CA1176553A - Method for producing a bright metalized foil or board - Google Patents

Abstract

ABSTRACT

A method for producing a metalized paper or board product having a bright surface and improved scratch resistance, comprises a transfer metalization technique utilizing a tie coating applied to the metal layer and an adhesive emulsion applied to the tie coating, the adhesive emulsion binding the metalized composite to the paper or board base. The adhesive emulsion is preferably applied in the wet state and penetrates the paper or board base when the base and emulsion are brought together between pressure rollers.

Description

5 ~ 3 . , METHOD FOR PRODUCING A BRIGHT
METALIZED FOIL OR BOARD

The present invention relates generally to the production of metalized paper or board products, and particularly to a transfer technique for applying the metal coating to the paper or board substrate, which results in the preparation of a metalized product having improved brilliance.

In general, the use of transfer techniques to apply metallic coatings to substrates, such as fabric, leather or plastic surfaces, is well known. Thus, the technique of gold leaf transfer was utilized in the l9th century by bookbinders, who employed gold foil transfer sheets to attach gold letters to leather bindings. The transfer sheets comprised a waxed carrier web over which a sheet of gold foil was placed, the gold foil coated on its free side with a heat-activated ad-hesive layer. In practise, the transfer sheet was hot pressed with a heated dje to adhere the metal foil to the leather, and the carrier was thereafter stripped away. The waxy parting layer that was coated initially over the carrier, served to maintain the gold leaf in position on the carrier prior to its transfer, and to permit release of the carrier after the gold had been affixed to the leather.

In recent times, the advent of vapor deposition of metals, such as aluminum and the like, has spurred further interest in the use of this metalization technique for the preparation of a variety of metalized substrates. Thus, techniques of both direct and transfer coating have been attempted on a variety of base materials, including porous materials such as cloth, leather, paper and the like. The potential usefulness for these metalized substrates is enormous, as, for example, ~ 1~65~3 metalized paper or board is broadly used for decorative pack-- aging, and other applications where the appearance of a metal surface is desired.

A number of techniques for the metalization of paper and board are known and are disclosed in the art. Thus, U.S.
Patent Number 3,043,728, to Stauffer, discloses a specific apparatus and associated method for preparing a metalized paper product, which relies on the initial application of the metalized layer to a drum and the transfer of the metal layer to the paper substrate which has been previously directly coated with an adhesive. U.S. Patent Number 3,235,395, to Scharf, discloses a transfer metalization technique that patentee states is applicable to paper. A heat or pressure sensitive adhesive is utilized ln this method.

Other transfer metalization techniques are disclosed in U.S.
Patent Numbers 2,703,772, to Keithly, 3,080,270, to Lorenz, and U.S. Patent Number 3,589,962, to Bonjour. All of these techniques, however, relate primarily to metalization of fabrics, and make secondary reference to metalization of paper, and in the instance of Lorenz, suggests that an initial coating must be placed on the substrate prior ta the transfer of the metal layer thereto.

Direct metalization techniques for the preparation of coated paper products are disclosed in U.S. Patent Number 3,463,659, to Dragoon et al., and U.S. Patent Number 3,730,752, to Guajardo Garza et al. In both instances, however, the patentees suggest that a preliminary coating or base coating of the paper substrate is necessary to facilitate application of the metal layer.

~ 17~553 Finally, U.S. Patent Number 4,153,494, to Oliva, discloses a metalization technique which when carefully reviewed, appears closer to the ancient art of gold leaf transfer. In particu-lar, Oliva utilizes a varnish, interposed between the metal layer and the substrate to be coated, such as paper or board, so that the metal layer will be adhesively bound thereto.
Oliva may apply the varnish either directly to the substrate to be coated, or to the metal layer which is subsequently transferred to the substrate.

Oliva, as well as the remainder of the prior art techniques discussed above, possess certain basic drawbacks, which most of the patentees above already acknowledge. In particular, paper and board substrates are porous materials having re-sidual moisture. The process of applying the metalized sur-face directly to the paper or board base is complicated bythe tendency of the base to exhibit outgassing during the application of the metal coating, that causes coating dis-continuities that result in the formation of a dull or matte finish to the metal surface.
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Alternately, when the metal layer is formed on a carrier and a transfer to the paper or board base is attempted, the condi-tions under which such transfer is usually conducted, i.e.
pressure and/or elevated temperature, results in the undesirable elimination of all moisture from the porous paper or board base, with the result that the paper or board base subsequently absorbs moisture from the atmosphere and develops surface discontinuities, known as "curling", "cockling", and "crowning", - all of which substantially detract from the smooth metalized appearance desired in the product.

~ :~7~553 In similar fashion, the direct application of adhesives to the paper or board base, as disclosed in certain of the prior art references, causes the same surface discontinuities to develop and the resulting metalized products exhibit the same deficiencies. Attempts to overcome this problem have centered around efforts to apply primer coatings by techniques that subsequently surface treat the paper or board base in an attempt to assure a smooth, sealed surface for the applica-tion of the metal layer. Such processes, however, are un-economical and frequently unreliable, and have enioyed limitedcommercial success, if any.

A need therefore exists for the development of a simple, in-expensive process that results in the preparation of a metal-ized paper or board product.offering uniform, improved brilliance and smoothness, together with durability and hard-ness in use.
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In accordance with the present invention, a method for pro-ducing a metalized paper or board product with improved surface smoothness and brightness, together with hardness and scratch resistance, is disclosed which comprises applying a lacquer coating to a carrier film to serve as the outer, protective surface of the metalized paper or board product, the lacquer coating being one capable of adherently bonding to a deposited metal surface, as well as receiving other display material that may be printed or otherwise coated on the outer surface thereof, Thereafter, a thin, continuous and adherent metal layer is vapor deposited on the lacquer coating, and a tie coating, preferably comprising a polyurethane film forming composition is thereafter applied thereto~

~ ~785~3 An adhesive coating is then applied to the tie coating, the adhesive coating preferably comprising an emulsion.
The carrier bearing the coatings and layers just described is then brought in contact with the paper or board base by feeding the two, with the adhesive coated surface facing the base, into the nip of a pair of pressure rollers while the adhesive remains wet, so that the adhesive is wet as it con-tacts the base, and penetrates the base after the base and the carrier are brought together between the pressure rollers.

Finally, the carrier and the base may be separated after their emergence from the pressure rollers, with the base having adherently bound thereto a multi-layered article comprising an outer coating of the lacquer, a next adjacent coating of the metal layer, a tie coating next adiacent the metal layer and an adhesive bond disposed between the tie coating and the paper or board base.

Preferably, the carrier may be a conventional material such as a polyester sheet or strip, the lacquer coating may be selected from cellulosic resins, such as nitrocellulose, or vinyl resins, such as vinylacetate-vinylchloride copolymers, and other equivalent materials. The vapor deposited metal is preferably aluminum, and the tie coat is preferably aliphatic polyurethane compositions. The adhesive may comprise a poly-meric emulsion including various vinyl polymers such as poly-vinylalcohol and polyvinylacetate homopolymers and copolymersas well as polyacrylic compositions. Preferably, the adhesive coating has an acidic pH, and more particularly a pH ranging from about 4.5 to about 5.5.

The present method is essentially a "wet process" in that the adhesive emulsion is wet as it contacts the paper or board base, and remains so for a time sufficient to penetrate the paper or board base during the bonding of the metalized layer thereto. The penetration of the paper or board base by the - ~17~553 wet adhesive is a feature of the invention that is particu-larly noteworthy in view of the prior art caveats against such a technique, as described earlier. Metalized paper or board products prepared by the present technique have uniformly smooth surfaces, and do not exhibit the prior art defects of "cockling", "crowning" and the like, despite the penetration of the wet adhesive into the base.

The adhesive bond formed between the base and the metalized composite is such that the carrier may be simply stripped away after passage of the base and carrier through the pressur-ized rollers. There is no need for a post-curing operation, or the application of heat together with pressure, as utilized in the prior art. The present method, by contrast, may be practiced with an optional final step wherein the already formed metalized product is heated to achieve further drying, by, for example, exposure of the coated product to a temper-ature of about 250F, for a period of about one minute. This is in marked contrast to the heating regimes utilized in the prior art, which achieve curing of the adhesive b~ exposure to higher temperatures for longer periods of time.

Accordingly, it is a principal object of the present invention to provide a method for the rapid and inexpensive manufacture of a metalized paper or board product.

It is a further object of the present invention to provide a method as aforesaid that results in the preparation of a prod-uct having improved surface smoothness, brilliance and hard-ness.
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It is a yet further object of the present invention to provide a method as aforesaid which utilizes a transfer technique em-ploying a wet adhesive without adversely effecting the coatedpaper or board base.

1 ~7~553 It is a still further object of the present invention to pro-vide a method as aforesaid which does not require the imposi-tion of a post-treatment to cure the adhesive binding the metalized layer to the base.

Other objects and advantages will become apparent to those skilled in the art from a review of the ensuing description which prGceeds with reference to the following illustrative drawings.

FIGURE 1 is a schematic plan view sequentially illustrating the various steps of the present method.

FIGURE 2 is a schematic fragmentary sectional view partly in phantom, illustrating the various layers of the metalized paper or board product prepared in accordance with the present invention.

In its broadest aspect, the present invention comprises the preparation of a metalized paper or board product having im-proved surface smoothness and brightness, and resistance to fracture upon flexure. The method comprises providing and feeding a carrier film, applying a lacquer coating to the carrier film, the lacquer coating to serve as the outer, pro-tective surface of the metalized paper or board product. The lacquer coating should preferably be capable of adherently bonding to a deposited metal layer, as well as receiving other display material that may be printed or otherwise coated on its outer surface.

After the application of the lacquer coating, a thin, con-tlnuous and adherent metal layer is deposited on the lacquer coating, to provide the brilliant metalized appearance to ~ ~7~5~3 the resulting paper or board product. A tie coating prefer-ably comprising a polyurethane composition, is thereafter applied to the outer surface of the metal layer, and is per-mitted to dry. Thereafter, an adhesive coating preferably comprising a wet emulsion, is applied over the tie coating to prepare the composite structure for transfer.

The next step in the method comprises feeding the carrier prepared as described above, and a base such as paper or board into the nip of a pair of pressure rollers, with the surface of the carr;er bearing the wet adhesive emulsion facing the paper or board base. As the carrier and the base are united between the rollers, the adhesive coating penetrates the base as it adheres thereto. Subsequently, the carrier may be stripped from the base, leaving the base having ad-herently bound thereto a multi-layered article, comprising an outer coating of the lacquer, a next adjacent coating of the metal layer, a tie coating next adjacent to the metal layer and an adhesive bond disposed between the tie coating and the base.

The carriers useful in the present invention includes those materials conventionally employed, that may be capable of withstanding repeated use in accordance with the present method. Thus, the carrier should be capable of successive coating and stripping, and recoating without exhibiting de-terioration during metalizing or under the tension of delamin-ation during the release of the transferred composite to the base. Suitable materials employed in accordance with the present invention as the carrier, include polyester films, various cellulose derivatives, vinyl compounds, elastomers and i 30 others. Preferably, a polyester film is employed. While the thickness of the carrier is not critical, a thickness of 1 mil is preferred.

~ 176553 g The lacquer coating useful in the present invention may be selected from a variety of materials capable of providing a durable outer surface for the coated paper or board product, that is receptive to printed, coated and embossed display material. The lacquer must also be capable of cleanly stripping away from the carrier in use, so that a smooth, continuous surface is left. A variety of lacquers are suit-able for this purpose, and include cellulose derivatives such as nitrocellulose, and vinyl polymers, including vinyl-chlor~de and vinylacetate polymers and copolymers. In par-ticular, a vinylchloride-vinylacetate copolymer may be uti-lized. The lacquer coat may be applied in various thicknesses, and is preferably applied in a thickness ranging from about 0.0005 to about 0.005 thousandths of an inch. The lacquer coat may be prepared with conventional organic solvents such as methyl ethyl ketone, ethyl alcohol, toluol and the like.

The lacquer coat may be clear, in the instance where it is desired to obtain a purely metallic appearance, or may be colored by incorporation of pigments, dyes and the like, to give various decorative appearances to the final paper or board product.

The application of the metal layer to the coated carrier may be accomplished by conventional techniques, and is preferably accomplished by vapor deposition. The invention does not re-late to the manner in whlch the metal coating is applied perse, and thus the techniques of vapor deposition of metal as are known in the art, may be utilized herein, and such con-ventional techniques are incorporated herein by reference.
As is known in the art, the number of metals that may be applied by this technique to form a tightly adherent, continuous coating is broad, and would include both precious and non-precious metals, such as gold, silver, tin, zinc, chromium and aluminum. In accordance with the present invention, ~ 1765~3 -lo-aluminum is the preferred metal and is applied by vapor depo-sition to a thickness that may range, for example, up to about 7 mils or greater. The exact thickness of the layer is dis-cretionary, and may vary with the intended application of the paper or board product.

The tie coating as noted earlier, provides improved hardness and scratch resistance to the paper or board product. Suit-able tie coatings include polyurethane compositions, and in particular, flexible polyurethanes formed with a polyol and an aliphatic isocyanate. Naturally, polyurethanes produced by the reaction of a polyol with an aromatic isocyanate such as toluene di-isocyanate, may be utilized as well, however, polyurethane compositions produced by the reaction of an ali-phatic isocyanate with a polyol have been found to result in a tie coating having improved resistance to yellowing or aging.

The polyurethane compositions may possess coatings ranging in thickness from about 0.005 thousandths of an inch to about 0.008 thousandths of an inch. The polyurethane tie coatings are particularly receptive and compatible with a subsequently applied emulsion adhesive, and thus fav~rably coact therewith, in addition to imparting improved hardness and scratch re-sistance to the resulting paper or board product.
., The adhesive coating of the present invention is preferably applied as a liquid emulsion and as noted earlier, is com-patible with the tie coating so that the bond between the metallic layer and the base will be firmly formed. Suitable adhesives include vinyl polymers, such as vinylacetate homo-polymers and copolymers, polyvinylalcohol emulsions, shellac emulsions and acrylic emulsions. In accordance with the present invention, the adhesive emulsion may preferably possess a pH

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~ 176$~3 in the acidic range, and more particularly a pH ranging from about 4.5 to 5.5~ It has been found that the employment of an adhesive emulsion of this pH range reduces the incidence of attack and deterioration of the metal layer during the life of the paper or board product.

As noted earlier, the adhesive is preferably applied as a wet emulsion, and the present process is accordingly charac-terized as a "wet process". By this it is meant that the adhesive remains wet from the time of its application, until it is applied against the adjacent surface of the paper or board base, as the base and the carrier are united between the nip of the pressure rollers. In this way, the wet adhesive emulsion may thoroughly penetrate the base, and preferably must do so, to assist in the formation of the improved bond between the metalized composite and the paper or board base that is characteristic of the present product. The ability Gf the present product to emerge from the pressure rollers in its completed form, without the exhibition of surface de-fects or dullness is one of the primary features of the present invention.

Referring now to FIGURE 1, the producti4n of ~he paper or board product proceeds in the following manner. A supply roll 11 delivers a sheet, strip or film of a carrier 12 to a series of coaters. The carrier 12 may, as noted earlier, comprlse a polyester film.

A lacquer coating 10 is then applied by coater 13, and may be applied to the thicknesses suggested earlier herein.
Carrier 12 then passes through the vacuum furnace 14 where a vapori~ed metal layer 15, which may comprise aluminum, is con-densed on its upper surface. The exact thickness of layer 15may vary as indicated earlier.

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~ 176553 Carrier 12 now bearing lacquer coating 10 and vaporized metal layer 15 thereover is then fed past a second coater 16 where a tie coat, preferably a polyurethane composition, is applied thereover. After the application of the tie coat, the carrier 12 passes to a coater lg where an emulsion coat or adhesive 19 is applied over the tie coat 17. The emulsion coat remains wet, as indicated earlier, and carrier 12 is then directed into the nip of opposed rollers 9, 9 simultaneously with the introduction of a sheet or strip of paper or board 20 from a supply roller 21 as illustrated. Thus, carrier 12 and paper ; or board 20 meet at the nip of rollers 9, 9, and the wet emulslon coat 19 makes contact with and thereafter penetrates the adjacent surface of the paper or board 20. At this point, the bond between the paper or board 20 and the multi-layered composite comprising the lacquer coating 10, the vaporized metal layer 15, the tie coat 17 and the emulsion coat 19 is complete, and the carrier 12 may be stripped away from the base so that it parts cleanly from lacquer coating 10 and may thereafter be retrieved for reuse in the present method. In such instance, carrier 12 may be a continuous band~

-` The paper or board base may be used in the form received, as prepared above, or may be given a heat treatment to hasten the drying of the adhesive coat 19. In such instance, the metalized paper or board product is heated in an oven at ; 25 approximately 250F for about one minute. This heating step, ; however, is optional.

The resulting product exhibits improved brilliance and scratch resistance, and ls capable of a variety of uses, including imprinting with colored inks, embossing and the like.

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~ :L7~553 Further, though the present invention has been described pri-marily with respect to the disposition of a metallic coating, it is to be understood that other coatings, such as pearl coatings and paint coatings including irridescent coatings such as "day-glo" may be utilized and the resulting products will possess the same brilliance, smoothness and scratch re-sistance.

The following examples illustrate the preparation of certain of the coatings useful in the method of the present invention.

EXAMPLE I

A lacquer coat was prepared having the following ingredients in the following amounts.

INGREDIENTS PARTS BY WEIGHT

Nitrocellulose (1/2 second viscosity) (70% wet in alcohol-Hercules Powder Company) 20 Methyl ethyl ketone 50 Denatured ethyl alcohol 30 A second formulation was prepared with a vinyl polymer as follows:
' INGREDIENTS PARTS BY WEIGHT

Y~nylacetate-vinylchloride copolymer (VAGH-Union Carbide Corp.3 15 ~ethyl ethyl ketone 50 Toluol 35 ~ 1765~3 The tie coats were prepared from polyurethane materials and poarticularly a material identified such as Mobay Chemical-DESMOCOLL* E 471, and DESMOCOLL* E 477.
Preferably, the tie coat is a flexible polyurethane derived from an aliphatic isocyanate and a polyol.

EXAMPLE II_ Two formulations of adhesive coats were prepared which are preferably applied to a weight of approximately 3.5 pounds per 1500 square feet. The coating compositions were as follows:
INGREDIENTS PARTS BY WEIGHT
Vinyl alcohol emulsion (Franklin Chemical Industries-FH2) 50 Water 50 , A second formulation was prepared as follows:
` INGREDIENTS PARTS BY WEIGHT
Polyvinylacetate homopolymer (AMSCO* Res 3 or AMSCO* Res 4 non-ionic manufactued by Union Chemical Company) 50 Water 50 ., .
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~ ~76553 . This invention may be embodied in other forms or carried out in other ways without departing from the spirit or essential characteristics thereof. The present disclosure is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indi-cated by the appended claims, and all changes which come within the meaning and range of equivalency are intended to be embraced therein.

Claims (12)

WHAT IS CLAIMED IS:

1. A method for producing a metalized paper or board product having improved surface smoothness and brightness, and resist-ance to fracture upon flexure, comprising:
A. providing a carrier film;
B. applying a lacquer coating to said carrier film, said lacquer coating to serve as the outer, protective surface of said metalized paper or board product and capable of ad-herently bonding to a deposited metal layer, as well as re-ceiving other display material that may be printed or other-wise coated on the outer surface thereof;
C. depositing a thin, continuous and adherent metal layer on said lacquer coating;
D. applying a tie coating to said metal layer, E. applying an adhesive emulsion coating to the tie coat-ing;
F. feeding the carrier of Step E and a base selected from paper and board, into the nip of a pair of pressure rollers, shortly after the performance of Step E, so that said adhesive coating remains wet as it contacts and penetrates said base;
and G. separating said carrier from said base, after their emergence from said pressure rollers, with said base having adherently bound thereto a multi-layered article comprising an outer coating of said lacquer, a next adjacent coating of said metal layer, a tie coating next adjacent to said metal layer and an adhesive bond disposed between said tie coating and said base.

2. The method of Claim 1 wherein the coated base of Step G
is thereafter heated to dry said adhesive coating.

3. The method of Claim 2 wherein said coated base is heated at a temperature of about 250°F, for about one minute.

4. The method of Claim 1 wherein said lacquer coating is colored.

5. The method of Claim 1 wherein said metal layer is applied to said lacquer coating by vacuum deposition.

6. The method of Claim 1 wherein said tie coating has an affinity for said adhesive coating.

7. The method of Claim 1 wherein said tie coating is a polyurethane coating.

8. The method of Claim 7 wherein said tie coating comprises a polyurethane coating prepared with an aliphatic isocyanate.

9. The method of Claim 1 wherein said adhesive coating comprises a material selected from vinylacetate homopolymers, vinylacetate copolymers, shellac emulsions, polyvinylalcohol emulsions and acrylic emulsions.

10. The method of Claim 1 wherein said adhesive coating possesses an acidic pH.

11. The method of Claim 9 wherein said adhesive coating possesses an acidic pH.

12. The method of Claim 10 or 11 wherein said pH
ranges from about 4.5 to about 5.5.