Powder-coated support and production method thereof
View Patent ↗An object is to provide a method for efficiently producing a powder-coated support, which does not require a drying process and can use, without limitation, even a resin that hardly forms a latex or an aqueous solution, and to provide a powder-coated support obtained by the production method, which exhibits less swelling of its base paper and has excellent smoothness and glossiness. A method produces a powder-coated support by applying a powdery resin composition containing at least a thermoplastic resin to at least one side of a base paper, and hot-pressing the resulting article. The hot pressing is preferably performed by heating the article at a temperature equal to or higher than the melt-starting temperature of the thermoplastic resin and cooling the same to a temperature of 80° C. or lower using a powder coating machine of cooling-removing system.
1. A method for producing a powder-coated support, comprising the steps of:
applying a powdery resin composition to at least one side of a base paper, the powdery resin composition containing at least a thermoplastic resin; and
hot-pressing the powdery resin composition on the base paper,
wherein the step of hot-pressing comprises
subjecting the coated layer of the powdery resin composition on the base paper to hot-pressing and then cooling with a belt member and a roller of a powder coating machine that can cool and thereby remove an article; and
removing the coated layer on the base paper from the belt member.
2. A method for producing a powder-coated support according to claim 1 , further comprising electrostatically applying the powdery resin composition to the at least one side of the base paper.
3. A method for producing a powder-coated support according to claim 1 , further comprising:
hot-pressing the coated layer to a melt-starting temperature of the thermoplastic resin in the powdery resin composition or higher; and
cooling the heated and pressurized coated layer to a temperature of 80° C. or lower.
4. A method for producing a powder-coated support according to claim 1 , wherein the thermoplastic resin in the powdery resin composition is at least one selected from polyester resins, acrylic resins, styrene-acrylic resins, polyethylene resins, ionomer resins, and polyurethane resins.
5. A method for producing a powder-coated support according to claim 1 , wherein the powdery resin composition further contains a white pigment.
6. A method for producing a powder-coated support according to claim 1 , wherein the powdery resin composition further contains at least one of fine inorganic particles and fine organic particles.
7. A method for producing a powder-coated support according to claim 1 , wherein the powdery resin composition is one of a transparent powdery resin composition and a white powdery resin composition.
8. A method for producing a powder-coated support according to claim 1 , wherein the belt member has a surface roughness in terms of an arithmetic average roughness Ra of 20 μm or less.
9. A method for producing a powder-coated support according to claim 1 , wherein the belt member is an endless belt.
10. A method for producing a powder-coated support according to claim 1 , wherein the belt member has a layer on its surface, the layer containing at least one selected from silicone rubbers, fluorocarbon rubbers, silicone resins, fluorocarbon resins, and mixtures thereof.
11. A powder-coated support comprising:
a base paper; and
a resin layer disposed on at least one side of the base,
wherein the powder-coated support is produced by:
applying the powdery resin composition to at least one side of the base paper, the powdery resin composition containing at least a thermoplastic resin; and
hot-pressing the powdery resin composition on the base paper to thereby fuse and solidify the powdery resin composition to form the resin layers,
wherein the step of hot-pressing comprises
subjecting the coated layer of the powdery resin composition on the base paper to hot-pressing and then cooling with a belt member and a roller of a powder coating machine that can cool and thereby remove an article; and
removing the coated layer on the base paper from the belt member.
12. A powder-coated support according to claim 11 , wherein the powdery resin composition is electrostatically applied to the at least one side of the base paper.
13. A powder-coated support according to claim 11 , wherein the powder-coated support has a Cobb sizing water absorbency of 10 g/m 2 or less.
14. A powder-coated support according to claim 11 , wherein the powder-coated support has a surface glossiness in terms of 20-degrees glossiness of 45 or more.
15. An electrophotographic material comprising:
a powder-coated support; and
a toner-image-receiving layer on the powder-coated support,
wherein the powder-coated support comprises:
a base paper; and
a resin layer disposed on at least one side of the base, and
wherein the powder-coated support is produced by:
applying the powdery resin composition to at least one side of the base paper, the powdery resin composition containing at least a thermoplastic resin; and
hot-pressing the powdery resin composition on the base paper to thereby fuse and solidify the powdery resin composition to form the resin layer.