Ink-jet recording medium for dye- or pigment -based ink-jet inks

Abstract

The present invention is drawn to a method of preparing a porous media substrate, comprising combining metal or semi-metal oxide particulates with a polymeric binder, wherein the metal or semi-metal oxide particulates are associated with at least one water soluble coating formulation additive. At least a portion of the water soluble coating formulation additive i) is in the form of unreacted additive, or ii) generates undesired electrolytes. Additional steps include removing at least a portion of the unreacted additive or undesired electrolytes, either before or after combining the metal or semi-metal oxide particulates with the polymeric binder, thereby forming a refined coating composition; and applying the refined coating composition to a media substrate to form an ink-receiving layer having a porous surface.

1 . A method of preparing a porous media substrate, comprising: 
 combining metal or semi-metal oxide particulates with a polymeric binder, wherein the metal or semi-metal oxide particulates are associated with at least one water soluble coating formulation additive, wherein at least a portion of the water soluble coating formulation additive i) is in the form of unreacted additive, or ii) generates undesired electrolytes;    removing at least a portion of the unreacted additive or undesired electrolytes, either before or after combining the metal or semi-metal oxide particulates with the polymeric binder, thereby forming a refined coating composition; and    applying the refined coating composition to a media substrate to form an ink-receiving layer having a porous surface.    
   
   
       2 . A method as in  claim 1 , wherein metal or semi-metal oxide is silica.  
   
   
       3 . A method as in  claim 1 , wherein metal or semi-metal oxide is alumina.  
   
   
       4 . A method as in  claim 1 , wherein the binder includes a member selected from the group consisting of polyvinyl alcohol, modified polyvinyl alcohol, and combinations thereof.  
   
   
       5 . A method as in  claim 1 , wherein water soluble coating formulation additive includes a member selected from the group consisting of ionic mordants, ionic multivalent ions, ionic organosilane reagents, acidic components, crosslinking agents, organic salts, inorganic salts, and combinations thereof.  
   
   
       6 . A method as in  claim 5 , wherein the water soluble coating formulation additive includes an ionic multivalent ion, said ionic multivalent ion including aluminum chlorohydrate.  
   
   
       7 . A method as in  claim 5 , wherein the water soluble coating formulation additive includes an ionic organosilane reagent, said ionic organosilane reagent including an amine moiety.  
   
   
       8 . A method as in  claim 5 , wherein the water soluble coating formulation additive includes an acidic component, said acidic component including an acidic crosslinking agent.  
   
   
       9 . A method as in  claim 8 , wherein the acidic crosslinking agent is boric acid.  
   
   
       10 . A method as in  claim 1 , wherein the refined coating composition further includes an air fade additive configured to improve air fade resistance of an image printed on the porous media substrate.  
   
   
       11 . A method as in  claim 10 , wherein the air fade additive is selected from the group consisting of hindered amines, thio compounds, and combinations thereof.  
   
   
       12 . A method as in  claim 1 , wherein the step of removing is by a process selected from the group consisting of ultrafiltration, dialysis, ion exchange, reverse osmosis, and combination of process thereof.  
   
   
       13 . A method as in  claim 12 , wherein the step of removing is by ultrafiltration.  
   
   
       14 . A method as in  claim 13 , wherein the ultrafiltration is carried out using a porous filter having an average pore size from 20 nm to 100 nm.  
   
   
       15 . A method as in  claim 1 , wherein the porous surface has a pH from about 4 to about 7.5.  
   
   
       16 . A method as in  claim 15 , wherein the porous surface has a pH from about 5 to about 6.  
   
   
       17 . A method as in  claim 1 , wherein the step of removing occurs prior to combining the metal or semi-metal oxide particulates with the polymeric binder.  
   
   
       18 . A method as in  claim 1 , wherein, after the applying step, the porous surface is subsequently coated with a second coating that is substantially devoid water soluble coating formulation additive.  
   
   
       19 . A method as in  claim 1 , wherein the media substrate includes an inorganic porous media precoat, and wherein the step of applying the refined coating composition to the media substrate is by overcoating the precoat.  
   
   
       20 . A method as in  claim 1 , further comprising the step of washing the ink-receiving layer.  
   
   
       21 . A method as in  claim 1 , wherein the washing step is to remove additional unreacted additive or undesired electrolytes.  
   
   
       22 . A media sheet, comprising: 
 a media substrate;    a refined coating composition applied to the media substrate, said refined coating composition including metal or semi-metal oxide particulates, a polymeric binder, and at least one water soluble coating formulation additive, wherein the water soluble coating formulation additive is present in the refined coating composition in amount less than an initial amount, said initial amount of the water soluble coating formulation additive including i) an amount of unreacted additive, or ii) generated undesired electrolytes, at least a portion of said unreacted additive or undesired electrolytes being removed from the initial amount prior to the refined coating composition being applied to the media substrate.    
   
   
       23 . A media sheet as in  claim 22 , wherein the media substrate is selected from the group consisting of paper, overhead projector plastic, coated paper, fabric, art paper, water color paper, and photobase.  
   
   
       24 . A media sheet as in  claim 22 , wherein the property that is enhanced is gloss uniformity upon printing ink on the media sheet.  
   
   
       25 . A media sheet as in  claim 22 , wherein the property that is enhanced is color gamut upon printing ink on the media sheet.  
   
   
       26 . A media sheet as in  claim 22 , wherein the property that is enhanced is humid bleed reduction upon printing ink on the media sheet.  
   
   
       27 . A media sheet as in  claim 22 , wherein the property that is enhanced is reduced coating composition cracking upon application to the media substrate and drying.  
   
   
       28 . A media sheet as in  claim 22 , wherein the property that is enhanced is ink-receiving capacity upon printing ink on the media sheet.  
   
   
       29 . A media sheet as in  claim 22 , wherein metal or semi-metal oxide is selected from the group consisting of silica, alumina, titania, zirconia, and combinations thereof.  
   
   
       30 . A media sheet as in  claim 22 , wherein the binder includes a member selected from the group consisting of polyvinyl alcohol, modified polyvinyl alcohol, and combinations thereof.  
   
   
       31 . A media sheet as in  claim 22 , wherein the water soluble coating formulation additive includes a member selected from the group consisting of ionic mordants, ionic multivalent ions, ionic organosilane reagents, acidic components, organic salts, inorganic salts, and combinations thereof.  
   
   
       32 . A media sheet as in  claim 22 , wherein the unreacted additive or the undesired electrolytes are removed by a process selected from the group consisting of ultrafiltration, dialysis, ion exchange, reverse osmosis, and combination of process thereof.  
   
   
       33 . A media sheet as in  claim 32 , wherein the step of removing is by ultrafiltration.  
   
   
       34 . A media sheet as in  claim 33 , wherein the ultrafiltration is carried out using a porous filter having an average pore size from 20 nm to 100 nm.  
   
   
       35 . A media sheet as in  claim 22 , wherein the coating composition further includes an air fade additive.  
   
   
       36 . A media sheet as in  claim 22 , wherein the porous surface has a pH from about 4 to about 7.5.  
   
   
       37 . A media sheet as in  claim 22 , wherein said unreacted additive or undesired electrolytes is removed from the initial amount prior to combining the metal or semi-metal oxide particulates with the polymeric binder.  
   
   
       38 . A media sheet as in  claim 22 , further including a second coating composition applied to the coating composition, said second coating composition being substantially devoid of any water soluble coating formulation additive.  
   
   
       39 . A media sheet as in  claim 22 , further including an inorganic porous media precoat applied between the media substrate and the coating composition.  
   
   
       40 . A media sheet as in  claim 22 , wherein the water soluble coating formulation additive enhances at least one of a coating preparation property, a coating application property, or a media performance property of the media sheet.