CONTENTS CHAPTER 22- PIGMENT COATING INTRODUCTION

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1 CONTENTS CHAPTER 22-PIGMENT COATING INTRODUCTION History Outlook Principal Grades Coating Process Coating Surface and Structure RAW MATERIALS FOR PAPER COATIKG Raw Stock for Paper Coating Composition Porosity, Uniformity, and Finish Strength Properties Permanence Brightness and Opacity Pigments for Paper Coating Clay Mineralogy of Clay Geology and Occurrence of Clay Commercial Preparation of Clay Physical and Chemical Properties of Clay Grades of Coating Clay Brightness of Coating Clay Particle Size of Coating Clay Viscosity of Coating Clay Screen Residue of Coating Clay ph of Coating Clay Free Moisture of Coating Clay Sampling of Coating Clay Dispersioh of Coating Clay Rheology of Coating Clay Binder Demand of Coating Clay Coated Paper Properties Affected by C1a.v

xviii CONTENTS Bentonite Calcium Carbonate Mineralogy of Calciunl Carbonate Geology and Occurrence of Calcium Carbonate Chemical Preparation of Calcium Carbonate Physical and Chemical Properties of

Titanium Dioxide Commercial Preparation of Titanium Dioxide Properties of Titanium Dioxide Dispersion of Titanium Dioxide Rheology of Titanium Dioxide Coated Paper Properties Affected by Titanium

2 xviii CONTENTS Bentonite Calcium Carbonate Mineralogy of Calciunl Carbonate Geology and Occurrence of Calcium Carbonate Chemical Preparation of Calcium Carbonate Physical and Chemical Properties of Calcium Carbonate Grades of Calcium Carbonate Dispersion of Calcium Carbonate Rheology of Calcium Carbonate Coated Paper Properties Affected by Calcium Carbonate Titanium Dioxide Mineralogy of Titanium Dioxide Commercial Preparation of Titanium Dioxide Properties of Titanium Dioxide Dispersion of Titanium Dioxide Rheology of Titanium Dioxide Coated Paper Properties Affected by Titanium Dioxide Other Pigments Calcined Clay Amorphous Silicas and Silicates Plastic Pign~ents Alumina Trihydrate Minor Pigments Colored Pigments Binders for Paper Coating Histoiy of Binders in Paper Coating Starch as a Coating Binder Dextrins Oxidized Starches Enzyme-Converted Starches Chemically Mod~fied Starches Water-Resistant Starch Coatings Animal Glue Cmein Soy Protein Polyvinyl Alcohol Cellulose Derivates Styrene-Butadiene Latex Polyvinyl A cetate Latex Acrylic Emulsion Additives for Paper Coating Foam-Control Agents Lubricants Wax Emulsions Preservatives

3 FIo w Modifiers Insolubilizers Other A dditives COATING MIXTURE PREPARATION Pigment Preparation Dispersing Agents Methods of Pigment Dispersion Binder Demand of Pigment Binder Preparation Casein and Soy Protein Preparation Starch Preparation Coating Mixture Application Solids Screening of Coating Mixture Binder Migration from Coating Mixture Binder Requirements for Different Coating Grades PIGMENT-COATING FORMULATION AND ITS EFFECT Rheology of the Coating Mixture Newtonian Flow Plastic Flow Pseudoplastic FIo w Dilatant FIo w Thixotropic FIo w Rheopexy Ostwald FIo w Viscometers Two-Coat Application in Pigment Coating Effect of Formulation on Properties of Coated Paper Optical Properties of Coated Paper Finish of Coated Paper Printability of Coated Paper PIGMENT-COATING PROCESSES Size Press Coating Roll Coating Consolidated Coating Process Kimberly Clark-Mead Coating Process St. Regis Coating Process Gravure Coater Reverse Roll Coater Other Roll Coaters Air-Knife coating Blade Coating Champion Rod Coater

4 XX CONTEXTS Champflex Coater Puddle-Type Blade Coater Inverted-Blade Coater BILL BLADE Coater Twin-Blade Coater Bent-Blade Coater Cast Coating DRYING OF PIGMENT-COATED PAPER Infrared Dryers Drum Dryers Air-Conveyor Dryers Air-Cap Dryers Air-Foil Dryers CALENDERING AND FINISHING OF PIGMENT-COATED PAPERS Calendering of Pigment-Coated Paper Finishing Processes PROPERTIES OF PIGJIEST-COATED PAPERS Brightness of Coated Paper Opacity of Coated Paper Smoothness of Coated Paper Finish of Coated Paper Ink Receptivity of Coated Paper Pick Strength of Coated Paper Other Properties of Coated Paper CHAPTER 23-PRINTING PRINTING PROCESSES Relief In faglio Plan ograph ic Sfencil or Porous Letterpress Flexography Gravure Lithography Screen Printing Printing Plates Printing Ink Transfer Printing Presses

PRINTING A JOB PREPARATORY (PREPLATEMAKING) OPERATIONS Typesetting or Composition Process Photography Halftone Photography Crossline Screens Contact Screens Other Methods of Making Halftone Images

5 PRINTING A JOB PREPARATORY (PREPLATEMAKING) OPERATIONS Typesetting or Composition Process Photography Halftone Photography Crossline Screens Contact Screens Other Methods of Making Halftone Images Screened Prints Tone Reproduction and Contrast Color Reproduction Color Separation Ideal versus Actual Pigments Black Printer Color Correction Masking D~rect Screening Electronic Scanning Screen A ngles Ink Trapping Image Assembly Stripping Step and Repeat Electronic Composition Systems PLATEMAKING AND PRINTING Letterpress Platemaking and Printing Photoengraving Photopolymer Plates Duplicate Plates Electrotype Stereotype Rubber and Plastic Printing Plates Plate Assembly for Letterpress Printing Letterpress Printing Platen Presses Flat- Bed Cylinder Presses Rotary Presses Belt Presses Flexographic Presses Makeready for Letterpress Printing Tension in Printing Advantages and Disadvantages of Letterpress Printing Gravure Platemaking and Printing Conventional System for Plate and Cylinder Making

6 xxii CONTENTS Direct Transfer or variable Area System Variable Area- Variable Depth System Other Methods for Gravure Plate and Cylinder Making Gravure Printing Advantages and Disadvantages of Gravure Printing Lithographic Platemaking and Printing Lithographic Platemaking Surface Plates Deep-Etch Plates Bimetal Plates Handling Lithographic Plates on the Press Lithographic Printing Tension in Printing Ink- Water Balance Advantages and Disadvantages of Offset Lithography Screen Printing Screen Making Screen Printing BINDING AND FINISHING SPECIALTY PRINTING Packaging Printing Greeting Cards Newspaper Printing Magazine Publishing Book Publishing Business Forms Commercial Printing Heat Transfer Printing COPYING AND DUPLICATING Offset Duplicator Copier/Duplicators Stencil Duplicators PRINTING INKS Pigments Used in Printing Inks Properties of Printing Ink Body Length Tack Drying Letterpress Inks Lithographic Inks Gravure Inks

Flexographic Inks Screen-Printing Inks Ink Types Radiation-Curing Inks Electron Beam (EB) Curing Inks Quick-Setting Inks Super Quick-Set Infrared Inks Heat-Set Inks Hiah-Gloss Inks eat-~ransjer Inks

7 Flexographic Inks Screen-Printing Inks Ink Types Radiation-Curing Inks Electron Beam (EB) Curing Inks Quick-Setting Inks Super Quick-Set Infrared Inks Heat-Set Inks Hiah-Gloss Inks eat-~ransjer Inks Moisture-Set Inks Magnetic Inks Scuff-Resistant Inks Fluorescent Inks Varnish and Lacquer Adjusting the Ink to the Paper Environmental, Energy, and Safety Considerations PRINTING INK TRANSFER PAPER AND PAPERBOARD PROPERTIES REQUIRED FOR PRINTING Runnability of Printing Paper Mechanical Condition of Printing Papers Strength Requirements of Printing Papers Moisture Behavior of Printing Papers Printability of Paper Smoothness and Compressability Absorbency and Ink Receptivity of Printing Papers Press Testing for Printability Print Quality CHAPTER 24-REPROGRAPHY TYPES OF REPROGRAPHIC PAPERS REPROGRAPHIC SYSTEMS Offset Lithography Mimeograph or Stencil Duplicating Carbon Paper Duplicating No Carbon Required (NCR) Paper Spirit Duplicating Hectograph (Gelatin) Duplicators Liquid Process (Spirit) Duplicators A zo Processes

xxiv cosresrs Photocopying Processes Blueprint Process Diazo Process Electrostatic Duplicating Indirect Xerography (Plain Paper Electrophotography) The Photoconductive Surface in Xerography

8 xxiv cosresrs Photocopying Processes Blueprint Process Diazo Process Electrostatic Duplicating Indirect Xerography (Plain Paper Electrophotography) The Photoconductive Surface in Xerography Sensitizing the Photoconductive Surface Exposing the Charged Surface Developing the Image Transferring the Image in Xerography Fixing of Image Cleaning the Photoconductive Surface Paper for Xerography Paper for Magnetic and Liquid Toner Systems Progress in Xerography Ink-Jet Printing Continuous Ink Jet On-Demand Ink Jet ink-jet Printing Systems Magnetic Recording Direct Xerography Dielectric Recording Electrosensitive Recording Thermographic Imaging Dual Spectrum Process Dry Silver Imaging Diazonium Imaging Processes Diffusion Transfer and Dye Transfer Reprography Other Reprographic Processes Electrolytic Processes Photopolymerization Free Radical Systems Photochromics CHAPTER 25-LAMINATING TYPES OF LAMINATED PRODUCTS ADHESION ADHESIVE TYPES ADHESIVE PROPERTIES SUBSTRATE PROPERTIES LAMINATING PROCESS

Applying the Adhesive Combining the Plies Setting the Adhesive Special Adhesive Requirements Lamination by Welding WATER-SOLUBLE AND COLLOIDALLY DISPERSED ADHESIVES Starch and Dextrin Adhesives

9 Applying the Adhesive Combining the Plies Setting the Adhesive Special Adhesive Requirements Lamination by Welding WATER-SOLUBLE AND COLLOIDALLY DISPERSED ADHESIVES Starch and Dextrin Adhesives Sodium Silicate Adhesive Protein Adhesives Other Aqueous Solution Adhesives EMULSION ADHESIVES Resin Emulsion Adhesives Rubber Latex Adhesives Asphalt Emulsion Adhesives ORGANIC SOLVENT ADHESIVES HOT-MELT ADHESIVES Hot-Melt Resin Adhesives Wax Adhesives Asphalt Adhesives Laminating with Hot Melts POLYMERIZABLE ADHESIVES LAMINATING OPERATIONS Multiple Ply Paper and Board Laminates Paper Tubes Paper Bags and Sacks GUMMED PAPERS AND TAPES RELATED PACKAGING OPERATIONS CHAPTER 26-CORRUGATING GENERAL CHARACTERISTICS OF CORRUGATED BOARD THE CORRUGATING MACHINE The Single Facer The Double Backer Corrugator Finishing Operations Mechanically Related Corrugator Problems

xxvi CONTESTS STARCH ADHESIVE Theory of Starch Adhesive Bonding Adhesive Bond Control with Starch Preparation of Starch Adhesive SPECIAL STARCH ADHESIVES No-Carrier Starch Adhesive Water-Resistant

10 xxvi CONTESTS STARCH ADHESIVE Theory of Starch Adhesive Bonding Adhesive Bond Control with Starch Preparation of Starch Adhesive SPECIAL STARCH ADHESIVES No-Carrier Starch Adhesive Water-Resistant Starch Adhesive Cold Corrugating Starch Adhesive SYNTHETIC ADHESIVES QUALITY CONTROL IN CORRUGATING Testing of Linerboard and Medium Testing of Corrugated Board Testing of Finished Corrugated Box CHAPTER 27-PAPER REISFORCEMENT BY POLYMER ADDITION FIBER-P0LY;ZIER BONDISG Adhesion Theory Bond Strength Improvement Bonding with Latex METHODS OF POLYMER ADDITION Beater Addition Beater Addition Methods Alum Process Snyder Process Bardac Process Wet-Web Saturation Saturation by Capillary and Hydrostatic Forces Polymer Location and Migration PROPERTIES OF POLYMER-REINFORCED FIBER NETWORKS Tensile Deformation of Paper The Effects of Polymer Addition Fiber-Poly mer Interaction Creep of Polymer-Reinforced Paper CHAPTER 28-PAPER LAMINATES TYPES AND HISTORY OF LAMINATES LAMINATING PROCESS DESCRIPTION

VARIABLES THAT AFFECT THE LAMINATING PROCESS Effect of Paper Substrate on Impregnation Effect of Resin and Treating System on Impregnation Factors That Affect B-Staging Types of Paper Used in

11 VARIABLES THAT AFFECT THE LAMINATING PROCESS Effect of Paper Substrate on Impregnation Effect of Resin and Treating System on Impregnation Factors That Affect B-Staging Types of Paper Used in Lamination Core Stock Paper Surface Papers Used in Decorative Laminates Solid Color and Print Sheets Overlay Paper Other Papers Used in Lamination Function of the Resin in Paper Laminates Phenol Formaldehyde Resins Melamine Formaldehyde Resins Epoxy Resins Decorative Laminates Industrial Laminates Copper-Clad Laminates CHAPTER 29-AQUEOUS AND SOLVENT COATING SOLUTION AND EMULSION PROPERTIES OF POLYMERS Polymer Solutions Viscosity and Rheologv of Polymer Solutions Preparation of Polymer Solutions Polymer Emulsions SOLVENTLESS AND 100 PERCENT SOLIDS COATING SYSTEMS FORMATION AND PROPERTIES OF COATING FILMS Film Formation Fundamental Properties of Coatings A dhesion Mechanical Properties Glass Transition Temperature Melting Temperature Gloss Permeability to Gases and Vapors FUNCTIONAL PROPERTIES OF COATED PAPERS Water and Water Vapor Barrier Grease Resistance

xxviii cos~rs~s Gas Barrier Release and Repellency Heat Sealing Gloss Friction Control COATED IMAGING SYSTEMS Carbonless Copy

Systems Puddle Coater Other Blade Coaters Roll Coaters Gravure Coaters Air-Knife Coaters Rod Coaters Drying of Functional Coatings

Polyvinyl Acetate and Copolymers Polyvinyl A lcohol Polyvinyl A cetal Polyacry lates Polyvinylidene Chloride Polyethylene and

12 xxviii cos~rs~s Gas Barrier Release and Repellency Heat Sealing Gloss Friction Control COATED IMAGING SYSTEMS Carbonless Copy Paper 1 Electrostatic Printing Electrophotographic Electrographic METALIZED PAPER COATING METHODS Blade Coating Application Systems Puddle Coater Other Blade Coaters Roll Coaters Gravure Coaters Air-Knife Coaters Rod Coaters Drying of Functional Coatings POLYMERS USED IN FUNCTIONAL COATINGS Natural ~ol~me;s and Derivatives Starch Cellulose Derivatives Proteins Synthetic Polymers Polyvinyl Acetate and Copolymers Polyvinyl A lcohol Polyvinyl A cetal Polyacry lates Polyvinylidene Chloride Polyethylene and Copolymers Polystyrene Butadiene Silicone Polymers Amino Resins A lkyd Resins Polyurethanes CHAPTER 30-EXTRUSION COATING EQUIPMENT FOR EXTRUSION COATING

Barrel Cooling Temperature Controllers Extruder Screws Extruder Adaptor System Screen Pack Breaker Plate Adaptor Valve Process Instrumentation Static Mixers Dies for Extrusion Coating Coextrusion

Properties of Polyethylene Polypropylene Extrusion Polyesters for Extrusion Ethylene Copolymers for Extrusion Ethylene Acrylic Acid Ionomers Ethylene Vinyl A cetate Nylon 2528 ADHESION PROMOTION

13 Barrel Cooling Temperature Controllers Extruder Screws Extruder Adaptor System Screen Pack Breaker Plate Adaptor Valve Process Instrumentation Static Mixers Dies for Extrusion Coating Coextrusion Extruder Carriage Laminator for Extrusion Coating POLYMERS USED IN EXTRUSION COATING Polyethylene Extrusion Drawdown Neck-In Adhesion of Polyethylene Taste and Odor of Polyethylene Barrier Properties of Polyethylene Polypropylene Extrusion Polyesters for Extrusion Ethylene Copolymers for Extrusion Ethylene Acrylic Acid Ionomers Ethylene Vinyl A cetate Nylon 2528 ADHESION PROMOTION SYSTEMS IN EXTRUSION COATING 2528 Coextrusion Adhesive Coatings Adhesion Promoters Surface Treatment CHAPTER 31-HOT-MELT COATING PREPARATION OF HOT MELTS APPLICATION OF HOT MELT COATINGS Curtain Coating Roll Coating

Report No. 83 ADHESIVES. February A private report by the PROCESS ECONOMICS PROGRAM PARK, CALIFORNIA STANFORD RESEARCH INSTITUTE I

Report No. 83 ADHESIVES. February A private report by the PROCESS ECONOMICS PROGRAM PARK, CALIFORNIA STANFORD RESEARCH INSTITUTE I Report No. 83 ADHESIVES by WING SIEN FONG February 1973 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I MENLO PARK, CALIFORNIA CONTENTS 1 INTRODUCTION........................