U.S. patent application number 17/686732 was filed with the patent office on 2022-06-16 for polyurethane-polyacrylate hybrid systems for packaging inks and coatings.
This patent application is currently assigned to SUN CHEMICAL CORPORATION. The applicant listed for this patent is SUN CHEMICAL CORPORATION. Invention is credited to Michael J. JUREK, David KLEIN, Juanita PARRIS.
Application Number | 20220186073 17/686732 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-16 |
United States Patent
Application |
20220186073 |
Kind Code |
A1 |
KLEIN; David ; et
al. |
June 16, 2022 |
POLYURETHANE-POLYACRYLATE HYBRID SYSTEMS FOR PACKAGING INKS AND
COATINGS
Abstract
Described herein are compositions suitable for use as binder
components for inclusion in printing inks and coatings, such as
those used in the gravure and flexographic printing process and
which are printed on substrates such as polyolefin (e.g.,
polyethylene, polypropylene) and poly(ethylene terephthalate)
(PET). The compositions are non-aqueous dispersions in which an one
or more ethylenically unsaturated acrylates or (meth)acrylates is
polymerized with a polyurethane, polyurethane-urea or polyurea in a
non-aqueous polymerization medium, such as esters, ketones, and
mixtures thereof, forming polymeric hybrid resins in the
polymerization medium, which are solvent-dispersible hybrid resins
of polyurethane-polyacrylate, polyurethane-urea-polyacrylate, and
polyurea-polyacrylate. Films of hybrid resins are also disclosed.
These materials exhibit improved film adhesion and are suitable for
flexographic and gravure printing inks, especially for printing
applications where adhesive lamination bond strengths are required,
especially plastic films packaging applications.
Inventors: |
KLEIN; David; (Wayne,
NJ) ; JUREK; Michael J.; (Oak Ridge, NJ) ;
PARRIS; Juanita; (Montvale, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SUN CHEMICAL CORPORATION |
Parsippany |
NJ |
US |
|
|
Assignee: |
SUN CHEMICAL CORPORATION
Parsippany
NJ
|
Appl. No.: |
17/686732 |
Filed: |
March 4, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16084150 |
Sep 11, 2018 |
11299649 |
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PCT/US2017/025841 |
Apr 4, 2017 |
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17686732 |
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62318262 |
Apr 5, 2016 |
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International
Class: |
C09D 175/14 20060101
C09D175/14; B32B 7/12 20060101 B32B007/12; B32B 27/06 20060101
B32B027/06; B32B 27/16 20060101 B32B027/16; B32B 27/32 20060101
B32B027/32; B32B 27/36 20060101 B32B027/36; C09D 175/04 20060101
C09D175/04; C09D 11/10 20060101 C09D011/10; C08F 283/00 20060101
C08F283/00; C08G 18/10 20060101 C08G018/10; C08G 18/32 20060101
C08G018/32; C08G 18/34 20060101 C08G018/34; C08G 18/48 20060101
C08G018/48; C08G 18/75 20060101 C08G018/75; C08G 18/76 20060101
C08G018/76 |
Claims
1-29. (canceled)
30. A multilayer structure comprising: a substrate, optionally
having a primer layer applied thereto; a plurality of ink layers;
optionally, an overprint varnish layer, wherein one or more of the
ink layers, optional primer layer, and optional overprint varnish
layer comprise a non-aqueous dispersion comprising: a non-aqueous
medium consisting of one or more solvents selected from the group
consisting of alcohols, esters and ketones, and one or more
polymeric hybrid resins selected from polyurethane-polyacrylate,
polyurethane-urea-polyacrylate, and polyurea-polyacrylate,
dispersed in the non-aqueous medium, wherein the hybrid resins are
produced in the non-aqueous medium in a polymerization reaction
between one or more ethylenically unsaturated acrylates and one or
more of a polyurethane, a polyurethane-urea, and a polyurea polymer
soluble in the medium, and wherein the non-aqueous dispersion
contains no aromatic hydrocarbon solvents.
31. The multilayer structure of claim 30, further comprising a
curing component, and wherein the multilayer structure is cured by
actinic radiation.
32. The multilayer structure of claim 30, further comprising a
second substrate positioned over the plurality of ink layers.
33. A multilayer laminated structure comprising: a substrate; a top
laminate layer; and intermediate layers between the substrate and
top laminate layer, comprising: an optional primer layer applied to
the substrate; a plurality of ink layers; and an optional overprint
varnish layer; wherein one or more of intermediate layers comprise
a non-aqueous dispersion comprising: a non-aqueous medium
consisting of one or more solvents selected from the group
consisting of alcohols, esters and ketones, and one or more
polymeric hybrid resins selected from polyurethane-polyacrylate,
polyurethane-urea-polyacrylate, and polyurea-polyacrylate,
dispersed in the non-aqueous medium, wherein the hybrid resins are
produced in the non-aqueous medium in a polymerization reaction
between one or more ethylenically unsaturated acrylates and one or
more of a polyurethane, a polyurethane-urea, and a polyurea polymer
soluble in the medium, and wherein the non-aqueous dispersion
contains no aromatic hydrocarbon solvents.
34. The multilayer laminated structure of claim 33, wherein the top
laminate layer comprises a layer of molten resin extruded onto the
intermediate layers; and/or wherein the multilayer laminated
structure further comprises an adhesive layer applied over the
intermediate layers; and wherein the top laminate layer comprises a
plastic film applied over the adhesive layer.
35. The multilayer laminated structure of claim 33, further
comprising a curing component, and wherein the multilayer laminated
structure is cured by actinic radiation.
36. The multilayer laminated structure of claim 33, further
comprising a second substrate positioned between the overprint
varnish and the plurality of ink layers.
37. A polymeric film comprising a hybrid polymer produced by
polymerizing one or more ethylenically unsaturated acrylates with a
polymer selected from a polyurethane, a polyurethane-urea, and a
polyurea.
38. A polymeric film of claim 37, wherein the film is derived from
a non-aqueous dispersion comprising: a non-aqueous medium
consisting of one or more solvents selected from the group
consisting of alcohols, esters and ketones, and one or more
polymeric hybrid resins selected from polyurethane-polyacrylate,
polyurethane-urea-polyacrylate, and polyurea-polyacrylate,
dispersed in the non-aqueous medium, wherein the hybrid resins are
produced in the non-aqueous medium in a polymerization reaction
between one or more ethylenically unsaturated acrylates and one or
more of a polyurethane, a polyurethane-urea, and a polyurea polymer
soluble in the medium, and wherein the non-aqueous dispersion
contains no aromatic hydrocarbon solvents; by separating the medium
from the hybrid resins, whereby a film comprised of the hybrid
resins is produced.
39. An ink-, coating-, primer-, or overprint varnish-composition,
comprising the film of claim 37.
40. An ink-, coating-, primer-, or overprint varnish-composition,
comprising the film of claim 38.
41. The multilayer laminated structure of claim 30, wherein the
substrate, plurality of ink layers; and/or overprint varnish layer,
comprises a polymeric film comprising a hybrid polymer produced by
polymerizing one or more ethylenically unsaturated acrylates with a
polymer selected from a polyurethane, a polyurethane-urea, and a
polyurea.
42. The multilayer laminated structure of claim 41, wherein the
polymeric film is derived from a non-aqueous dispersion comprising:
a non-aqueous medium consisting of one or more solvents selected
from the group consisting of alcohols, esters and ketones, and one
or more polymeric hybrid resins selected from
polyurethane-polyacrylate, polyurethane-urea-polyacrylate, and
polyurea-polyacrylate, dispersed in the non-aqueous medium, wherein
the hybrid resins are produced in the non-aqueous medium in a
polymerization reaction between one or more ethylenically
unsaturated acrylates and one or more of a polyurethane, a
polyurethane-urea, and a polyurea polymer soluble in the medium,
and wherein the non-aqueous dispersion contains no aromatic
hydrocarbon solvents; by separating the medium from the hybrid
resins, whereby a film comprised of the hybrid resins is
produced.
43. The multilayer laminated structure of claim 33, wherein the
substrate, top laminate layer; and/or intermediate layers between
the substrate and top laminate layer comprises a polymeric film
comprising a hybrid polymer produced by polymerizing one or more
ethylenically unsaturated acrylates with a polymer selected from a
polyurethane, a polyurethane-urea, and a polyurea.
44. The multilayer laminated structure of claim 43, wherein the
polymeric film is derived from a non-aqueous dispersion comprising:
a non-aqueous medium consisting of one or more solvents selected
from the group consisting of alcohols, esters and ketones, and one
or more polymeric hybrid resins selected from
polyurethane-polyacrylate, polyurethane-urea-polyacrylate, and
polyurea-polyacrylate, dispersed in the non-aqueous medium, wherein
the hybrid resins are produced in the non-aqueous medium in a
polymerization reaction between one or more ethylenically
unsaturated acrylates and one or more of a polyurethane, a
polyurethane-urea, and a polyurea polymer soluble in the medium,
and wherein the non-aqueous dispersion contains no aromatic
hydrocarbon solvents; by separating the medium from the hybrid
resins, whereby a film comprised of the hybrid resins is
produced.
45. The multilayer laminated structure of claim 34, comprising a
polymeric film comprising a hybrid polymer produced by polymerizing
one or more ethylenically unsaturated acrylates with a polymer
selected from a polyurethane, a polyurethane-urea, and a
polyurea.
46. The multilayer laminated structure of claim 45, wherein the
polymeric film is derived from a non-aqueous dispersion comprising:
a non-aqueous medium consisting of one or more solvents selected
from the group consisting of alcohols, esters and ketones, and one
or more polymeric hybrid resins selected from
polyurethane-polyacrylate, polyurethane-urea-polyacrylate, and
polyurea-polyacrylate, dispersed in the non-aqueous medium, wherein
the hybrid resins are produced in the non-aqueous medium in a
polymerization reaction between one or more ethylenically
unsaturated acrylates and one or more of a polyurethane, a
polyurethane-urea, and a polyurea polymer soluble in the medium,
and wherein the non-aqueous dispersion contains no aromatic
hydrocarbon solvents; by separating the medium from the hybrid
resins, whereby a film comprised of the hybrid resins is produced.
Description
[0001] The present application claims priority to U.S. provisional
patent application No. 62/318,262, filed Apr. 5, 2016, which is
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure is directed to non-aqueous
dispersions of polymeric hybrid resins of
polyurethane-polyacrylate, polyurethane-urea-polyacrylate, and
polyurea-polyacrylate.
[0003] Further disclosed are printing inks, coatings, primers, and
overprint varnishes that include the non-aqueous dispersions or the
polymeric hybrid resins isolated therefrom, or the hybrid resins
transferred from one medium to another solvent medium. Such
materials can be used as binders in the printing inks, coatings,
etc.
BACKGROUND OF THE INVENTION
[0004] Recent diversification in the materials used to form
packages, bags, and/or containers has led to the need for an
improvement in the performance of printing inks or coating used to
ornament or label such packaging and to provide suitable surface
protection. Such inks or coating agents should exhibit excellent
adhesion to different kinds of plastic films and should also
exhibit blocking resistance and adaptability to boiling or
retorting treatment. For example, printing ink formulations for
printing on plastic films should provide improved printability,
adhesion to a wider range of films and improved blocking resistance
than what is provided by conventional inks and coatings.
[0005] In the field of food packaging, bags or containers made of
laminated film materials are used for among other reasons, they are
sanitary, they provide a barrier between the package contents and
the ink so that they do not contact each other, and they provide
barrier properties (e.g., moisture, oxygen) and a satisfactory
appearance when printed. Laminated film materials of this kind may
be produced for example, by extrusion lamination and by adhesion
lamination. In the extrusion lamination method, a plastic film
substrate is printed with an ink, and in some instances, a primer
is applied to the inked surface and then a molten resin such as
polyolefin is extruded on to the inked surface. In the adhesive
laminating method, an adhesive is applied onto the inked surface of
the plastic film substrate, and a plastic film is then laminated
onto the same surface.
[0006] Laminating inks must possess good adhesion to the substrate
that is printed, as well as good adhesiveness (e.g., lamination
strength) to the film to be laminated. When the laminated film
materials undergo subsequent boiling or retorting treatment, in
which packages are immersed in hot water for the purpose of cooking
or sterilization of the contents, the laminated film materials
should not delaminate during treatment. The above-mentioned
performance requirements for printing inks and coatings are
dependent in many instances upon the performance of the binder
resin that is used. In the case of inks used for printing plastic
film, one or more different binder resins may be selected to meet
the stated performance requirement for the inks.
[0007] When a binder resin in an ink or coating hardens, the
resulting film should exhibit blocking resistance but have reduced
adhesion to the plastic film and reduced lamination strength. For
instance, when certain kinds of binder resins are used, such as
acrylic-based binder resins, polyamide-based binder resins and
polyester-based binder resins, the structure of the binder resin
includes an aromatic ring or a highly polar functional group, which
hardens the resin film. However, aromatic rings and highly polar
functional groups could result in the reduction of adhesion and
lamination strength. Thus, in some instances such resins may not be
suited for use binder resin component for laminating inks and
coatings.
[0008] The hardness of a polyurethane resin in a coated film and
its adhesion to a plastic film may be improved by increasing the
concentration of urethane bonds in the polyurethane molecule. An
ink containing a polyurethane resin of this kind provides good
adhesiveness and lamination strength, as compared to inks
containing other resins providing ink films having the same
hardness. For this reason, polyurethane resins in which the
urethane bond concentration is increased have been used as binders
for printing inks and coatings for use in laminates of plastic
films. However, polyurethane resins in which the urethane bond
concentration is highly increased do not provide sufficient
adaptability for printing or adhesion stability. To eliminate this
problem, a two-component reaction type resin system can be used
that is composed of one component containing a polyurethane resin
and the other component containing a polyisocyanate compound as a
curing agent. However, the two-component reaction type resin system
has its own problems. Since the main component must be mixed with
the curing agent immediately before being used, it is inconvenient
to handle, it has a short pot life, and the ink or coating after
printing is unstable. Further, the use of expensive curing agents
substantially raises costs of packaging bags or containers.
[0009] Plastic film substrates such as those used in laminates are
often printed using flexographic printing or gravure printing. In
flexographic printing, the flexographic ink or coating is applied
to the surface of a resilient letter-press image, and the image is
then transferred to the plastic print stock. Flexographic inks, for
example, may typically contain a polar organic solvent such as an
alkanol, which dissolves ink binder components but which does not
swell or otherwise deteriorate the letter-press image. In gravure
printing, the gravure ink is deposited in image wells in the flat
surface of a gravure plate, and the deposited ink image is then
transferred to the print stock. Since gravure printing is often
carried out at high speeds, the gravure ink may contain volatile
organic solvents such as alkyl esters, which dissolve ink binder
components and are rapidly removed during the drying process.
[0010] Accordingly, flexographic ink and gravure ink each have
specific performance requirements related to the different
characteristics of these printing methods. As a result, the inks
and coatings for each application are formulated to meet the
requirements, and this includes the binder components used in
flexographic and gravure inks. Such specific binder components,
which may be designed for one ink type, may be incompatible in
solvent systems of other ink types. This may necessitate the
preparation and storage of two distinct ink systems, and the
expenses attendant thereto.
[0011] While there continues to be a need for an improved
laminating ink and coating in general, there also is a need for a
single binder resin system which can be used to formulate inks and
coatings useful for both flexographic and gravure printing
applications.
[0012] Solvent-borne flexible packaging printing inks are widely
used in the graphic arts industry. Such printing inks are
economical and provide versatility, quality and simplicity. Such
inks permit a roll of material to be printed with multiple colors
in a continuous web at speeds of over 300 meters per minute, and
the printed material can be fed into converting machines for
slitting, forming or laminating. However, these inks must be
formulated in order to insure high bond strength and block
resistance. In addition, solvent-borne flexible packaging inks are
generally not receptive to water-borne primers or adhesives.
[0013] Recent diversification in package bags or containers has
required a high degree of performance for printing inks or coating
agents used for the ornamentation or surface protection. Such inks
or coating agents should exhibit good adhesiveness to various kinds
of plastic films and blocking resistance, and good adaptability for
boiling or retorting treatment. For instance, printing inks for
plastic films are needed to provide improved printability, adhesion
to a wider range of films, and improved blocking resistance and
faster printing speeds when compared to conventional printing ink
formulations.
[0014] Blocking is a problem which may occur when printing on
non-absorbent substrates such as flexible packaging. Blocking
manifests itself as a sticking or transfer of the image to the
underside of the web. Adhesion of the ink to the substrate is a
particularly difficult problem to resolve in the case of
non-absorbent substrates (e.g., flexible packaging). With paper
printing, there is usually no problem of adhesion since the ink is
able to penetrate the paper and thus "grab" the surface. However,
in the case of non-absorbent substrates, adhesion is affected by
chemical and physical bonds. Wetting between the surface of the
substrate and the ink is also a consideration.
[0015] Solvent-based inks represent the bulk of the laminating inks
consumed for packaging. The main resins used in solvent
applications are acrylics, modified acrylics, polyamides, and
urethanes. These soluble resins typically wet out and adhere to the
film surfaces and laminated structures with superior bonds.
[0016] In the manufacture of printing inks, efforts are
continuously made to develop new and improved polymeric
compositions useful as pigment binders in inks for printing a
variety of substrates. In particular, there is demand for those
inks which can be printed or laminated on polyolefin substrates
such as polyethylene, polypropylene or poly(ethylene
terephthalate). These inks must possess a number of qualities to be
commercially useful, including good acetate solubility and
reducibility, and good viscosity stability in solution, among
others.
SUMMARY OF THE INVENTION
[0017] The present disclosure is directed to non-aqueous
dispersions of polymeric hybrid resins of
polyurethane-polyacrylate, polyurethane-urea-polyacrylate, and
polyurea-polyacrylate.
[0018] The polymeric hybrid resins are synthesized by free radical
polymerization in a suitable solvent/medium that includes one or
more ethylenically unsaturated acrylic monomers, such as for
example, (meth)acrylic ester monomers, and a polymer soluble in the
medium that is one or more of a polyurethane, a polyurethane-urea,
and a polyurea. A non-aqueous dispersion system containing the
polymeric hybrid resins is thus produced. Further disclosed are
printing inks, coatings, primers, and overprint varnishes that
include the non-aqueous dispersions, and/or the polymeric hybrid
resins isolated therefrom, and/or the hybrid resins transferred to
another solvent medium. Such materials can be used as binders in
the printing inks, coatings, etc., and are well suited for use in
flexographic and gravure printing processes. When included in an
ink and/or coating composition, the presence of the non-aqueous
dispersions in the inks, coatings, etc. improve film adhesion,
which is beneficial for printing applications where good bond
strength exhibited in adhesive lamination is required. Such
applications include plastic film packaging applications.
[0019] The printing inks, coatings, etc. may be printed on
substrates such as polyolefin (e.g., polyethylene, polypropylene)
and poly(ethylene terephthalate) (PET), and other substrate
materials. Printing may be by way of the gravure and flexographic
printing processes. The solvent mediums may be, for example,
esters, ketones, and mixtures thereof.
[0020] In another aspect of the present disclosure, described
herein are polymeric films comprising polymeric hybrid resins of
polyurethane-polyacrylate, a polyurethane-urea-polyacrylate, and a
polyurea-polyacrylate. In still another aspect, the polymeric films
derive from the non-aqueous dispersions, e.g., by separating the
medium from the hybrid resin, to produce a film comprised of the
polymeric hybrid resins. In a still further aspect, the separation
may include the removal of the medium by drying with or without
heat. Such films may be used in printing inks, coatings, etc. The
films may be incorporated into another solvent medium, which also
be used in in printing inks, coatings, etc.
[0021] In another aspect of the present disclosure, described
herein are ink-, coating-, primer-, or overprint
varnish-compositions (collectively, "compositions"), comprising the
described non-aqueous dispersions and/or polymeric films. The
compositions may further comprise one or more of a solvent and a
colorant.
[0022] In still another aspect of the present disclosure, described
herein is a multilayer structure comprising:
[0023] a substrate, optionally having a primer layer applied
thereto;
[0024] a plurality of ink layers; and
[0025] optionally, an overprint varnish layer, wherein one or more
of the ink layers, optional primer layer, and optional overprint
varnish layer comprise the compositions that include the
non-aqueous dispersions described herein. The multilayer structure
may further include a second substrate positioned over the
plurality of ink layers. The multilayer structure may further
include a curing component, and the multilayer structure may be
cured by actinic radiation.
[0026] In yet still another aspect of the present disclosure,
described herein is a multilayer laminated structure
comprising:
[0027] a substrate;
[0028] a top laminate layer; and
[0029] intermediate layers between the substrate and top laminate
layer, comprising: [0030] an optional primer layer applied to the
substrate; [0031] a plurality of ink layers; and [0032] an optional
overprint varnish layer; [0033] wherein one or more of intermediate
layers comprise the compositions that include the non-aqueous
dispersions described herein.
[0034] In another aspect, the multilayer laminated structure
includes a top laminate layer that is a layer of molten resin
extruded onto the intermediate layers. The multilayer laminated
structure may further include an adhesive layer applied over the
intermediate layers, wherein the top laminate layer comprises a
plastic film applied over the adhesive layer. The multilayer
laminated structure may further include a second substrate
positioned over the plurality of ink layers. The multilayer
laminated structure may further include a curing component, and the
multilayer structure may be cured by actinic radiation.
DETAILED DESCRIPTION OF THE INVENTION
[0035] In one inventive aspect, non-aqueous dispersions are
produced that include a solvent/medium comprising polymeric hybrid
resins that are the products of a polymerization reaction in the
solvent/medium between a polymer soluble in the medium that is one
or more of a polyurethane, a polyurethane-urea, and a polyurea and
one or more ethylenically unsaturated acrylic monomers, oligomers,
or polymers. Such one or more ethylenically unsaturated acrylic
monomers, oligomers, or polymers may be, for example, one or more
unsaturated acrylic or (meth)acrylic ester monomers. Free radical
polymerization may be the mechanism of polymerization in the
solvent/medium, in which case polymerization may be initiated by
introducing a peroxy initiator into the solvent/medium that
contains the reaction components. The hybrid resin of polyurethane,
polyurethane-urea, polyurea and polymerized acrylate preferably
comprises about 30 wt % to about 40 wt % polyurethane,
polyurethane-urea, or polyurea. Preferably, such hybrid resins have
number average molecular weights (Mn) of about 1,000 Daltons to
about 200,000 Daltons, preferably about 2,000 Daltons to about
100,000 Daltons, and most preferably about 5,000 Daltons to about
20,000 Daltons.
[0036] In one aspect of the present disclosure, the ratio of the
polyurethane, polyurethane-urea, or polyurea to acrylate polymer in
the hybrid resins is, on a molar basis, 10/90 to 90/10, more
preferably, 25/75 to 50/50, and most preferably, 30/70 to
40/60.
[0037] In another aspect of the present disclosure, described
herein are polymeric films comprising a hybrid polymer produced by
copolymerization of an acrylate with a polymer selected from a
polyurethane-polyacrylate, a polyurethane-urea-polyacrylate, and a
polyurea-polyacrylate. Such films may be comprised of the hybrid
resins produced in the non-aqueous medium by separating same from
the solvent/medium, thereby producing a film comprised of the
hybrid resin.
[0038] In another aspect of the present disclosure, the molecular
weights of the non-aqueous dispersions containing the hybrid
polymers are sufficiently high to allow for the formation of
coherent films that can be used as a laminating adhesive. Number
average molecular weights (Mn) may be about 1,000 Daltons to about
200,000 Daltons, preferably about 2,000 Daltons to about 100,000
Daltons, and most preferably about 5,000 Daltons to about 20,000
Daltons.
[0039] The non-aqueous dispersions and films of the hybrid polymers
described herein are suited for inclusion in inks, coatings,
primers, and overprint varnish compositions. In particular,
non-aqueous dispersions and films of the hybrid polymers are well
suited for use in printing inks used in the methods exemplified by:
flexographic, gravure, digital, rod, curtain, cascade, roll, slot,
spray processes, and combinations thereof. In particular, they are
well-suited for inclusion in flexographic and gravure printing
inks. Since the hybrid polymer compositions described herein
exhibit improved film adhesion, the non-aqueous dispersions and
films of the hybrid polymers are particularly well-suited for
inclusion in inks used in printing items where good adhesive
lamination bond strengths are a consideration, such as, for
example, plastic films packaging applications.
[0040] In one aspect of the polymer systems described herein, where
the hybrid polymer produced in the non-aqueous dispersion is the
product of an acrylate and a polyurethane-urea polymer that is
soluble in the medium, the polyurethane-urea polymer may be the
reaction product of: (a) a diisocyanate component; (b) a diol
component having (i) a first diol having a molecular weight
preferably below 2000; and (ii) a polymeric diol having a molecular
weight preferably below 3000; and (c) a diamine based on the
equivalents of the unreacted NCO groups; whereby the resulting
polyurethane-urea resin is soluble in organic solvent, such as, for
example, n-propyl acetate, n-propanol, and mixtures thereof. During
the co-polymerization in the solvent medium, heat is added and a
free radical polymerization reaction between the polyurethane-urea
polymer and the acrylic monomers takes place in the presence of
peroxyester initiators to produce hybrid
polyurethane-urea-polyacrylate resin within the non-aqueous
dispersion. The hybrid polymer systems described herein may be used
in solvent-based laminating inks, in flexographic inks, and in
gravure inks.
[0041] In another aspect of the present disclosure, described is a
solvent-based laminating ink useful in flexographic and/or gravure
printing comprising the hybrid polyurethane-urea-polyacrylate resin
described above, present in a non-aqueous dispersion or as a film,
and one or more solvents, preferably organic solvents. Optionally,
the laminating inks include a colorant.
[0042] In one aspect of the present disclosure, the solvent/medium
in which the polymerization of the hybrid polymers takes place is a
polar non-aqueous solvent/medium such as, for example, esters,
ketones, and mixtures thereof. The acrylate monomers and the
polyurethane, polyurethane-urea or polyurea are soluble in the
selected solvent medium. In another aspect, the solvent/medium is
chosen from n-propyl acetate, ethyl acetate, n-butyl acetate,
n-hexyl acetate, methyl ethyl ketone; methyl isobutyl ketone, and
mixtures thereof.
[0043] In yet another aspect of the present disclosure, described
is a method for printing an image on a polymeric substrate
comprising: (a) printing the laminating or surface printing inks
described herein onto a surface of the polymeric substrate as an
image; and (b) drying the image, whereby a tack-free image is
formed. The image is firmly adhered to the substrate and un-blocked
when contacted under pressure at ambient temperatures to a second
surface of the substrate.
[0044] The solubility of the polyurethane, polyurethane-urea, and
polyurea resins in ester and alcohol/ester solvents/mediums allows
for the formulation of a versatile ink or coating composition,
e.g., usable in both flexographic and gravure applications, with
only minor formulation modifications. The described polymeric
hybrid resins of polyurethane-polyacrylate,
polyurethane-urea-polyacrylate, and polyurea-polyacrylate formed
during polymerization are preferably stable in the medium, e.g.,
discreet layers do not form in the medium. Discreet layers, such as
a layer of solid and a layer of liquid, evidence an absence of
stability. The non-aqueous dispersions described herein exhibit a
positive Tyndall effect, which is evidence of a dispersion
comprised of particles of the polymeric hybrid resins that may have
some degree of solubility in the medium (e.g., partial
insolubility), or the particles may be fully insoluble in the
medium.
[0045] Preferably, the medium is an organic medium in which the
starting polyurethane, polyurethane-urea and polyurea are soluble.
Examples of such mediums comprise, for example, esters, ketones,
alcohols, and mixtures thereof, such as the mixture of an alcohol
and an ester. Such non-aqueous dispersions are particularly useful
in formulating packaging laminating inks. The polymeric hybrid
resins formed in the medium are insoluble therein, or only
partially soluble (e.g., partially insoluble).
[0046] The hybrid resins disclosed herein, whether in the
non-aqueous dispersion or as a film coating can be formulated into
an ink composition without adjuvants; without grinding same in
polyvinyl butyral; and/or without blending same into a
nitrocellulose base, e.g., a pigment dispersed with nitrocellulose
in organic solvent and ground to a desired particle size.
Laminating or surface printing inks and coating compositions formed
with the non-aqueous dispersions of hybrid resins or coatings of
hybrid resins exhibit excellent lamination bond strengths, low
tack, block resistance, printability, and superior adhesion on a
wide variety of films (substrates) compared to laminating inks and
coatings made with conventional and commercially available resin
binder systems.
Polyurethane Resin-Based Hybrid Polymers
[0047] In one aspect of the present disclosure, the non-aqueous
dispersion includes a hybrid polymer that is the reaction product
of a polyurethane resin that is soluble in the medium and one or
more ethylenically unsaturated acrylates, wherein the
solvent-soluble polyurethane resin derives from the condensation of
di-isocyanate (e.g., having NCO groups), and approximately
equimolar quantities of a di-alcohol or a mixture of di-alcohols.
The resulting polyurethane resin has the structure:
-(-A-NH--CO--O--R.sub.2--O--CO--NH--).sub.n-A-NH--CO--O--R.sub.2--O--CO--
-NH-A-
where A is an aryl or alkyl group; R.sub.2 comprises R.sub.3 and
R.sub.4, wherein R.sub.3 is an alkyl or a polymeric group having a
molecular weight below 2000, and wherein R.sub.4 is a polymeric
group having a molecular weight below 3000 and n has the value of 1
or 2. Typically, the molecular weight of R.sub.3 is less than the
molecular weight of R.sub.4, and the molar ratio of R.sub.4 to
R.sub.3 ranges between about 90:10 and about 10:90. A preferred
ratio of R.sub.4 to R.sub.3 is about 55:45. Preferably, the resin
has a number average molecular weight between about 1,000 and about
60,000 Daltons.
Polyurethane-Urea Resin-Based Hybrid Polymers
[0048] In one aspect of the present disclosure, the non-aqueous
dispersion includes a hybrid polymer that is the reaction product
of a polyurethane-urea resin that is soluble in the medium and one
or more ethylenically unsaturated acrylates, wherein the
solvent-soluble polyurethane-urea resin derives from the
condensation of polyurethane pre-polymer preferably containing 1.3
to 6.0 wt % of unreacted isocyanate (i.e., NCO) groups, and 80% to
120% of a diamine based on the equivalents of the unreacted NCO
groups. The resulting polyurethane-urea resin has the
structure:
NH.sub.2--R.sub.1--NH--CO--NH(--U--NH--CO--NH--R.sub.1--NH--CO--NH--).su-
b.m--U--NH--CO--NH--R.sub.1--NH.sub.2
wherein R.sub.1 is a covalent bond or a C.sub.1-C.sub.10 alkyl
group, m is 2-4 and --U-- has the structure:
-(-A-NH--CO--O--R.sub.2--O--CO--NH-).sub.n-A-NH--CO--O--R.sub.2--O--CO---
NH-A-
wherein -A- is an aryl or alkyl group; R.sub.2 comprises R.sub.3
and R.sub.4, wherein R.sub.3 is an alkyl or a polymeric group
having a molecular weight below 2000, and wherein R.sub.4 is a
polymeric group having a molecular weight below 3000 and n has the
value of 1 or 2. Typically, the molecular weight of R.sub.3 is less
than the molecular weight of R.sub.4, and the molar ratio of
R.sub.4 to R.sub.3 ranges between about 90:10 and about 10:90. A
preferred ratio of R.sub.4 to R.sub.3 is about 55:45. Preferably,
the resin has a number average molecular weight between about
10,000 and about 80,000. A solvent soluble polyurethane-urea resin
is described in U.S. Pat. No. 6,723,820, incorporated herein by
reference. This polyurethane-urea resin is PUC, used in at least
some of the examples, infra, of the present disclosure.
Polyurea Resin-Based Hybrid Polymers
[0049] In one aspect of the present disclosure, the non-aqueous
dispersion includes a hybrid polymer that is the reaction product
of a polyurea resin that is soluble in the medium and one or more
ethylenically unsaturated acrylates, wherein the polyurea resin
derives from the condensation of di-isocyanate (i.e., NCO) groups,
and approximately equimolar quantities of a diamine or diamines.
The diamine in this case generally should be more flexible to
remain non-crystalline and soluble in a solvent. The resulting
polyurea resin has the structure:
NH.sub.2--R.sub.1(--NH--CO--NH--R.sub.2--NH--CO--NH--).sub.x--R.sub.1--N-
H.sub.2
wherein R.sub.1 is a covalent bond or a C.sub.1-C.sub.10 alkyl
group or an ethylene glycol or propylene glycol or a combination
thereof with a repeat length of 1 to 20 units, and x is 5-100.
Suitable diamines used to make the polyurea are available from
Huntsman Chemicals under the trade names Jeffamine.RTM. Diamines,
such as, for example, the D, ED, and EDR series.
[0050] The non-aqueous dispersions described herein can be prepared
using pre-formed resins of polyurethane, polyurethane-urea or
polyurea added to an organic solvent/medium as soluble feedstock. A
free radical polymerizable monomer, such as acrylate and
(meth)acrylate monomers, and a suitable initiator component such as
a peroxy initiator may then be added to the solution to produce a
hybrid polyurethane-polyacrylate, polyurethane-urea-polyacrylate or
polyurea-polyacrylate hybrid resin present in a non-aqueous
dispersion.
[0051] Examples of suitable ethylenically unsaturated acrylate
monomers that may be co-polymerized with the polyurethane,
polyurethane-urea, or polyurea resins include monofunctional
ethylenically unsaturated acrylate and (meth)acrylate monomers such
as: isobutyl acrylate; cyclohexyl acrylate; iso-octyl acrylate;
n-octyl acrylate; isodecyl acrylate; iso-nonyl acrylate;
octyl/decyl acrylate; lauryl acrylate; 2-propyl heptyl acrylate;
tridecyl acrylate; hexadecyl acrylate; stearyl acrylate;
iso-stearyl acrylate; behenyl acrylate; tetrahydrofurfuryl
acrylate; 4-t.butyl cyclohexyl acrylate; 3,3,5-trimethylcyclohexane
acrylate; isobornyl acrylate; dicyclopentyl acrylate;
dihydrodicyclopentadienyl acrylate; dicyclopentenyloxyethyl
acrylate; dicyclopentanyl acrylate; benzyl acrylate; phenoxyethyl
acrylate; 2-hydroxy-3-phenoxypropyl acrylate; alkoxylated
nonylphenol acrylate; cumyl phenoxyethyl acrylate; cyclic
trimethylolpropane formal acrylate; 2(2-ethoxyethoxy) ethyl
acrylate; polyethylene glycol monoacrylate; polypropylene glycol
monoacrylate; caprolactone acrylate; ethoxylated methoxy
polyethylene glycol acrylate; methoxy triethylene glycol acrylate;
tripropyleneglycol monomethyl ether acrylate; diethylenglycol butyl
ether acrylate; alkoxylated tetrahydrofurfuryl acrylate;
ethoxylated ethyl hexyl acrylate; alkoxylated phenol acrylate;
ethoxylated phenol acrylate; ethoxylated nonyl phenol acrylate;
propoxylated nonyl phenol acrylate; polyethylene glycol o-phenyl
phenyl ether acrylate; ethoxylated p-cumyl phenol acrylate;
ethoxylated nonyl phenol acrylate; alkoxylated lauryl acrylate;
ethoxylated tristyrylphenol acrylate;
N-(acryloyloxyethyl)hexahydrophthalimide; N-butyl 1,2 (acryloyloxy)
ethyl carbamate; acryloyl oxyethyl hydrogen succinate;
octoxypolyethylene glycol acrylate; octafluoropentyl acrylate;
2-isocyanato ethyl acrylate; acetoacetoxy ethyl acrylate;
2-methoxyethyl acrylate; dimethyl aminoethyl acrylate;
2-carboxyethyl acrylate; 4-hydroxy butyl acrylate, the
(meth)acrylates thereof; and combinations thereof.
[0052] Multifunctional ethylenically unsaturated acrylate and
(meth)acrylate monomers may also be used, such as, for example:
1,3-butylene glycol diacrylate; 1,4-butanediol diacrylate;
neopentyl glycol diacrylate; ethoxylated neopentyl glycol
diacrylate; propoxylated neopentyl glycol diacrylate;
2-methyl-1,3-propanediyl ethoxy acrylate; 2-methyl-1,3-propanediol
diacrylate; ethoxylated 2-methyl-1,3-propanediol diacrylate; 3
methyl 1,5-pentanediol diacrylate; 2-butyl-2-ethyl-1,3-propanediol
diacrylate; 1,6-hexanediol diacrylate; alkoxylated hexanediol
diacrylate; ethoxylated hexanediol diacrylate; propoxylated
hexanediol diacrylate; 1,9-nonanediol diacrylate; 1,10 decanediol
diacrylate; ethoxylated hexanediol diacrylate; alkoxylated
hexanediol diacrylate; diethyleneglycol diacrylate; triethylene
glycol diacrylate; tetraethylene glycol diacrylate; polyethylene
glycol diacrylate; propoxylated ethylene glycol diacrylate;
dipropylene glycol diacrylate; tripropyleneglycol diacrylate;
polypropylene glycol diacrylate; poly (tetramethylene glycol)
diacrylate; cyclohexane dimethanol diacrylate; ethoxylated
cyclohexane dimethanol diacrylate; alkoxylated cyclohexane
dimethanol diacrylate; polybutadiene diacrylate; hydroxypivalyl
hydroxypivalate diacrylate; tricyclodecanedimethanol diacrylate;
1,4-butanediylbis[oxy(2-hydroxy-3,1-propanediyl)]diacrylate;
ethoxylated bisphenol A diacrylate; propoxylated bisphenol A
diacrylate; propoxylated ethoxylated bisphenol A diacrylate;
ethoxylated bisphenol F diacrylate; 2-(2-Vinyloxyethoxy)ethyl
acrylate; dioxane glycol diacrylate; ethoxylated glycerol
triacrylate; glycerol propoxylate triacrylate; pentaerythritol
triacrylate; trimethylolpropane triacrylate; caprolactone modified
trimethylol propane triacrylate; ethoxylated trimethylolpropane
triacrylate; propoxylated trimethylol propane triacrylate; tris
(2-hydroxy ethyl) isocyanurate triacrylate; e-caprolactone modified
tris (2-hydroxy ethyl) isocyanurate triacrylate; melamine acrylate
oligomer; pentaerythritol tetraacrylate; ethoxylated
pentaerythritol tetraacrylate; di-trimethylolpropane tetra
acrylate; dipentaerythritol pentaaacrylate; dipentaerythritol
hexaaacrylate; ethoxylated dipentaerythritol hexaacrylate; the
(meth)acrylates thereof; and combinations thereof.
[0053] Other functional monomer types that are capable of being
used in part in the formulations include cyclic lactam such as
N-vinyl caprolactam; N-vinyl oxazolidinone and N-vinyl pyrrolidone,
and secondary or tertiary acrylamides such as acryloyl morpholine;
diacetone acrylamide; N-methyl acrylamide; N-ethyl acrylamide;
N-isopropyl acrylamide; N-t.butyl acrylamide; N-hexyl acrylamide;
N-cyclohexyl acrylamide; N-octyl acrylamide; N-t.octyl acrylamide;
N-dodecyl acrylamide; N-benzyl acrylamide;
N-(hydroxymethyl)acrylamide; N-isobutoxymethyl acrylamide;
N-butoxymethyl acrylamide; N,N-dimethyl acrylamide; N,N-diethyl
acrylamide; N,N-propyl acrylamide; N,N-dibutyl acrylamide;
N,N-dihexyl acrylamide; N,N-dimethylamino methyl acrylamide;
N,N-dimethylamino ethyl acrylamide; N,N-dimethylamino propyl
acrylamide; N,N-dimethylamino hexyl acrylamide; N,N-diethylamino
methyl acrylamide; N,N-diethylamino ethyl acrylamide;
N,N-diethylamino propyl acrylamide; N,N-dimethylamino hexyl
acrylamide; and N,N'-methylenebisacrylamide, and combinations
thereof.
[0054] In one aspect of the present disclosure, the ratio of the
polyurethane, polyurethane-urea, or polyurea to acrylate polymer in
the hybrid resins is, on a molar basis, 10/90 to 90/10, more
preferably, 25/75 to 50/50, and most preferably, 30/70 to
40/60.
[0055] While not being bound by any theory, since the polyurethane,
polyurethane-urea, and polyurea parent polymers are soluble and
stable in the solvent/medium used for the polymerization, it seems
that an interaction, such as a grafting reaction, occurs between
the ethylenically unsaturated acrylates and parent polymers of
solvent-soluble polyurethane, polyurethane-urea, and polyurea, or
the interaction may be another unknown effect. In any event, the
resulting hybrid resins are at least partially insoluble (and
possibly fully insoluble) in the non-aqueous dispersion. The
partial insolubility can be readily observed in some samples as a
stable milky-white fluid. In other cases, particles can be observed
in an otherwise clear solution when a laser light is passed through
the sample. This is known as the Tyndall effect, or Tyndall
scattering. The Tyndall effect is light scattered by particles in a
colloid or particles in a fine suspension. The Tyndall effect is
used to determine the size and density of particles in aerosols and
other colloidal matter. In laboratory environments, a hand held
laser pointer can be used as the source to identify particles in
(an apparent) solution. In one aspect, the non-aqueous dispersions
of the present disclosure exhibit positive Tyndall effects,
evidencing a dispersion of at least partially insoluble particles,
which particles may be microparticles, e.g., having sizes
expressible in micrometers.
[0056] Non-aqueous dispersions prepared in accordance with the
present invention may be transferred to a second non-aqueous
medium, e.g., a non-aqueous medium that is different from the
non-aqueous medium in which the dispersions are prepared. Examples
of solvents to which the polar functional non-aqueous dispersions
can be transferred include alcohols such as, for example, ethanol,
n-propanol, isopropanol, and n-butanol; esters such as, for
example, n-butyl acetate, n-hexyl acetate, and pentyl propionate;
ethers such as, for example, the monoethyl, monobutyl and monohexyl
ethers of ethylene glycol; ketones such as, for example, methyl
ethyl ketone methyl isobutyl ketone, and diisobutyl ketone;
aromatic hydrocarbons such as, for example, xylene and toluene; and
mixtures thereof. For use in energy cure coating/printing
applications, the non-aqueous dispersions prepared in accordance
with the present invention may be transferred to a second
non-aqueous medium, e.g., a non-aqueous medium that is different
from the non-aqueous medium in which the dispersions are prepared.
This includes multi-ethylenically unsaturated acrylates such as
those listed above; monofunctional ethylenically unsaturated
monomers such as those listed above; and other functional monomer
classes such as those listed above; and oligomers described as
multi-ethylenically unsaturated acrylates having repeat backbone
units, such as polyester acrylates, polycarbonateacrylates,
urethane acrylates, and epoxy acrylates and mixtures and the
like.
[0057] Transfer to a different medium can be achieved by a variety
of methods, for example, by spray-drying, freeze-drying,
coagulation, or centrifugation of the original non-aqueous medium
followed by re-dispersion of the polymeric material, e.g., the
polymeric hybrid resins, in the new medium. In one particular
aspect, transfer of the polymeric material to the new medium is
accomplished by adding a different organic medium to the original
non-aqueous dispersion and then removing the original solvent
medium by distillation, thereby forming a new aqueous dispersion
medium comprised of the polymeric material dispersed in the
different organic medium. All of these methods are well understood
by those skilled in the art and will not be discussed in detail
here.
Solvent-Based Laminating Ink
[0058] The solvent-based laminating or surface printing ink of the
present invention comprises the non-aqueous dispersion described
herein, e.g., a non-aqueous dispersion comprising the polymeric
hybrid resins selected from polyurethane-polyacrylate,
polyurethane-urea-polyacrylate, and polyurea-polyacrylate in a
non-aqueous medium; optionally a colorant; and an organic solvent.
More than one such non-aqueous dispersion, such as a combination of
polyurethane-polyacrylate and polyurethane-urea-polyacrylate
non-aqueous dispersions may be present in an ink, or one of the
aforedescribed non-aqueous dispersions may be present with another
kind of non-aqueous dispersion in an ink. The ink system of the
present invention has a unique characteristic in that it may be
used in either flexographic or gravure printing by making
relatively minor adjustments to the formulation (e.g. adjusting the
solvent and viscosity). In particular, the ink of the present
invention comprises, based on the weight of the ink: about 15 wt %
to about 50 wt % of the hybrid resin; about 6 wt % to about 30 wt %
of the colorant; and about 10 wt % to about 60 wt % of organic
solvent. Component concentrations may be adjusted for use in
flexography or gravure printing.
Method of Printing a Laminating Ink
[0059] In one aspect of the present disclosure, the laminating or
surface printing ink as described is image-wise printed onto a
surface of a polymeric substrate, thereby forming a dried ink image
which is tack-free and is firmly adhered to the surface of the
substrate, and un-blocked when contacted under pressure at ambient
conditions to a second surface of the substrate.
[0060] Although any polymeric substrate may be printed with this
method, preferred polymeric substrates include, in sheet form,
polyethylene, polypropylene, orientated polypropylene (OPP),
orientated polystyrene (OPS), polyethylene terephthalate (PET),
glycol-modified polyethylene terephthalate (PET-G), polylactic acid
(PLA) cellulose acetate, cellulose acetate butyrate, polycarbonate,
polyamide, polyvinylidene chloride (PVDC) coated polyethylene
terephthalate, PVDC coated polypropylene, metallized polyethylene
terephthalate, or metallized polypropylene. Particularly preferred
film substrates used for lamination are oriented polypropylene and
treated polyester films.
[0061] In a preferred embodiment of the present invention, a second
substrate may be applied or laminated onto the dried ink image on
the first substrate by any conventional method. Thus, the second
substrate may be applied as an extruded melt onto the dried image
to form the second substrate; or a preformed second substrate may
be laminated to the dried ink image through an adhesive layer. The
second substrate may be composed of the same material as the first
substrate or it may be different, depending on the nature of the
end use of the printed laminate. In one embodiment, the second
substrate is a polyethylene.
Colorant
[0062] The inks of this invention contain one or more colorants
such as soluble dyes, pigments or mixtures thereof. Such inks
typically contain one or more pigments dispersed therein. The
pigment may be any conventional organic or inorganic pigment such
as Pigment Yellow 1, Pigment Yellow 3, Pigment Yellow 12, Pigment
Yellow 13, Pigment 14, Pigment Yellow 17, Pigment Yellow 63,
Pigment Yellow 65, Pigment Yellow 73, Pigment Yellow 74, Pigment
Yellow 75, Pigment Yellow 83, Pigment Yellow 97, Pigment Yellow 98,
Pigment Yellow 106, Pigment Yellow 114, Pigment Yellow 121, Pigment
Yellow 126, Pigment Yellow 127, Pigment Yellow 136, Pigment Yellow
174, Pigment Yellow 176, Pigment Yellow 188, Pigment Orange 5,
Pigment Orange 13, Pigment Orange 16, Pigment Orange 34, Pigment
Red 2, Pigment Red 9, Pigment Red 14, Pigment Red 17, Pigment Red
22, Pigment Red 23, Pigment Red 37, Pigment Red 38, Pigment Red 41,
Pigment Red 42, Pigment Red 112, Pigment Red 170, Pigment Red 210,
Pigment Red 238, Pigment Blue 15, Pigment Blue 15:1, Pigment Blue
15:2, Pigment Blue 15:3, Pigment Blue 15:4, Pigment Green 7,
Pigment Green 36, Pigment Violet 23, Pigment Black 7, titanium
dioxide, carbon black, and the like. The classes of dyes suitable
for use in present invention are selected from acid dyes, natural
dyes, direct dyes either cationic or anionic direct dyes, basic
dyes, and reactive dyes. The acid dyes, also regarded as anionic
dyes, are soluble in water and mainly insoluble in organic solvents
and are selected, from yellow acid dyes, orange acid dyes, red acid
dyes, violet acid dyes, blue acid dyes, green acid dyes, and black
acid dyes. European Patent 0 745 651, incorporated herein by
reference, describes a number of acid dyes which are suitable for
use in the present invention.
[0063] The yellow acid dyes selected include Acid Yellow 1 (CI.
10316); Acid Yellow 7 (CI. 56205); Acid Yellow 17 (CI. 18965); Acid
Yellow 23 (CI. 19140); Acid Yellow 29 (CI. 18900); Acid Yellow 36
(CI. 13065); Acid Yellow 42 (CI. 22910); Acid Yellow 73 (CI.
45350); Acid Yellow 99 (CI. 13908); Acid Yellow 194; and Food
Yellow 3 (CI. 15985). The orange acid dyes selected include Acid
Orange 1 (CI. 13090/1); 35 Acid Orange 10 (CI. 16230); Acid Orange
20 (CI. 14603); Acid Orange 76 (CI. 18870); Acid Orange 142; Food
Orange 2 (CI. 15980); and Orange B. The red acid dyes selected
include Acid Red 1 (CI. 18050); Acid Red 4 (CI. 14710); Acid Red 18
(CI. 16255); Acid Red 26 (CI. 16150); Acid Red 27 (CI. 16185);
BASOVIT.TM. 425E (available from BASF Corporation) a Xanthone based
acid dye also known as Acid Red 51 (CI. 45430); Acid Red 52 (CI.
45100); Acid Red 73 (CI. 27290); Acid Red 87 (CI. 45380); Acid Red
94 (CI. 45440); Acid Red 194; and Food Red 1 45 (CI. 14700). The
violet acid dyes selected include Acid Violet 7 (CI. 18055); and
Acid Violet 49 (CI. 42640). The blue acid dyes selected include
Acid Blue 1 (CI. 42045); Acid Blue 9 (CI. 42090); Acid Blue 22 (CI.
42755); Acid Blue 74 (CI. 73015); Acid Blue 93 (CI. 42780); and
Acid Blue 158A (CI. 15050). The green acid dyes selected include
Acid Green 1 (CI. 10028); Acid Green 3 (CI. 42085); Acid Green 5
(CI. 42095); Acid Green 26 (CI. 44025); and Food Green 3 (CI.
42053). The black acid dyes selected include Acid Black 1 (CI.
20470); Acid Black 194 55 (BASANTOL.TM. X80, available from BASF
Corporation, an azo/1:2 CR-complex also known as. The direct dyes
selected for use in the present invention include Direct Blue 86
(CI. 74180), Direct Red 199, Direct Red 168, Direct Red 253 (CI.
Not Assigned) and Direct Yellow 107/132 (C.I. Not Assigned). The
direct dyes are commonly used in coloration of pulp paper. The
natural dyes selected for use in the present invention include
Alkanet (C.I. 75520,75530); Annatto (CI. 75120); Carotene (CI.
75130); Chestnut; Cochineal (CI. 75470); 65 Cutch (CI. 75250,
75260); Divi-Divi; Fustic (CI. 75240); Hypernic (CI. 75280);
Logwood (CI. 75200); Osage Orange (CI. 75660); Paprika; Quercitron
(CI. 75720); Sanrou (CI. 75100); Sandal Wood (CI. 75510, 75540,
75550, 75560); Sumac; and Turmeric (CI. 75300).
[0064] The reactive dyes selected for use in the present invention
include Reactive Yellow 37 (monoazo dye); Reactive Black 31 (bisazo
dye); Reactive Blue 77 (phthalocyanine dye) and Reactive Red 180
and Reactive Red 108 dyes. Acid dyes such as, for example, Acid
Black 194; Acid Red 51, Acid Blue 9; Acid Green 26; Acid Yellow 36,
Acid Orange 142, Direct Blue 86, Direct Red 253 and Direct Yellow
107/132 dyes may be preferred dyes.
Organic Solvent
[0065] A number of organic solvents may be used in conjunction with
formulating the laminating or surface printing inks of the present
invention. Useful organic solvents include ester solvents such as,
for example, ethyl acetate and n-propyl acetate; and polar solvents
such as, for example, ester/alcohol mixtures. Alcohols may be used
as the solvent, such as, for example, ethanol, n-propanol, and
glycols such as, for example, ethylene glycol. Preferably, the
ink-formulating solvent is similar to or the same as the process
solvent described supra in connection with the preparation of the
hybrid resins.
Adjuvants
[0066] The solvent based laminating or surface printing inks of the
present invention may further contain additives known in the art
that are used to modify flow, surface tension, gloss, flow, pigment
wetting and abrasion resistance of the cured coating or printed
ink. Such additives contained in inks or coatings typically are
surface-active agents, waxes, shelf-life stabilizers, etc. and
combinations thereof. These additives may function as leveling
agents, shelf-life stabilizers, wetting agents, slip agents, flow
agents, dispersants and de-aerators. Preferred additives include
fluorocarbon surfactants, silicones and organic polymer
surfactants. Examples include the Tegorad product lines (Tegorad
are trademarks and are commercially available products of Tego
Chemie, Essen, Germany) and the Solsperse product lines (Solsperse
are trademarks and are commercially available products of Lubrizol
Company).
EXAMPLES
Method of Molecular Weight Determination:
[0067] The molecular weights and polydispersity values were
measured via Gel Permeation Chromatography (GPC) using a Waters 515
HPLC Pump equipped with a Waters 2410 refractive index detector
with Waters Millennium chromatography software, version 3.0, and a
Phenogel GPC 4 column set 300.times.7.8 mm OD, 5 particle size and
pore sizes of 100 .ANG., 500 .ANG., 10{circumflex over ( )}3 .ANG.
and 10{circumflex over ( )}4 .ANG.. All samples were prepared as
follows: a 2% solution is made by weighing approximately 0.2 g in
10 mL of THE in a 20 mL clear borosilicate vial. The vial and
contents are mixed on a Titer Plate Shaker for 20 minutes at
ambient temperature and then allowed to stand for 24 hours. Two to
five mL is then filtered through a 0.45 m Millipore Filter. Fifty
(50) L is injected. As used herein, "polydispersity" or
"dispersity" is the measure of the broadness of a molecular weight
distribution of a polymer. It is calculated as Mw/Mn, wherein Mw is
the weight average molecular weight of the polymer, and Mn is the
number average molecular weight of the polymer.
Method of Determining Tack:
[0068] Tack was measured with a calibrated Electronic Inkometer
(Thwing-Albert Instrument Co.). The material is metered to one
milliliter of fluid drawn up into a syringe and placed onto the top
rubber roller of the inkometer. The inkometer is turned `on` to
start the rollers rotating and the tack value reported is the
maximum value reached. The inkometer is operating at 90.degree. F.
and 180 rpm.
Method of Making Ink:
[0069] In a grounded container a cyan based (Sun Chemical
nitrocellulose base 52217-0310) cyan pigment base and hybrid
polymer/polyurethane resin were mixed in a Dispermat-FT (VMA
Getzmann GMBH) at 1000-1500 rpm for 3 minutes. N-propyl acetate
solvent was added and the batch was further mixed at 1000 rpm for 1
minute, after which the viscosity was measured with a Zahn #2 cup
(ASTM, Paul H. Gardner, Co. Pompano Beach, Fla.). Subsequent
additions of solvent were mixed in the same manner until press
viscosity of between 25 and 29 seconds with a Zahn #2 is
achieved.
Method of Determining the Adhesive Lamination Bond Strength:
[0070] Substrate films were printed with #8 Meyer rod and dried at
80.degree. C. for 15 seconds. Polymer solutions were all proofed at
30% solids. Polypropylene [AET 523-3] and polyethylene
terephthalate [Papertec, Garfield, N.J.] films were used as
substrates for printing. A thin layer of adhesive was applied over
the print with a #8 Meyer bar and dried at 80.degree. C. for 15
seconds. The adhesive is a mixture of 40.7% Adcote 577 and 2.6%
Adcote 577B and 57.1% ethyl acetate. A polyethylene film was
laminated over the print with a Hot Roll Laminator
[Cheminstruments, Fairfield, Ohio] at room temperature and 40 psi.
The laminated structures were allowed to sit for a minimum of 24
hours at room temperature before testing bond strength. The
structure was cut into sample strips measuring one inch wide and
the 180 degree peel force required to cause delamination was
determined using an Instron Tensile Tester 3342 [825 University
Ave., Norwood, Mass. 02062-2643]. The sample undergoing testing was
placed in the jaws of the Instron. The sample was held at a right
angle to the moving jaw and the sample was pulled apart at 300
mm/min. Values for lamination bond strength are recorded, and the
procedure is repeated, and an average value is reported. The value
has units of g/linear inch. A higher number is an indication of the
strength of the lamination bond.
Method of Determining the Tyndall Effect
[0071] An 8 oz. sample jar is filled with the polymerized hybrid
resin in the solvent medium and the jar is capped. A laser
(deep-red color, about 650 nm) is passed through the solvent
medium. Particles, if present, will scatter the laser light. This
is indicative of a positive Tyndall effect result. If the jar
contained a solution, then the light would pass cleanly through the
solution, providing a negative Tyndall effect result.
Press Trial
[0072] A flexographic unit on the Chesnut press (Richard Chesnut
Co. Fairfield, N.J.) was used to print onto Corona treated
polyethylene terephthalate or polypropylene substrate (25 cm
width). The print unit had an open chamber doctor blade system and
ceramic anilox rollers (360 lines/cm). After printing, the printed
substrate went through a 10 foot oven at 82.degree. C. Linear speed
was varied from 200 to 1000 feet/min.
Base Resins
[0073] The examples that follow employ base resins, e.g.,
polyurethane and polyurethane-urea resins designated herein as PUA,
PUB, and PUC. The resins are described below:
TABLE-US-00001 Designation Polyurethane Resin Source PUA A
polyurethane described in Example UB5 of U.S. Pat. No. 7,563,835
that is soluble in the medium. PUB A polyurethane-urea resin
identified as "Polyurethane C" in U.S. 2010/0279041 on page 7
thereof that is soluble in the medium. PUC A polyurethane-urea
resin described in U.S. Pat. No. 6,723,820, e.g., in col. 4 lines
17-44 that is soluble in the medium.
[0074] PUA is the polyurethane reaction product of toluene
diisocyanate (Bayer), 2,2-dimethylol butanoic acid (Mitsubishi),
dimer diol 1075 (Henkel), and 2-methyl-1,3-propanediol (Arco),
present in a molar ratio of, respectively: 0.95/0.25/0.12/0.48. It
has the following properties: acid number 42, MW.sub.w: 6000, and
softening point: 120.degree. C.
[0075] PUB is a polyurethane-urea resin prepared by reacting 259
parts poly(tetramethylene ether) glycol 2000, 43 parts
poly(tetramethylene ether) glycol 1000, 11 parts 1,4-butanediol,
and 2 parts dimethylpropionic acid (DMPA) with 105 parts isophorone
diisocyanate (IPDI) in propyl acetate, and then reacting 570 parts
of the resulting product with 9 parts of ethylene diamine in
propanol. PUB has the following properties: Mw 22,200, a viscosity
of 546 cP. and a non-volatile content of 31.8%.
[0076] In addition to the description in the above table, PUC is
more fully described earlier in this disclosure.
[0077] The disclosures of U.S. Pat. Nos. 6,723,820 and 7,563,835
and U.S. Patent Application Publication No. 2010/0279041 are
incorporated herein by reference.
[0078] The following examples illustrate specific aspects of the
present invention and are not intended to limit the scope thereof
in any respect and should not be so construed.
Inventive Example 1 (Polyurethane-Polyacrylate Hybrid Resin)
[0079] 125.5 g of PUA [Sun Chemical Corporation] and 236.3 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, condenser, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 47.0 g
isobutyl methacrylate [Evonik Industries], 17.2 g of stearyl
methacrylate [Sigma-Aldrich Corporation], and 1.7 g of acrylic acid
[Sigma-Aldrich Corporation] were added to dropping funnel number 1.
75.25 g of n-propyl acetate and 0.6 g Luperox 26M50 [t-butyl peroxy
2-ethylhexanoate, 50% in mineral spirits, [Arkema]] were added to
dropping funnel number 2. The reaction was heated to 100.degree. C.
and then the contents of dropping funnels 1 & 2 were added to
the flask over 3 hours. After the additions were finished the
reaction was held at this temperature for an additional 3.5 hours,
and then the contents of the flask were cooled to 60.degree. C. and
discharged into a glass jar. The reaction product was an opaque,
tannish-white dispersion with Mn 35,000 Daltons. An opaque, waxy
film was obtained by drying a sample of the reaction product at
room temperature overnight.
Inventive Example 2 (Polvurethane-Polyacrylate Hybrid Resin)
[0080] 88.1 g of PUA [Sun Chemical Corporation] and 145.8 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, condenser, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 58.5 g
isobutyl methacrylate [Evonik Industries] was added to dropping
funnel number 1. 50.8 g of n-propyl acetate and 0.5 g Luperox 26M50
were added to dropping funnel number 2. The reaction was heated to
100.degree. C. and then the contents of dropping funnels 1 & 2
were added to the flask over 3 hours. After the additions were
finished the reaction was held at temperature for 30 minutes, at
which time a mixture of 0.2 g Luperox 26M50 and 3.05 g n-propyl
acetate was added to the flask. The reaction was held at
temperature for an additional 3.5 hours. After which the contents
of the flask were cooled to 60.degree. C. and then discharged into
a glass jar. The reaction product was opaque, tannish-white
dispersion with Mn 3,600 Daltons. An opaque, hard, brittle film was
obtained by drying a sample of the reaction product at room
temperature overnight.
Inventive Example 3 (Polyurethane-Polyacrylate Hybrid Resin)
[0081] 57.4 g of PUA [Sun Chemical Corporation] and 145.8 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, condenser, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 79.8 g
isobutyl methacrylate [Evonik Industries] and 11.1 g stearyl
methacrylate [Sigma-Aldrich Corporation] were added to dropping
funnel number 1. 50.9 g of n-propyl acetate and 0.9 g Luperox 26M50
were added to dropping funnel number 2. The reaction was heated to
100.degree. C. and then the contents of dropping funnels 1 & 2
were added to the flask over 3 hours. After the additions were
finished the reaction was held at temperature for 30 minutes, at
which time a mixture of 0.4 g Luperox 26M50 and 3.8 g n-propyl
acetate was added to the flask. The reaction was held at
temperature for an additional 3.5 hours. After which the contents
of the flask were cooled to 60.degree. C. and then discharged into
a glass jar. The reaction product was opaque, tannish-white
dispersion with Mn 4,200 Daltons. An opaque, hard, brittle film was
obtained by drying a sample of the reaction product at room
temperature overnight.
Inventive Example 4 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0082] 33.3 g of PUB [Sun Chemical Corporation] and 84.0 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, condenser, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 51.8 g
isobutyl methacrylate [Evonik Industries Industries] was added to
dropping funnel number 1. 29 g of n-propyl acetate and 0.5 g
Luperox 26M50 were added to dropping funnel number 2. The reaction
was heated to 100.degree. C. and then the contents of dropping
funnels 1 & 2 were added to the flask over 3 hours. After the
additions were finished the reaction was held at temperature for 30
minutes, at which time a mixture of 0.2 g Luperox 26M50 and 2.3 g
n-propyl acetate was added to the flask. The reaction was held at
that temperature for an additional 3.5 hours, after which the
contents of the flask were cooled to 70.degree. C. and then
discharged into a glass jar. The reaction product was opaque
dispersion with Mn 20,000 Daltons. A translucent tough film was
obtained by drying a sample of the reaction product at room
temperature overnight.
Inventive Example 5 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0083] 28.5 g of PUB [Sun Chemical Corporation] and 72.2 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, condenser, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 45.5 g
isobutyl methacrylate [Evonik Industries Industries] was added to
dropping funnel number 1. 25.4 g of n-propyl acetate and 0.4 g
Luperox 26M50 were added to dropping funnel number 2. The reaction
was heated to 100.degree. C. and then the contents of dropping
funnels 1 & 2 were added to the flask over 3 hours. After the
additions were finished the reaction was held at that temperature
for 30 minutes, at which time a mixture of 0.2 g Luperox 26M50 and
1.7 g n-propyl acetate was added to the flask. The reaction was
held at that temperature for an additional 2.25 hours, after which
the contents of the flask were cooled to 85.degree. C. and then
discharged into a glass jar. The reaction product was opaque
dispersion with Mn 29,000 Daltons. A translucent, slightly flexible
hard film was obtained by drying a sample of the reaction product
at room temperature overnight.
Inventive Example 6 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0084] 32.9 g of PUB [Sun Chemical Corporation] and 84.6 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, condenser, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 78.7 g
isobutyl methacrylate [Evonik Industries Industries] was added to
dropping funnel number 1. 29.3 g of n-propyl acetate and 0.5 g
Luperox 26M50 were added to dropping funnel number 2. The reaction
was heated to 100.degree. C. and then the contents of dropping
funnels 1 & 2 were added to the flask over 3 hours. After the
additions were finished the reaction was held at that temperature
for 30 minutes, at which time a mixture of 0.2 g Luperox 26M50 and
1.8 g n-propyl acetate was added to the flask. The reaction was
held at that temperature for an additional 3.0 hours, after which
the contents of the flask were cooled to 55.degree. C. and then
discharged into a glass jar. The reaction product was opaque
dispersion with Mn 18,000 Daltons. A translucent, tough film was
obtained by drying a sample of the reaction product at room
temperature overnight.
Inventive Example 7 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0085] 62.0 g of PUB [Sun Chemical Corporation] and 169.6 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, condenser,
temperature sensor, gas inlet, and two dropping funnels. 154.3 g
isobutyl methacrylate [Evonik Industries Industries] was added to
dropping funnel number 1. 58.4 g of n-propyl acetate and 1.1 g
Luperox 26M50 were added to dropping funnel number 2. The reaction
was heated to 100.degree. C. and then the contents of dropping
funnels 1 & 2 were added to the flask over 3 hours. After the
additions were finished the reaction was held at that temperature
for 30 minutes, at which time a mixture of 0.4 g Luperox 26M50 and
3.6 g n-propyl acetate was added to the flask. The reaction was
held at that temperature for an additional 2.25 hours, after which
the contents of the flask were cooled to 75.degree. C. and then
discharged into a glass jar. The reaction product was opaque
dispersion with Mn 23,000 Daltons. A translucent tough, flexible
film was obtained by drying a sample of the reaction product at
room temperature overnight.
Inventive Example 8 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0086] 64.5 g of PUC [Sun Chemical Corporation] and 195 g of
n-propyl acetate were weighed into a 1.0 l 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, condenser,
temperature sensor, gas inlet, and two dropping funnels. 154.2 g
isobutyl methacrylate [Evonik Industries] was added to dropping
funnel number 1. 60.7 g of n-propyl acetate and 1.15 g Luperox
26M50 were added to dropping funnel number 2. The reaction was
heated to 100.degree. C. and then the contents of dropping funnels
#1 & #2 were added to the flask over 3 hours. After the
additions were finished the reaction was held at that temperature
for 30 minutes, at which time a mixture of 0.4 g Luperox 26M50 and
3.7 g n-propyl acetate was added to the flask over 30 minutes. The
reaction was held at that temperature for an additional 3.0 hours,
after which the contents of the flask were cooled and then
discharged into a glass jar. The reaction product was a translucent
dispersion with Mn 14,000 Daltons. A translucent hard, flexible
film with good adhesion to aluminum was obtained by drying a sample
of the reaction product at room temperature overnight.
Inventive Example 9 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0087] 200.6 g of PUB [Sun Chemical Corporation] and 120.5 g
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, condenser,
temperature sensor, gas inlet, and condensing column. Two addition
funnels were connected to the flask. Addition funnel #1 contained
92.2 g isobutyl methacrylate [Evonik Industries] and 65.1 g of
methyl methacrylate [Sigma-Aldrich Corporation]. Addition funnel #2
contained 44.1 g of n-propyl acetate and 0.85 g Luperox 26M50. The
reaction was heated to 100.degree. C. and then the contents of
dropping funnels 1 & 2 were added to the flask over 2 hours.
Thirty minutes after the addition has finished a third dropping
funnel containing 34.1 g n-propyl acetate and 0.35 g Luperox 26M50
was connected to the flask. The contents of the addition funnel
were added drop-wise over 30 minutes to the flask. After the
addition was finished the reaction was held at that temperature for
additional 3 hours, after which the contents of the flask were
cooled to 60.degree. C. and then discharged into a glass jar. The
reaction product was a hazy dispersion with Mn 29,000 Daltons.
Inventive Example 10 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0088] 201 g of PUB [Sun Chemical Corporation] and 123.2 g n-propyl
acetate were weighed into a 1.0 L 4-necked round bottom flask
equipped with a heating mantle, overhead stirrer, condenser,
temperature sensor, gas inlet, Dean-Stark trap, and condensing
column. The contents of the flask were distilled to remove
n-propanol in the standard method. The distillate removed was 178 g
and was replaced with 179.4 g n-propyl acetate. The Dean-Stark trap
was removed. Two addition funnels were connected to the flask.
Addition funnel #1 contained 92.2 g isobutyl methacrylate [Evonik
Industries], and 65.75 g of methyl methacrylate [Sigma-Aldrich
Corporation]. Addition funnel #2 contained 45 g of n-propyl acetate
and 0.83 g Luperox 26M50. The reaction was heated to 100.degree. C.
and then the contents of dropping funnels 1 & 2 were added to
the flask over 3 hours. Thirty minutes after the addition has
finished a third dropping funnel containing 34.9 g n-propyl acetate
and 0.34 g Luperox 26M50 was connected to the flask. The contents
of the addition funnel were added drop-wise over 30 minutes to the
flask. After the addition was finished the reaction was held at
that temperature for additional 3 hours, after which the contents
of the flask were cooled to 60.degree. C. and then discharged into
a glass jar. The reaction product was a hazy dispersion with Mn
24,000 Daltons.
Inventive Example 11 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0089] 240.8 g of PUB [Sun Chemical Corporation] and 125.5 g
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, condenser,
temperature sensor, gas inlet, and condensing column. Two addition
funnels were connected to the flask. Addition funnel #1 contained
68.8 g isobutyl methacrylate [Evonik Industries], and 48.8 g of
methyl methacrylate [Sigma-Aldrich Corporation]. Addition funnel #2
contained 44.2 g of n-propyl acetate and 1.70 g Luperox 26M50. The
reaction was heated to 100.degree. C. and then the contents of
dropping funnels 1 & 2 were added to the flask over 2 hours.
Thirty minutes after the addition, a third dropping funnel
containing 34.4 g n-propyl acetate and 0.71 g Luperox 26M50 was
connected to the flask. The contents of the addition funnel were
added drop-wise over 30 minutes to the flask. After the addition
was finished the reaction was held at that temperature for
additional 3 hours, after which the contents of the flask were
cooled to 60.degree. C. and then discharged into a glass jar. The
reaction product was a hazy dispersion with Mn 10,000 Daltons.
Inventive Example 12 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0090] 33.0 g of PUC [Sun Chemical Corporation] and 83.9 g of
n-propyl acetate were weighed into a 1.0 L 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, condenser,
temperature sensor, gas inlet, and two dropping funnels. 77.1 g
isobutyl methacrylate [Evonik Industries] was added to dropping
funnel number 1. 29.8 g of n-propyl acetate and 0.5 g Luperox 26M50
were added to dropping funnel number 2. The reaction was heated to
100.degree. C. and then the contents of dropping funnels 1 & 2
were added to the flask over 3 hours. After the additions were
finished the reaction was held at that temperature for 30 minutes,
at which time a mixture of 0.2 g Luperox 26M50 and 1.8 g n-propyl
acetate was added to the flask. The reaction was held at that
temperature for an additional 3.0 hours, after which the contents
of the flask were cooled to 75.degree. C. and then discharged into
a glass jar. The reaction product was opaque dispersion with Mn
23,000 Daltons. A hard, brittle film was obtained by drying a
sample of the reaction product.
Inventive Example 13 (Polyurethane-Polyacrylate Hybrid Resin)
[0091] 347.5 g of PUA [Sun Chemical Corporation] was distilled to
remove isopropyl alcohol and 0.95 g of isobutylmethacrylate were
weighed into a 1.0 L 4-necked round bottom flask equipped with a
heating mantle, overhead stirrer, temperature sensor, gas inlet,
and two dropping funnels. 17.2 g isobutyl methacrylate [Evonik
Industries] was added to dropping funnel number 1. 20.2 g of
n-propyl acetate and 0.4 g Luperox 26M50 were added to dropping
funnel number 2. The reaction was heated to 100.degree. C. and then
the contents of dropping funnels 1 & 2 were added to the flask
over 2 hours. After the additions were finished the reaction was
held at that temperature for 30 minutes, at which time a mixture of
0.06 g Luperox 26M50 and 10.1 g n-propyl acetate was added to the
flask over 30 minutes. The reaction was held that at temperature
for an additional 3.0 hours, after which 3.7 g n-propyl acetate was
added to the flask, and then the contents of the flask were cooled
and discharged into a glass jar. The reaction product was a
translucent dispersion with Mn 10,000 Daltons. The ratio of PU:Ac
is 85:15.
Inventive Example 14 (Polyurethane-Polyacrylate Hybrid Resin)
[0092] 66.5 g of PUA [Sun Chemical Corporation] was distilled to
remove isopropyl alcohol, 140.1 g n-propyl acetate, and 5.5 g of
isobutylmethacrylate were weighed into a 1.0 L 4-necked round
bottom flask equipped with a heating mantle, overhead stirrer,
temperature sensor, gas inlet, and two dropping funnels. 102.6 g
isobutyl methacrylate [Evonik Industries] was added to dropping
funnel number 1. 40.2 g of n-propyl acetate and 2.5 g Luperox 26M50
were added to dropping funnel number 2. The reaction was heated to
100.degree. C. and then the contents of dropping funnels 1 & 2
were added to the flask over 2 hours. After the additions were
finished, the reaction was held at that temperature for 30 minutes,
at which time a mixture of 0.2 g Luperox 26M50 and 20.2 g n-propyl
acetate was added to the flask over 30 minutes. The reaction was
held at temperature for an additional 3.0 hours, after which 25 g
n-propyl acetate was added to the flask, and then the contents of
the flask were cooled and discharged into a glass jar. The reaction
product was a translucent dispersion with Mn 15,000 Daltons. The
ratio of PU:Ac is 15:85.
Inventive Example 15 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0093] 422 g of PUB [Sun Chemical Corporation] and 484 g of
n-propyl acetate were weighed into a 3.0 l 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, temperature
sensor, gas inlet, and two dropping funnels. 386 g isobutyl
methacrylate [Evonik Industries] was added to dropping funnel
number 1. 237 g of n-propyl acetate and 8.79 g Luperox26M50 were
added to dropping funnel number 2. The reaction was heated to
100.degree. C. and then the contents of dropping funnels 1 & 2
were added to the flask over 3 hours. After the additions were
finished the reaction was held at that temperature for 30 minutes,
at which time a mixture of 1.7 g Luperox 26M50 and 103 g n-propyl
acetate was added to the flask. The reaction was held at
temperature for an additional 2.25 hours, after which the contents
of the flask were cooled to 85.degree. C. and then discharged into
a glass jar. The reaction product was opaque dispersion with Mn
10,000 Daltons. A translucent, slightly flexible hard film was
obtained by drying a sample of the reaction product.
Inventive Example 16 (Polyurethane-Urea-Polyacrylate Hybrid
Resin)
[0094] 352.9 g of PUB [Sun Chemical Corporation] and 671 g of
n-propyl acetate were weighed into a 3.0 L 4-necked round bottom
flask equipped with a heating mantle, overhead stirrer, temperature
sensor, gas inlet, and two dropping funnels. 457.7 g isobutyl
methacrylate [Evonik Industries] was added to dropping funnel
number 1. 235.7 g of n-propyl acetate and 9.75 g Luperox 26M50 were
added to dropping funnel number 2. The reaction was heated to
100.degree. C. and then the contents of dropping funnels 1 & 2
were added to the flask over 3 hours. After the additions were
finished the reaction was held at that temperature for 30 minutes,
at which time a mixture of 1.8 g Luperox 26M50 and 173 g n-propyl
acetate was added to the flask. The reaction was held at
temperature for an additional 2.25 hours, after which the contents
of the flask were cooled to 85.degree. C. and then discharged into
a glass jar. The reaction product was opaque dispersion with Mn
10,000 Daltons. A translucent, slightly flexible hard film was
obtained by drying a sample of the reaction product.
Comparative Example 1: A Simple Mixture of Polyurethane and
Polyacrylate Resins
[0095] 2.5 g of PUA [Sun Chemical Corporation] and 7.5 g of
polyacrylate resin solution [Mz+1.about.130,000; 22.5% solids in
n-propyl acetate, 13% stearyl methacrylate [Sigma-Aldrich
Corporation] and 87% isobutyl methacrylate (i-BMA) [Evonik
Industries] were placed in a glass vial and then sealed. The vial
was then placed into a 93.degree. C. oven for 48 hours, vigorously
shaken and once removed was allowed to cool to room temperature.
Upon inspection, the contents of the vial were divided into two
separate layers with a solid bottom layer and a cloudy, liquid
layer on top.
Comparative Example 2: Attempted Reaction Between Polyurethane
Resin and a Commercially Available Polyacrylate Resin
[0096] 32.99 g of PUA [Sun Chemical Corporation], 246.9 g of
n-propyl acetate, 51.66 g Joncryl 611 [BASF] were weighed into a
1.0 L, 4-necked round bottom flask equipped with a heating mantle,
overhead stirrer, temperature sensor, gas inlet, and condenser. The
contents of the flask were heated to 100.degree. C. with stirring
to dissolve the resins. 31.7 g of n-propyl acetate and 0.72 g
Luperox 26M50 were added to a dropping funnel. The contents of the
dropping funnel were added to the flask over 1.5 hours. After the
addition was finished the reaction was held at temperature for an
additional 3.5 hours, after which the contents of the flask were
cooled to 80.degree. C. and discharged into a glass jar. The
reaction produced two (2) discreet layers, with solid polymer on
bottom and clear liquid on top. The formation of two discreet
layers demonstrates that there is an absence of stability in the
medium.
TABLE-US-00002 TABLE 1 Tyndall effect results on polymer systems
Sample Tyndall Effect Stable Tack Comparative Example 1 No No
Comparative Example 2 No No PUC No Yes 12.4 Example 1 Yes Yes 3.8
Example 2 Yes Yes Not measured Example 3 Yes Yes 4.2 Example 4 Yes
Yes 4.1 Example 5 Yes Yes 4.5 Example 6 Yes Yes 3.9 Example 7 Yes
Yes 3.1 Example 8 Yes Yes 9.2 Example 9 Yes Yes 1.8 Example 10 Yes
Yes 6.1 Example 11 Yes Yes Not measured Example 12 Yes Yes 6.0
Example 13 Yes Yes 4.9 Example 14 Yes Yes 7.0 Example 15 Yes Yes
6.2 Example 16 Yes Yes 6.4
[0097] Comparative Example 1 shows that mixing polyurethane and
polyacrylate together does not yield a stable dispersion.
Comparative Example 2 shows that mixing polyurethane and
polyacrylate and then adding an initiator and heating does not lead
to a stable dispersion. In neither comparative example did the
clear solution give a positive Tyndall effect so were not
non-aqueous dispersions. All Inventive Examples had significantly
lower tacks than reference solution PUC which is an important
property needed for high speed printing
Comparative OPV Testing
[0098] Inventive Example 6 was used with 5% added Incozol LV
(Incorez Ltd) a bis-oxazolidine crosslinker and compared to
Sleeveflex OPV (Sun Chemical). Each was printed over Sunate C blue
ink (Sun Chemical CRVGS5034607) on PET-G film using a 160 line
flexo hand proofer. Each print was allowed to air dry between each
application. The Spray & Wash resistance of the OPV was
assessed by soaking a Q-tip in the Spray & Wash and rubbing the
OPV until the OPV failed and the Q-tip became colored by the
underlying inks. The number of back and forth wipe is an indication
of the ability of the OPV to protect the underlying inks from the
Spray and Wash. The higher the number of wipes, the better is the
coating. The OPV based on Inventive Example 6 with 5% added Incozol
LV required 100+ wipes compared to the Sleevflex OPV which failed
after 10 wipes.
Comparative Lamination Testing
[0099] Inventive Example 12, a hybrid
polyurethane-urea-polyacrylate resin containing PUC and for
comparison, PUC, were both diluted to approximately 30% solids with
n-propyl acetate. Both were coated onto substrate onto
polypropylene and laminated. Testing occurred after 24 and 144
hours. Lamination results indicate the dispersion hybrid polymer
has improved lamination bond strength compared to its base
polyurethane on polypropylene film.
TABLE-US-00003 TABLE 2 Lamination bond strength of control
polyurethane-urea (PUC) resin and dispersion polymer Polypropylene
[24 hr.] Polypropylene [144 hr.] [g/linear inch] [g/linear inch]
PUC 380 450 Inventive Example 12 450 475
TABLE-US-00004 TABLE 3 Ink formulations for Chesnut press trial
Inventive Inventive Comparative Ink A Ink B Ink C Cyan Base 50.7
49.8 45.8 Inventive Example 15 33.7 -- -- Inventive Example 16 --
33.2 -- PUC -- -- 30.8 n-propyl acetate 15.6 17 23.4 Total 100.0
100.0 100.0 % resin solids from varnish only 11.5 11.9 9.8
Viscosity w/Zahn #2 cup (sec) 26.6 26.4 25.8 Tack-press ready
ink-180 rpm @ 2.1 1.4 6.2 90.degree. F. (g-linear in)
[0100] The initial tack of the resin system was measured and then
made into inks as described above. The tack values of the inks
based on the inventive non-aqueous dispersions were much lower than
the ink made from the solution resin. Tack is an important property
needed for high speed printing.
[0101] The inks were run on the Chesnut press and the printed films
were made into lamination testing samples as described earlier.
Samples were tested after being laminated at 24 hours and 30 days
to determine bond strength as a function of time. The samples were
laminated to either polypropylene film (PP) or polyethylene
terephthalate (PET) film for the testing.
TABLE-US-00005 TABLE 4 Adhesive Bond Strengths for Laminate
Structures Made From Chesnut Press Trial On PP PP - 24 hours PP -
30 days Inventive Ink A 255 265 Inventive Ink B 328 293 Comparative
Ink C 250 258
[0102] Inventive Ink A is based on Inventive Example 15 which
contains 40% polyurethane-urea-polyacrylate resin (PUB). It has
bonds comparably on polypropylene after 24 hours and 30 days to
Comparative Ink C, which is made from 100% PUC (polyurethane-urea
resin). Inventive Ink B is based on Inventive Example 16 which
contains 30% polyurethane-urea-polyacrylate resin (PUB). In terms
of bonding on polypropylene after 24 hours and 30 days, it is
superior to Comparative Ink C. The improved bond strength was
achievable at a lower overall tack value for the inventive inks,
which is more conducive for high speed printing applications.
TABLE-US-00006 TABLE 5 Adhesive bond strengths for laminate
structures made from Chesnut press trial on PET Adhesion strength
of laminate [g/linear inch] PET - 24 hours PET - 7 days PET - 30
days Inventive Ink B 370 383 393 Comparative Ink C 300 265 395
[0103] Inventive Ink B is based on Inventive Example 15 which
contains 30% polyurethane-urea-polyacrylate resin. Compared to
Comparative Ink C, which is made from 100% solution polyurethane,
inventive ink B has superior bonding properties on polyethylene
terephthalate after 24 hours and 7 days and comparable bonding
properties after 30 days. The improved bond strength was achievable
at a lower overall tack value for the inventive inks, which is more
conducive for high speed printing applications.
[0104] The present invention has been described in detail,
including the preferred embodiments thereof, but is more broadly
applicable as will be understood by those skilled in the art. It
will be appreciated that those skilled in the art, upon
consideration of the present disclosure, may make modifications
and/or improvements on this invention that fall within the scope
and spirit of the invention. Since modifications will be apparent
to those of skill in this art, it is intended that this invention
be limited only by the scope of the following claims.
* * * * *