digital printer (every page unique)
• Electroreprographic with offset blanket
• Liquid toner
Pigments in anionic P(Et/AA)
Suspended in volatile oil
• Up to seven colors and use of custom
colors
• Offset print quality
Conforms to surface
High resolution
• Growing digital market Digital Press
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3 Confidential and proprietary.
Objective
• An easy-to-use additive that imparts 3-star performance (by HP standards) at a cost at least 25% lower than current systems
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4 Confidential and proprietary.
Toner Adhesion Measurement (HP Method)
• Tape test under controlled conditions
• Best rating is 3-stars Adhesion >90% for black, >80% for 290% photo black
• 290% Photo Black (52% y, 66% m, 72% c, 100% k)
• Image scanned and analyzed
• Rochester Institute of Technology (RIT)
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5 Confidential and proprietary.
History of Indigo Paper Additives
Polyethyleneimine
• Expensive
• Time-consuming
• Yellowing
Poly(ethylene/acrylic acid) dispersion
• Inefficient
• Compatibility issues
• Difficult to run
• Trouble with broke
Anionic polystyrene
• Less addition (< 6#/ton)
• Easy-to-use
• 2-star, or weak 3-star performance
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How the Additives Work and Introduction of a New Concept and Product
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7 Confidential and proprietary.
Thermodynamics of Adhesion Between Polymers
• Materials will mix or adhere if free energy decreases
D Gmix = Gf - G0 =(Hf - TSf) - (H0 - TS0) = (Hf - H0) - T(Sf - S0)
D Gmix = DHmix - T DSmix
Entropy of Mixing
• Favorable
• Mixing is more
random
Heat of Mixing
• Unfavorable
• Unless interaction
= (Hf - H0 ) - XAB
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8 Confidential and proprietary.
• Polyethyleneimine
Water soluble
Ionic interactions
Heat of mixing becomes favorable
XAB = dAB – ½(dAA + dBB)
_ _
Ink with anionic change
PEI has cationic charge
+
+
+
+
dAB becomes larger
XAB becomes larger (favorable)
Mechanisms of Adhesion
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9 Confidential and proprietary.
• Poly(ethylene/acrylic acid)
Dispersion
Same chemistry as in ink
Melts together
Heat of mixing unfavorablebut is very small
“Like-dissolves-like”
P(EtAA)
P(EtAA) P(EtAA)
P(EtAA)P(EtAA)
P(EtAA)
XAB = 0 and DHmix = 0
Mechanisms of Adhesion
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10 Confidential and proprietary.
• New Concept
Water soluble
No ionic interactions
Heat of mixing becomes favorable
XAB = dAB – ½ (dAA + dBB)
• By decreasing self interaction
dAA made smaller
XAB becomes larger (favorable)
BB BB
A
AA
Mechanisms of Adhesion
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11 Confidential and proprietary.
• New Concept
Water soluble
No ionic interactions
Heat of mixing becomes favorable
XAB = dAB – ½ (dAA + dBB)
• By decreasing self interaction
dAA made smaller
XAB becomes larger (favorable)
B
B B B
A
AA
Mechanisms of Adhesion
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12 Confidential and proprietary.
• New Concept
Decreasing self interaction
Potential for strong dipole interaction
Favorable to mixing/adhesion
Mechanisms of Adhesion
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13 Confidential and proprietary.
Initial Experiment
73
68
82
67
99
80
55 56
62
53
99
61
40
50
60
70
80
90
100
blank starch anionic PS P(Eth:AA) EXP #1 EXP #2
Ima
ge
Ad
he
sio
n (%
)
100% Black 290% Photo Black Exceptional
Dixon Coater on Fine Paper
4% Ethylated Starch, 0.2% Additives
Testing by RIT
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Wonder is the
beginning of wisdom. — Socrates
Let the sea resound, and all that is in it.
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15 Confidential and proprietary.
Concept Confirmed
60
70
80
90
100
Ima
ge
Ad
he
sio
n (%
)
100% Black 290% Photo Black
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16 Confidential and proprietary.
Product Optimization
85
90
95
100
0 0.1 0.2 0.3 0.4
% A
dh
esio
n% Formulation to Paper
Photo Print Adhesion
Original
Optmized
• Optimized
• Performance varies by base sheet
• Enhancements ongoing
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17 Confidential and proprietary.
Case History #1
GOAL: Make HP Indigo Grade
• Wet-End: precipitated calcium carbonate (PCC) and some sizing
• Size Press: cationic starch, optical brightening agent (OBA), sodium chloride (NaCl)
0.4% New Product
RESULTS: 3-Star Qualification
• Qualified on first run
• No wet-end changes
• No size press changes
• No issues with runnability
• No changes of other properties
70
80
90
100
100% Black 290% PhotoBlack
Image A
dhe
sio
n (%
)
Qualification Testing
Also easily passed blanket
compatibility test
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18 Confidential and proprietary.
Commercial Case Study Details – Mill A
Grades from 55 pound to 100 pound have been qualified
• 6 dry pounds per ton of DPZ-667
• Optimization trials will continue
• Strong 3-star (99 plus adhesion), no blanket compatibility issues
• ~ 16% filler content with PCC
• 55 pound grade has typical properties of 115 Sheffield Smoothness and 22 Gurley Porosity
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19 Confidential and proprietary.
Performance - Mill Results
• Wet-end PCC
• Size press: Cationic Starch; OBA, Salt; 0.3% DPZ-667
CONDITIONS:
• 100% Black Print - 100% Repeat - 99% adhesion
• 290% Photo Print – 100% Repeat - 99% adhesion
ADHESION:
• Perfect! No change in size press viscosity or pick-up
RUNNABILITY:
• Unchanged
PAPER PROPERTIES:
• Test easily passed
INDIGO BLANKET COMPATIBILITY:
• Qualified
3-STAR QUALIFIED:
• Trial paper sold as offset with no issues.
ISSUES:
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20 Confidential and proprietary.
Bottom Line: A Versatile Solution
• Wet-end
Low and high levels of PCC
AKD and ASA sizing
Wide range of sizing level
Virgin and recycle fiber
Wide range of basis weights
• Size Press
Anionic, Ethylated, Cationic Starches
Puddle and Metered Size presses
All size press additive are compatible
Sheet Porosity Important
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21 Confidential and proprietary.
Performance - Additives
• OBA
• Salts
• Some defoamer
• Some proprietary additives
Things that can be added with no impact:
Learning more all the time
Compatibility test should be conducted for each size press formulation (ask Solenis about this)
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22 Confidential and proprietary.
Case History #2 (challenging base sheet)
GOAL: Make HP Indigo Grade
• Wet-end: PCC & low level ASA Sizing, 115g/m2 , Gurley Porosity of just 13
• Size-Press: Ethylated starch, OBA, NaCl
• Goal: High level of photo adhesion
RESULTS: 3-Star Qualification
• No runnability issues
• Muted response to ID-115 – unable to reach high 90s of adhesion
• No loss of any other properties
• Qualified on first run
• Sheet sold for offset printing
70
80
90
100
w/o ID-115 w 0.3% ID115
Image A
dhe
sio
n (%
)
RIT testing Photo Images
OPTIONS
1. Switch to cationic starch
2. Addition of rheology modifier
3. Solenis proprietary additive
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23 Confidential and proprietary.
Variations for Difficult Base Sheet
80
85
90
95
100
Ethylated Cationic
% A
dhesio
n
100% Black 290% Photo Black
Effect of Changing Size Press Starch
One could also add a rheology modifier
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24 Confidential and proprietary.
Advantages for Papermakers
CHARACTERISTIC P(Et/AA) New Product
Water Soluble No Yes
Starch Compatibility Limited All
Efficiency Poor Excellent
OBA Compatibility Limited All
Solids 25-30 15-35
Recycle Broke May cause issues Unlikely to cause issues
Runnability Deposits, Incompatibility No adverse effects
Cost Too Much 25% less for materials
more savings by quicker
grade changes
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25 Confidential and proprietary.
Performance – Pilot Results
Conditions: Light weight commercial base sheet w/o surface size; Dixon coater; 80#/ton
ethylated starch
With this base sheet most of performance obtained with just 3#/ton DPZ-667
50
55
60
65
70
75
80
85
90
95
100
0 2 4 6 8 10 12
% A
dh
esio
n
#/ton active DPZ-667
INDIGO INK ADHESION – RIT TESTING (New Tape)
100% black
290% Photo
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26 Confidential and proprietary.
Performance: Optimum Conditions
• Keep product at the paper surface
More closed sheets are better
Normal or higher starch viscosity
Cationic starch versus non-ionic or anionic starches
Metered size press equipment
• Better if size press temperature is below 55oC
• Rheology modifiers: Topcat98 starch, HEHEC, Ecosphere,
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27 Confidential and proprietary.
Specialization
• For many mills the standard product works great!
• Not every mill has the same goals
• Some base sheets can present unique issues
• Some paper machines have unusual limitations
• Solenis is willing to work with each mill to be successful
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28 Confidential and proprietary.
INTELLECTUAL PROPERTY
Three patent applications
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29 Confidential and proprietary.
AVAILABILITY
Commercial in any quantity in USA
Limited quantities in Europe until REACH listed (2018), available for trials and small production scale
Lead time for orders:
USA: 2-3 weeks / Europe: Yet to be established
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30 Confidential and proprietary.
REGULATORY INFORMATION
FDA - In the future, no issues expected
REACH COMPLIANCE – In progress, trials can be run in Europe
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31 Confidential and proprietary.
OTHER PROPERTIES
Enhances dry toner adhesion
Ink-jet additive compatible (as tested to-date)
No effect on offset printing
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32 Confidential and proprietary.
GOAL
• An easy to use additive that imparts 3-star performance by HP standards at a cost at least 25% lower than current systems.
* 100% adhesion has been achieved even with 290% photoprinting