SURFACE IJIEN<l1ENA IN o)ATINGS AND PRINTING TECliNOLCX;Y

Mahen1ra K. Shama

Easbnan <l1emical Conpany

Kin;Jsport, 'IN 37662

'!his paper describes various aspects of water-based

coatings and printing processes with special ~is on
the surface characteristics of coating/printing films.
'!he film formation depends significantly on the surface
properties of formulated coating/ink, and their
interactions with substrates. Several surface parameters
in relation to coating defects are briefly described.
'!he nechanisms of printing processes and coating/ink film
formation by water-based systems are presented. It has
been shown that the formation of surface tension gradient
during film curing detennines the quality of the coating
and printing films. Results demonstrate that the
incorporation of suitable additives in the formulation
can cx:msiderably minimize the crater formation. '!he
hydroplilic-lipophilic balance (HLS) concept and the
effect of surfactant concentration on pigment dispersion
in an aqueous medium are discussed. An attempt was made
to correlate the performance parameters of ink and coated
film with the properties of the formulated coatings or inks
containing various ingredients in order to obtain desired
properties of the coating/printing films.

INTROUJCI'ION

Several possible methods such as solvent recovery, incineration,

high solids coatings, reactive coating systems (e.g. UV curable, EV
curable) and water-based coating and printing systems are available to
COlWerters to COIll>ly with federal, state and local Environmental
Protection Aqe.T'Cj (EPA) standards. Arrong these alternatives, it was
difficult to estimate which COIll>liance method would be most effective and
econcxnical for operating each plant. Each of these alternatives has
various advantages and disadvantages, as well as needs finn commibnent
from COlWerters in terms of time, !l1al1pCMer and capital for equipment
1OCldification. As a long-term COIll>liance strategy, many colWerters have
decided to evaluate the water-based coating and printing systems.

Surface Phenomena and Fine Particles in Water-Based Coatings and Printing Technology
Edited by M.K. Sharma and F.l. Micale, Plenum Press, New York, 1991
 Water-based coating and printing systems have several advantages:
cost effective, rerluce volatile organic c:x:tIp)l.lIrl (VOC) emissions, involve
minimum use of and exposure to hazardous organic solvents , easily harrlled
and perfonns well in certain applications. on the other harrl, the main
disadvantages include: sla.v drying, foaming, machinability problem,
stability of fonnulated coatings and printing inks and poor wetting of
an::ljor adhesion to la.v surface energy substrates. rm-ing the past years,
considerable p~_~ been made to overcome these problems employing
water-based systems.

Several water-based coating/printing fonnulations involve binder in

the fonn of fine particles dispersed in the system. '!hese are often
kna.vn as pseudolatex (e.g. colloidal dispersion). I f binder employed in
coating/printing fonnulations is present in the dispersion fonn, the
mechanism of film fonnation is considerably different as carpared to film
fonnation from binder in solution fonn. '!he pseudolatex particles must
coalesce in order to fonn a continuous and smooth film. '!he mechanism of
film fonnation from colloidal dispersion is schematically illustrated in
Figure 1.

Most colloidal dispersions are milky in color due to large particle

size carpared to rolecular solution (e.g. clear). In order to achieve
desired coating/printing properties, the size of these particles must be
rerluced to a significant extent, which can be obtained by adding
plasticizer, suitable solvent as well as by curing at high temperature.
one must consider these alternatives for coating/printing from
water-based systems containing binder in the fonn of colloidal dispersion
fonn.

'!he studies published so far on water-based coating/printing systems

often have little appreciation of the surface and interfacial aspects of

Aqueous
- _....... Dispersions

! Water Evaporation

Closed Packing of Particles with Water-Filled Voids

9JWjJ1jJJl»)1Jft»J1 Surface

1
Polymer Deformation
Water Evaporation
, / Continuous Coating
~I------------------------~ Rim
7/77/7/7/7//7///7/7//7 Surface

Fig. 1. Mechanism of Film Fonnation from Aqueous Dispersions of

Polymer.