PROCESS FOR THE APPLICATION OF BRILLIANT METALLIC INKS TO PAPER OR PAPERBOARD
A process for applying an energy-curable primer and a brilliant metallic ink to a paperboard or paper substrate is provided. The primer may be cured using an energy curing system such as a UV or EB curing system. The curable primer facilitates the orientation of the metallic pigment particles to provide a coherent reflectance of light and optimal reflectance. Advantageously, the primer-cured paper may be “spot-coated” with the metallic ink at pre-designated areas, which minimizes the amount of metallic ink used. In exemplary embodiments, the metallic paper is over-coated with one or more transparent or opaque inks. Additionally, the cured, primer coated paper may be subjected to corona discharge to remove excess solvent and compounds in the liquid phase within the matrix of the cured primer and/or to increase the surface tension of the primer. In certain circumstances, the metallic paper and the end product are recyclable and repulpable.
1 . A method of forming a brilliant metallic coated paper material comprising:
applying a substantially level layer of energy-curable primer coating to a first major surface of the paper material;
curing the layer of energy-curable primer to create an ink receptive and substantially inactive interface layer, a top surface of the inactive interface layer having a relatively high surface tension;
applying a reflective metallic ink to at least a portion of the cured primer layer, such that the metallic ink has lower surface tension than the top surface of the inactive interface layer, and includes a plurality of reflective metallic particles and deposited in a substantially planar orientation; and
drying the metallic ink to form a metallic ink layer on the cured primer.
2 . A method as in claim 1 , wherein the applying comprises applying the primer directly to a first major surface of the paper material.
3 . A method as in claim 1 , wherein the applying comprises applying the primer to an intermediate layer already present on the first major surface of the paper material.
4 . A method as in claim 1 , further comprising applying one or more opaque or transparent inks sequentially onto said metallic ink layer.
5 . The method of claim 1 , further comprising applying a transparent top coat to said metallic ink layer.
6 . The method of claim 1 , wherein said curing comprises irradiating the energy-curable primer with an ultraviolet or electron beam curing apparatus.
7 . The method of claim 1 , wherein at least one of said energy curable primer and said metallic ink is toned.
8 . The method of claim 1 , further comprising subjecting said cured primer layer to corona discharge prior to applying said metallic ink to said cured primer layer.
9 . The method of claim 1 , wherein said energy-curable primer is applied to said paper in a print unit in a paper printing apparatus,
wherein said metallic ink is applied to said cured primer layer in a subsequent print unit in said paper printing apparatus, and
wherein said curing occurs externally to said paper printing apparatus.
10 . The method of claim 1 , wherein said paper material comprises a material selected from the group consisting of paper and paperboard.
11 . The method of claim 1 , further comprising:
cutting the coated paper material to form blanks;
scoring the blanks; and
folding the scored blanks to form a package.
12 . A metallic paper or paperboard comprising:
a paper web having on a major surface thereof a coating of a cured primer forming a cured primer layer; and
a coating of a metallic ink having therein metallic ink particles, said metallic ink being positioned on said cured primer layer and forming a metallic ink layer, the particles being in a substantially planar orientation.
13 . The metallic paper or paperboard of claim 12 , wherein said orientation of said metallic particles minimizes light scattering and maximizes light reflectance to the human eye.
14 . The metallic paper or paperboard of claim 12 , further comprising a transparent top coat positioned on said metallic ink layer.
15 . The metallic paper or paperboard of claim 12 , further comprising one or more layers of opaque or transparent inks sequentially positioned on said metallic ink layer.
16 . The metallic paper or paperboard of claim 12 , wherein said metallic ink is located on designated portions of said cured primer layer so as to form a predetermined design or logo on said cured primer layer.
17 . A carton product comprising:
a metallic paper substrate or paperboard scored and folded into a box having at least three sides, each said side having an external face and an internal face; and
an interior portion located within said box for containing a product,
wherein said metallic paper comprises:
a paper web having on a major surface thereof a coating of an energy-cured primer forming a cured primer layer; and
a coating of a metallic ink having therein metallic ink particles, said metallic ink being positioned on said cured primer layer and forming a metallic ink layer, the particles being in a substantially planar orientation, and
wherein said metallic ink layer is located on one or both of said external faces and said internal faces.
18 . The carton product of claim 17 , wherein an ink layer underlies the primer layer.
19 . The carton product of claim 17 , further comprising a transparent top coat positioned on said metallic ink layer.
20 . The carton product of claim 17 , further comprising one or more layers of opaque or transparent inks sequentially positioned on said metallic ink layer.