Ink Jet Dispersions… Challenges & Opportunities IMI Ink Jet Conference February 5-6, 2015
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
About RJA Founded in 2002 We’ve grown to be a key supplier of nano-particle pigment dispersions We sell dispersions to manufacturers of Ink Jet Inks We don’t make inks Strong technical & customer support We maintain high ethical standards, and contribute to our industry and community
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Primary Market: Digital • UV, Solvent & Aqueous Colorants Imaging – Graphic Arts • Expanding to New Applications – High Value Industrial Focus
• Adding New Equipment & Staff
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Objective for today • Overview Expanding Applications for Ink Jet • Review Materials / Dispersion requirements for these • Identify Challenges & Opportunities • Get your feedback on important applications and needs.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Ink Jet Applications are Expanding • Digital Presses. Roll and Sheet fed. • Hi Speed Label and direct to Package Printing. • White Materials • 3-D Printing materials. • Textile Printing Tees, Stand-ups, Apparel • Architectural Applications - Ceramics, Laminates • Flexible Printed Electronics • Others …
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Printing:
“Supersized” rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Wide Format, Rigid Substrate, UV Flatbed
rja
Printer
Model
Speed sf/hr
Drop size
DPI
Nozzles
Durst Rho
1312
6600
12
1000
65000+
MTL Nurstar
304D
2700
6-42
1440
16000
HP Scitex
FG10000
6456
15-45
600
312 heads
Incadigital
S50i
7803
27
600
224 heads
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Printing: Evolving to the Digital Press rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Wide format – Fixed Array • Xerox IPJ2000 – 1600x1600 – 6 in/sec (6300 sf/hr) – 42” wide fixed array heads – 70,400 nozzle heads – Aqueous dye inks – (Fuji Xerox – Memjet) – Shown at SGIA
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
In Line Digital Printing Presses Printer
Model
Tech
Speed sf/hr
DPI
Width (in)
Prosper 5000XLi
Aqueous IJ
78000
175 line screen
24.5
Komori – Konica Minolta Sheet Fed
KM-1/IS29
UV Curable Piezo
15000
1200
29
Landa Roll & Sheet
S-10 & family
Aqueous “Nanography”
6500 - 12500
1200 + grey scale
29.5
T410
Aqueous IJ
126000
1200
42”
Kodak Roll Fed
HP
Prosper 5000
rja
S-10
dispersions,llc
KM-1
T410
A Leader in Ultra-Fine Particle and Pigment Dispersions
Narrow Format, Fixed Array, Digital Label Printers
EFI
Printer
Model
Tech
Speed sf/hr
DPI
Width (in)
Durst
Tau 330
UV
10000
1000
13
EFI / Jetrion
4900-300
UV
5200
1080
13
Komori / INX
NW210-E
UV LED / Xaar
3300
720
8.25
Digital Series
UV
15000
600
12.5
Mark Andy
Durst
Mark Andy
rja
dispersions,llc
Komori / INX
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital - Direct to Package • Machines Dubuit – Robotic Printer – Ink Jet Deposition – UV curable inks.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Printing:
Textiles rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Textile Wide Format, roll-roll Printer Konica Minolta – Reactive, Disperse, Acid dye inks Mimaki Direct Dye and Dye Sub
Model
Speed sf/hr
Drop size
DPI
Nozzles
Nassenger Pro 1000 Pro 120
4300 1200
14
900x720
82944
649 /380
Variable 7-21
1440
5760
JV5-320DS
KonicaMinolta Mimaki
Nassenger Pro 120 -1200 sf/hr
JV5-Textile Belt printer
rja
dispersions,llc
Nassenger Pro 1000 – 4300 sf/hr
A Leader in Ultra-Fine Particle and Pigment Dispersions
Tee Shirt - Printing
Kornit Avalanche 1000
AnaJet mPower
Epson F2000
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Materials require Colorants • That don’t fade • That don’t settle • That don’t clog nozzles of ever higher resolution and Fixed Array print heads • Have the right viscosity, rheology, particle size • That have stability under wide ranging conditions. • That can be easily incorporated into inks
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Non-fading chemistries • Process Magenta, Red – Quinacridones: PR122, PR202, PV19 • Lightfast, transparent, process magenta shades
– DPP:
PR254
• Lightfast, semi-opaque, medium red
• Process Yellows – Benzimidazolone : PY151 (Lightfast, transparent, green shade) – Azo Ni-Complex PY150 (Lightfast, transparent, economical) – Single Azo PY120 (Lightfast, transparent, medium shade) – Double Azo PY155 (Lightfast, transparent, expensive) – Isoindoline PY139 (Lightfast, transparent, red shade)
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Non-fading chemistries – cont. • Process Cyan – Phthalocyanine Blue 15:3 • Lightfast, Transparent, process cyan
– Phthalocyanine Blue 15:4 • Lightfast, Transparent, Process cyan – with synergist.
• Process Black PBl 7 • White PW 6 – TiO2 (High density pigment – 4.7. Will “soft settle”) • Others: Orange 64, 79, and 43, Green 7, 36; PB60, PV 23 & 55
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
…that won’t settle • Need smaller particles to prevent settling and nozzle clogging. • Stokes Law states : Settling velocity ~ kr2 / viscosity k is a constant, and r is the particle radius. (small particles and hi viscosity prevent settling)
• High viscosity doesn’t work for ink jet applications. • Small particles tend to attract and aggregate. – Dipole moment attraction vs Brownian motion – V = 4ε[(σ/r12) - (σ/r6)]
rja
dispersions,llc
(Lennard-Jones 6-12 Potential)
A Leader in Ultra-Fine Particle and Pigment Dispersions
Particle Attraction (Cont.) • Nano Particles can be stabilized with the right dispersants to prevent agglomeration over time. – Polymeric – Surfactant (for aqueous) – Pigment surface treatments
• A nano-pigment dispersion needs to be stable in an ink to the point that there is no significant particle size change over several years. • No changes in viscosity, color, and particle size after heat aging.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Particle Size – Ink Jet-ability • Factors: – Primary particle size of underlying material – Milling process
• Goal – 80 to 150 nm mean size – Very sharp peaked distribution. (D99 less than 300nm) – Zero large particles in tail. (everything well under 1 um)
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Particle Size and drop formation for Ink Jet • For best jetting, need a stable, narrow particle size distribution of small particles to prevent: – Erratic Drop Formation – Settling – Particle Size Growth
• Viscosity, surface tension, and density affect drop break up. Higher viscosity results in longer necks, more satellites.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
D3010-FX-R122 25% in 2-PEA
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Filterability • Particle size analysis has trouble with large particles at low concentrations. • Cost of filtering ink (change of filters, loss of pigment) can be significant. • Trouble-free operation of the new Fixed Array heads requires inks free of particles more than ~ 500nm. • Cleanliness testing for filterability – Test by filtering multiple aliquots of concentrate under vacuum. Record time for first and last aliquot – take ratio of first to last.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Stability • Shelf Life – 6 months or more • Tranportation – 4 weeks at elevated temperatures. • Stable when “Let-down” in inks. – Ink vehicle chemistry matters. (adhesion promoters..) – Ink viscosity must remain stable, with no sedimentation.
• Test by Heat Aging: – Concentrate: 4 weeks at 55C – shelf life – Ink let-down 8 weeks at 65C without viscosity change.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Pourable Dispersions: 25%/wt pigment
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
White Dispersions • Emerging need for opaque whites to allow Ink Jet color printing on darker substrates. • Textiles, 3D printed objects , as well as Graphics • Lots of issues – How to get opacity – pigment choice, size distribution – How to get it to work – high density pigments settle – How to print textiles without “soaking in”
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Refractive index. High Index – light is redirected strongly. High reflectivity
Low Index – light penetrates to substrate. Low reflectivity http://www2.dupont.com/ Titanium_Technologies/en_US/ tech_info/literature/Coatings/ CO_B_H_65969_Coatings_Brochure.p df
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Refractive Index Example
http://www2.dupont.com/Titanium_Technologies/en_US/tech_info/literature/ Coatings/CO_B_H_65969_Coatings_Brochure.pdf
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Diffraction - Scattering
http://www2.dupont.com/Titanium_Technologies/en_US/tech_info/literature/ Coatings/CO_B_H_65969_Coatings_Brochure.pdf
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
“Dispersion quality” Effects
http://www2.dupont.com/Titanium_Technologies/en_US/tech_info/literature/ Coatings/CO_B_H_65969_Coatings_Brochure.pdf
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
D2050-W6 50% /wt Aqueous
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
How to mitigate soft settling • Recirculating heads.
Xaar 1002
Dimatix Galaxy
• Recirculating printer systems - Ricoh • Additives – may affect stability / compatibility
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Textile Printing Challenge – White Opacity • Ink has to be stable in storage and use, yet able to “crash” on contact with a primer. • Polymer Immersion Technology (DuPont) – Salt solution used as primer on fabric – Proprietary polymer reacts and deposits on surface. – Heat post-treatment to fix
• Tee Shirt printers use this approach (and others) – Epson, Kornit, AnaJet, …
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Printing:
3D rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
3D Printing • 3D Systems – Home & Professional – ProJet x60 color printers
• Stratasys / Objet – Full line – New Dental System
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
3D Printing Technologies • Fused Filament Fab
• Multi-jet™
– (hot melt extrusion) – Plastic Jet, FDM™ – Thermoplastics ABS ABSi, PPSF, PC
• Stereolithography
– Piezo head jets photocurable or wax resin layers
• Color-Jet™
– Laser beam intersections cure reactive photopolymer – build up layers.
rja
dispersions,llc
– Core layer spread – Ink Jet deposition of colored binder – cures core, provides color
A Leader in Ultra-Fine Particle and Pigment Dispersions
Challenges / Opportunities 3D • Need for realistic colors as well as shapes. • Whites / shades • Full Color parts. • Chemically, UV curable • Initial deposition has been extrusion or SLA • IJ Deposition emerging
rja
dispersions,llc
ProJet 460plus Output from Stratasys website
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Printing: Architectural rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Flooring, Laminates • Commercial Floor Graphics - since 1990s • Ceramic Tiles. - Now well established. – EFI, Durst, Tekwin, – Xaar, Dimatix heads. – Inorganic slurrys (colored frit) jetted then fired. – (dye sub also used for “non-wear” surface decoration)
• Laminates – Gravure printed papers – embedded in laminate – Mfg Cost / sf is barrier. Aqueous inks
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
IJ Challenges / Opportunities • Architectural – Jetting frit is challenge – recirculating heads offer a soln. – Cost of materials is low – hard to make a good business – Laminates – profit issue - laminates can retail for $2 /sf. – Dynamic, growing market opportunity. Lots of applications that support costs. – For laminates, Digital Presses will be able to print at much lower costs/sf than current wide format printers.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Digital Printing: Electronics rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Electronics • Applications for printed electronics – Flexible consumer electronics / wearables – Solar cells (OSU, MIT, others) http://oregonstate.edu/ua/ncs/node/14094 • CIGS / Chalcopyrite materials (Copper Indium Gallium Selenide) • Additive – reduce waste. • No vacuum deposition - lower cost process • Flexible and paper substrates possible (solar window shade?)
– Low cost, light weight batteries. • Harvard / Illinois team • 3D printed battery.
rja
• http://www.seas.harvard.edu/news/2013/06/printing-tiny-batteries
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Challenges and Opportunities Electronics • Existing deposition processes are well entrenched, and offer high quality thin film products. • Promise of additive manufacturing: – reduced waste of expensive and scarce materials, – lower process cost.
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Perspectives • New Technology always takes longer than you expect. • Ink Jet Manufacturing is a great opportunity • Life span of IMI Ink Jet Conferences gives us a timeline. Look how far we’ve come. • We’re all still pioneering new landscapes! – Jetting biology - organogenesis … ?
• …. It’s a great time for Ink Jet
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
Manufactured in USA • Moving Forward
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
RJA Dispersions, LLC 2745 Harvey Street Hudson, Wisconsin 54016 715-808-0172 Fax: 715-808-0474 Contact: Joseph Ward, VP Marketing
[email protected] www.rjadispersions.com
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
rja
dispersions,llc
A Leader in Ultra-Fine Particle and Pigment Dispersions
