U.S. patent number 3,904,411 [Application Number 05/119,911] was granted by the patent office on 1975-09-09 for photoimaging and color proofing.
This patent grant is currently assigned to Monsanto Company. Invention is credited to Floyd B. Erickson, Robert A. Heimsch, Eric T. Reaville.
United States Patent |
3,904,411 |
Erickson , et al. |
September 9, 1975 |
Photoimaging and color proofing
Abstract
This invention concerns a procedure for photoimaging
photosensitive coatings, development by selectively removing part
of the coating, and transfer of the image to another support. The
procedure is useful for production of multicolor images by multiple
transfers of images from color separations.
Inventors: |
Erickson; Floyd B. (St. Louis,
MO), Heimsch; Robert A. (St. Louis, MO), Reaville; Eric
T. (Webster Groves, MO) |
Assignee: |
Monsanto Company (St. Louis,
MO)
|
Family
ID: |
22387134 |
Appl.
No.: |
05/119,911 |
Filed: |
March 1, 1971 |
Current U.S.
Class: |
430/257; 430/293;
430/913; 522/48; 522/71; 522/158; 430/256; 430/322; 522/9; 522/63;
522/75; 522/159; 430/286.1 |
Current CPC
Class: |
G03F
7/26 (20130101); G03F 3/106 (20130101); Y10S
430/114 (20130101) |
Current International
Class: |
G03F
7/26 (20060101); G03F 3/10 (20060101); G03C
011/12 (); G03C 007/16 () |
Field of
Search: |
;96/28,45,30,14,15 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Torchin; Norman G.
Assistant Examiner: Goodrow; John L.
Claims
What is claimed is:
1. The process of making colored prints which comprises forming a
plurality of color separation exposures on photosensitive polymeric
coatings on supports, said coatings comprising a solid polymer
having carbon-to-carbon double bond unsaturation and a
photooxidation photosensitizer capable of absorbing light energy
and utilizing same in the presence of oxygen to cause formation of
a bond between oxygen and the polymer, applying a liquid to develop
images in said coatings by selectively removing either exposed or
non-exposed areas from said support, placing one of said images in
contact with a backing and removing said support, thereby
transferring the part of the coating forming an image from said
support to said backing, and thereafter transferring in similar
manner another of said images to the first in registered
relationship therewith.
2. The process of claim 1 in which the images are half-tone
images.
3. The process of claim 1 in which the images are half-tone images
of at least about 150 lines per inch.
4. The process of claim 1 in which yellow, cyan, magenta and black
images are transferred in register to form a four color composite
picture.
5. The process of claim 1 in which the supports have a release
coating surface so that the polymeric coating has low to moderate
adherence thereto.
6. The process of claim 5 in which the polymeric coatings contain
pigments which make them more readily removable from the support by
action of solvents.
7. The process of claim 6 in which the liquid used for development
is a poor solvent for the polymer in the coating and removes the
non-exposed areas of the coating to form an image.
8. The process of claim 6 in which the liquid is a non-aromatic
hydrocarbon.
9. The process of claim 1 in which excited state oxygen reacts
directly with the polymer and the photosensitive coatings contain
pigments in 10 to 50 parts by weight based on polymer and in
respective colors yellow, cyan, magenta and black.
10. The process of claim 1 in which the polymer is a
butadiene-styrene interpolymer and a porphyrim photosensitizer is
used.
11. The process of claim 1 in which a dye is added to at least one
of the images after exposure.
12. The process of claim 1 in which portions of the coating in
non-exposed areas are removed to form an image comprised of a
discontinuous coating.
13. The process of claim 1 in which portions of the coating in
exposed areas are removed by a polar solvent.
14. The process of claim 1 in which portions of the coating in
non-exposed areas are removed by a non-aqueous solvent having a
solubility parameter below 8.
15. The process of claim 1 in which the tranfer is accomplished by
pressure contact without application of solvent.
16. The process of claim 15 in which heat is employed in the
transfer.
17. The process of claim 1 in which the coating has a thickness no
greater than 5 microns.
Description
The present invention is concerned with photoimaging and
photoprinting, particularly in aspects thereof useful in color
proofing.
Various methods of image reproduction are known, including various
ways of reproducing a picture by photoprinting. Some methods
involve transfer of an image from one support to another, and
effective ways of achieving such transfer have recognized
value.
An object of the invention is to provide new and improved image
transfer processes. A further object is to provide photoimaging
procedures and compositions which are especially useful in such
transfer processes.
SUMMARY OF THE INVENTION
The present invention involves image transfer processes in which
images are formed and solvent-developed on a support and then
transferred to another support. The invention also involves the use
in such processes of photoimaged materials which are wellsuited to
such transfer processes. A system particularly wellsuited is one
involving a polymeric substrate in which an image is formed by
peroxy groups bonded to the polymer. Photo-crosslinking or
polymerizing systems can also be employed, such as systems
involving iodoform and a diene polymer, or an acrylonitrile/diene
polymer and a polynuclear aromatic-carbonyl compound sensitizer.
The transfer processes are particularly useful for reproducing
multicolor images, utilizing subtractive color components. Pigments
are useful in providing the desired colors. Preparation of such
multicolor images is particularly useful in color proofing, which
involves preparing a photoproof from color separation
transparencies, as a check on the accuracy of the transparencies
before the transparencies are utilized in making a printing plate.
Such procedures generally involve preparation of line or half-tone
images, but present procedures can also be used for continuous tone
images.
In another aspect the present invention is directed to a procedure
for making multi-color images, in which images are separately
formed on separate supports by a photoimaging procedure,
solvent-developed, and then the developed images transferred in
register to a single support. Alternatively, one of the images can
be formed and developed on the final support, and the other images
then transferred in register to it.
In the present invention a photooxidation imaging technique is
particularly useful, the technique being one which involves
formation of images in a polymer by oxidation of the polymer to
form hydroperoxy groups in the imaged areas. The aforesaid techique
is described in a copending application of Robert A. Heimsch and
Eric T. Reaville, Ser. No. 644,121 filed June 7, 1967, and a
continuation-in-part thereof Ser. No. 15,727, filed Feb. 16, 1971
and issued Feb. 5, 1974 as U.S. Pat. No. 3,790,389. The aforesaid
photoimaging procedure produces latent images in terms of
hydroperoxidized areas of the polymers. The hydroperoxidized areas
differ in various properties from non-hydroperoxidized areas, and
this makes possible various means of developing visible images,
such as those depending on dye receptivity, solubility,
conductivity, permeability, etc. In the present transfer processes,
a photosensitive coating is provided on a temporary support. The
coating is adherent to such support, but by a bond which is readily
broken. Release paper can suitably be used for such support. In
some aspects, the present invention involves solvent development
techniques. The solvent is applied to the photosensitive coating
after photoimaging, and either imaged or non-imaged areas of the
coating are selectively removed, depending upon the type of
solvent. The procedure does not require particularly good solvents,
as it is only necessary to have solvents sufficient to swell or
penetrate through the coating and fragment the coating or loosen
its bond to the support, thereby permitting portions of the coating
to be washed away. After portions of the coating are selectively
washed away, leaving in effect, a developed relief image, the image
is then transferred to another support. The transfer is by contact,
ordinarily with heat and pressure. In one aspect the present
invention involves a procedure in which a coating containing a
latent image comprised of polymer containing hydroperoxy groups,
and polymer not containing such groups, is developed with a solvent
to remove selectively one of such areas, and the remaining coating
in the form of an image is then transferred to another support by
contact therewith, ordinarily with the application of heat and
pressure. In the transfer process heat is applied to make the
coating surface tacky. The heated coating then becomes adhesively
bonded to the surface to which it is to be transferred. The
resulting sandwich is then separated, ordinarily after cooling, and
the coating adheres to the surface to which it is to be
transferred, rather than to the original surface.
In carrying out the present invention a photosensitive coating is
present on a surface to which it has low to moderate adhesion, and
the coating is photoimaged while on such surface. The coating
should have some adherence to the surface to permit some handling
without removing the coating, and to give some stability and
support to the image during development. If a coating has
insufficient adherence to a particular support, the mere mechanical
force of a solvent spray can dislodge it without regard to any
solvent effect of the solvent employed. However, the adherence
should be low enough to permit transfer therefrom. Thus the
adherence to the photoimaging support should be less than the
adherence to the receptive surface to which the image is to be
transferred. Thus low energy surfaces should be used as the support
for photoimaging, such as those characterized as release surfaces,
or having release coatings or parting agents. Various materials are
commonly used as release coatings, e.g., fluorocarbons, silicones,
paraffins, soaps, mold release agents, etc.
In preferred aspects, the present invention involves use of
pigmented photosensitized coatings. The pigments are primarily
employed as colorants. However the pigments also have an effect on
the polymeric film properties, contributing greatly to the action
of various solvents in effecting removal of areas of the polymer
from its support in developing images.
The present process has a number of advantages. A number of the
advantages are mainly concerned with the transfer step. The present
transfer process is a relatively simple, dry contact transfer.
Prior art procedures have often involved the use of solvents,
including water, in the transfer step. It can be seen that a dry
contact procedure is more convenient than one involving use of a
solvent to loosen the image or even float it away from its support
prior to transfer. Moreover when it is necessary to use aqueous
systems, there is a resulting problem of the dimensional stability
of some support materials, particularly paper materials, including
paperboard, as well as of the image materials themselves.
Similarly, the development procedure in the present invention can
utilize non-aqueous solvents, thereby avoiding problems of
dimensional instability or disintegration of paper support
materials as a result of spraying or other treatment with
water.
The present invention includes both positive and negative working
procedures. It can be seen that there is an advantage in being able
to use the same photosensitive coatings in either a positive or
negative system, depending upon convenience in a particular shop or
with respect to a particular job. Also the present procedures have
the proper combination of sensitivity and controllability. Thus,
reasonably short exposures can be used in the photoimaging to
obtain the desired degree of resolution and fidelity, but the
systems are not so sensitive as to require extremely careful
control of exposure times, development times, etc. or other
variables, which would be a problem if carried out by various
different people in various shops. The present invention is
suitable for use in proofing the fine work done in off-set
printing, which has around 150 lines to the inch, and there appears
to be no reason for not employing it for up to 300 lines per inch
or more. It can, of course, be used in less demanding applications,
but most uses will probably involve imaging from half-tone
transparencies having at least 60 lines per inch, and ordinarily
150 lines per inch. It will be noted that to hold high light dots
at 150 lines per inch would involve producing dots of around 30 to
40 microns or less, assuming about 10 percent coverage in such
areas.
In the preparation of multi-color prints, the present procedure has
some time saving advantages. For example, some prior procedures
involve a transfer to the final support, followed by the exposure
and development step, for the image from each color separation.
Thus for a 4-color proof, the procedure must be carried out four
times, in series. In the present invention four exposures can be
carried out simultaneously on separate supports, followed by four
development procedures, and it is only the transfer which must be
done in series.
In general the procedures for obtaining color separations from
originals, making color separation half-tones therefrom, and the
general use of such half-tones in producing colored images are well
established. The present invention is mainly concerned with aspects
of the procedure involving the use of color separations,
particularly use of color separation halftones, but there is an
interrelationship between such aspects of the procedure and the
rest of the reproduction procedure. Color separations can be made
from the original, employing red, green and blue filters. The color
separation negative from the red flter, i.e. red light record
negative, has the highest optical density in areas of the original
transmitting red and the lowest optical density in areas absorbing
red. This color separation negative can be converted to a positive
in which the densities are reversed from the foregoing, and the
positive can then be employed with a screen to produce a half-tone
negative. In the half-tone negative the image is formed of dots
which do not vary greatly in their optical density, the dots being
of high density, substantially opaque, while non-dot areas are of
low density, substantially transparent. The tone density depends
upon the proportion of an area covered by dots. The half-tone
negative resulting from the red filter will have the highest
density, i.e., proportion of dots, in the area corresponding to the
red transmitting area of the original, and the lowest optical
density in areas of the original absorbing red. The red light
record half-tone negative is then used to produce an image by the
exposure, development and transfer steps taught herein. The
resulting image has its lowest optical density in areas
corresponding to those of the original which transmit red, and its
highest optical density in the areas of the original absorbing red.
The foregoing is accomplished by employing the photooxidation
imaging as a negative working system, i.e., by removing parts of
the photosensitive coating which are not photooxidized. Since the
image has its highest density in red absorbing areas, a color
subtracting red is used in such areas, namely cyan. The cyan
pigmented photosensitive coating remains in the photooxidized areas
following the solvent development. The image as developed then
consists of cyan colored dots comprised of polymeric coating
material and cyan colorant. The dots are then transferred to a
second support. In use of half-tones, the dot coverage can run from
less than 5 percent of an area to more than 95 percent of an area,
and it should be recognized that the dot terminology is applicable
even though the dot coverage in high density areas may be
substantially contiguous. However, there will generally be some
separate, discrete dots in an image, and the present procedures for
half-tone imaging generally involve transfer of separate, discrete
dots of coating material from one surface to another. In this
connection it should be noted that the dot of coating material
itself is transferred; that is, it is not a case of using the
coating material as a printing surface from which to transfer ink
or other coloring material to another surface.
The procedure for the other color separations corresponds to that
for the red record, with the changes being in the filter used and
in the colorant employed. Thus a blue filter is used to make the
blue record negative, and the color subtracting blue which is
employed in the photosensitive coating is yellow. A green filter is
used to make the green record negative, and the color subtracting
green which is employed in the photosensitive coating is magenta.
Similarly, when four color pictures are made employing black in
addition to the other colors, the appropriate color separation
negative can be made in recognized manner, as by employing white
light, or successive exposures with red, blue and green filters,
and the color subtracting white, i.e. black, is then employed as
colorant in the photosensitive coating.
In the procedural steps exemplified above, negative working was
employed in that half-tone negatives were utilized to obtain the
yellow, magenta and cyan images. If desired, halftone positives can
be used with positive working to obtain the positive yellow,
magenta and cyan image when photooxidation photoimaging is
employed. This provides an advantage in the adaptability and
flexibility of the procedures in that one proofing system can be
used as either positive or negative working, as happens to be
convenient to fit in with procedures of any particular printing or
other copying system being employed. To have positive working, the
exposed, i.e., photooxidized areas are removed. This can be
accomplished by use of a polar solvent. Since the positive working
is used with a half-tone positive separation, the photooxidized
area which is removed in positive working is the same area of the
coatig which is removed as nonoxidized area when negative working
is employed with half-tone negatives. Thus the color relationship
is same for the positive working system as for the negative, i.e.,
cyan is used with the red light record, magenta with the green
light record, and yellow with the blue light record. It will be
recognized, of course, that the transfer involves a lateral
reversal of the image. This can be readily controlled by reversing
or non-reversing the transparency in the exposure step in known
manner, depending upon the direction from which the photosensitive
coating is to be imaged, and the direction from which the
transferred image is to be viewed, i.e., directly or through a
transparent support. For example, when both the imaging and the
viewing are to be done on opaque supports, the transparency is
reversed for the imaging step to allow for the lateral reversal
upon transfer. Also, if for some reason one of the images is
produced directly upon the final support, it will have to be the
reverse image of the other images on temporary supports which are
then transferred in register to such image.
In the above description it will be recognized that there can be
variations in the order of step from the original to color
separation negatives, positives, half-tones, etc., and that the
half-tone can be produced simultaneously with production of
negatives or positives. Moreover there can be additional
conversions from negative to positive to negative etc., for
converting images, masking purposes, or other reasons. It will also
be recognized that the present process is adaptable to various
color correction techniques, such as those involving additional
masking exposures known to the art. Moreover additional dyes or
coloring materials can be used to give background colors, amplify
images, etc., or for other reasons. The colors in the present
procedure are ordinarily determined primarily by the colors of
coating material, from dyes or pigments, which are not removed in a
washing development step. However, additional colorants can be
added, as for example dyes in solvent solution, and this addition
can be selective as in the case of photooxidation photoimaging the
photooxidized areas tend to accept polar materials and the
nonphotooxidized areas to accept non-polar materials. While such
additional colorants can be added at any time, ordinarily they will
be added prior to the solvent-development step. Then the colorant
will selectively absorb, e.g., on photooxided areas, and any excess
can be washed off with the development solvent. The colorants can
be added after development, but then selectivity depends on the
imaged areas compared to the bare support in developed areas.
Colors are more difficult to wash out of the voids in a developed
image, and if left, they may transfer to some extent in the
transfer step.
The present invention involves use of a photosensitive layer
containing carbon-to-carbon double bond unsaturation. Such layers
are capable of undergoing crosslinking, polymerization, or
oxidation reactions under the influence of light to effect a change
in properties which can produce a latent image which is subject to
development and transfer as taught herein. The photosensitive layer
should be relatively stable in form to prevent undue migration of
compounds containing the unsaturated group, if such compound should
be of relatively low molecular weight or liquid. Ordinarily any
film-forming materials will provide a stable matrix to prevent
migration of the oxygen containing substituents with polymeric
materials generally being used. Of course, some of the layer
materials disclosed herein have both the unsaturated groups and the
properties for forming stable films or coatings, e.g., high
molecular weight polymers containing residual unsaturation, such as
styrene/butadiene copolymers. Thus in general there will be no need
for using separate binder materials, but the use of such are fully
consonant with the present invention. Even though a particular
polymer in itselt has all the properties necessary to serve as a
photosensitive substrate, it may nevertheless also be used in
conjunction with other polymeric binder materials which do not have
unsaturated groups, or in conjunction with other materials which do
have such groups.
The photosensitive layers include photopolymerizable layers
containing carbon-to-carbon double bond unsaturation, i.e.,
ethylenically unsaturated compounds, and suitable binders therefor,
such as the photopolymerizable materials disclosed in Planbeck U.S.
Pat. No. 2,760,863, and Celeste U.S. Pat. No. 3,469,982. Such
photopolymerizable materials can be activated as taught in the
aforesaid patents, for example by actinic light and various free
radical catalysts, for example polynuclear quinones which are
compounds having two intracyclic carbonyl groups attached to
intracyclic carbon atoms in a conjugated carbocyclic ring system.
Suitable such initiators include 9,10-anthraquinone,
1-chloroanthraquinone, 2-chloroanthraquinone,
2-methylanthraquinone, 2-ethylanthraquinone,
2-tert-butylanthraquinone, octamethylanthraquinone,
1,4-naphthoquinone, 9,10-phenanthrenequinone,
1,2-benzanthraquinone, 2,3-benzanthraquinone,
2-methyl-1,4-naphthoquinone, 2,3-dichloronaphthoquinone,
1,4-dimethylanthraquinone, 2,3-dimethylanthraquinone,
2-phenylanthraquinone, 2,3-diphenylanthraquinone, sodium salt of
anthraquinone alphasulfonic acid, 3-chloro-2-methylanthraquinone,
retenequinone, 7,8,9,10-tetrahydronaphthacenequinone, and
1,2,3,4-tetrahydrobenz(a)anthracene-7,12-dione. Other
photoinitiators which are also useful, even though some may be
thermally active at temperatures as low as 85.degree.C., are
described in Plambeck U.S. Pat. No. 2,760,863 and include vicinal
ketaldonyl compounds, such as diacetyl, benzil, etc.;
.alpha.-ketaldonyl alcohols, such as benzoin, pivaloin, etc.,
acyloin ethers, e.g., benzoin methyl and ethyl ethers, etc.,
.alpha.-hydrocarbon substituted aromatic acyloins, including
.alpha.-methylbenzoin, .alpha.-allylbenzoin and
.alpha.-phenylbenzoin. The photosensitive layers also include
layers containing ethylenic unsaturation which are
photocrosslinkable, such as materials disclosed in Celeste U.S.
Pat. No. 3,526,504, including polyvinyl cinnamate and activators
therefor. It is not seen to be necessary to determine whether
particular materials would react or be classed as
photopolymerizable or photocrosslinkable, or both, as the
consequent change in properties permits development of images,
aside from the particular mechanism. the photosensitive layers
include the photosensitive compositions disclosed in the copending
application Ser. No. 15,856 of Richard M. Anderson and Robert A.
Heimsch filed Mar. 2, 1970, involving ethylenically unsaturated
polymer and a halogen compound sensitizing agent, and can also
include the metal organic compounds there disclosed; suitable
sensitizing agents are, for example, iodoform or carbon
tetrabromide, and metal organic compounds include various chelates,
enolates, and fatty acid salts, e.g., copper octoate. The
photosensitive layers also include the acrylonitrile/diene
interpolymers with activated aromatic ketone sensitizers, as
disclosed in application Ser. No. 40,417 of Robert A. Heimsch, John
S. Bartosczewicz, and Robert J. Slocombe filed May 25, 1970. The
acrylonitrile/isoprene, acrylonitrile/butadiene and other
copolymers disclosed therein, as well as the polynuclear quinones
and other sensitizers there disclosed can suitably be employed. It
will be noted that need for or suitability of various sensitizers
will vary with the particular unsaturated material, but suitable
selections can be made in view of the foregoing teachings.
It is particulary preferred to use photooxidation photoimaging in
the present invention because of versatility, convenient
workability, and various other features of such procedures as
pointed out in the present application. In such procedures the
various layer materials containing unsaturation referred to herein
can be employed. Any of the materials disclosed in the aforesaid
applications Ser. No. 644,121 and Ser. No. 15,727 (C-11-21-0189)
can be employed. The photooxidizable layer may be any natural or
synthetic material containing suitable carbon-to-carbon
unsaturation, which material is spreadable on a suitable base
support such as a glass or metal plate, a plastic solid or sheet,
or a paper sheet or board surface, etc., and is sufficiently
non-volatile at the temperature used. For use of this invention at
ordinary room temperature the substrate material should have a
molecular weight above about 140 so that it will not be removed
from the surface or from the reaction site by migration in the
oxidized form or by evaporation from the treated surface. The
photooxidizable substrate may contain the suitable carbon-to-carbon
unsaturation as part of its structure or molecules containing
suitable carbon-to-carbon unsaturation may be added thereto. Higher
molecular weight polymers or other materials may be used as a
binder for low molecular weight materials containing the
unsaturation to provide a suitably stable layer or film for
imaging.
Natural materials which may be used in photooxidation include rosin
and the double bond containing components thereof, terpenes such as
abietic-acid, neoabietic acid, maleopimaric acid, levopimaric acid,
.alpha.-pinene, camphene, 3-carene, citronellol, aldehyde modified
rosin materials such as formaldehyde modified rosins, and fortified
rosin materials such as those obtained by reacting the rosin with
alpha, beta-olefinically unsaturated polycarboxylic acids and
anhydrides thereof, and partial and complete esters of such acids
as maleic acid, fumaric acid, itaconic acid, aconitic acid,
citraconic acid, etc., both saponified or unsaponified with an
alkaline material. Other examples include the use of unsaturated
fatty oils either in the glyceride ester form or in the free acid
form. A few examples of such oils include olive, peanut, almond,
neat's foot, pecan nut, lard, tung, safflower, cottonseed and
soybean oils. Nonglyceride source unsaturated oils such as tall oil
may also be used.
Unsaturated hydrocarbons of natural and synthetic origin may also
be used in photooxidation. Examples of such materials include the
aliphatic olefinically unsaturated hydrocarbons having an average
of at least about 10 carbon atoms, e.g., 1-dodecene, 1-tridecene,
1-tetradecene, 1-pentadecene, 1-hexadecene, 1-docosene, docosene,
1-pentacosene and the internally unsaturated olefins such as
7-heptadecene, 7,10-heptadecadiene, etc., the aromatic olefinically
unsaturated hydrocarbons in the unpolymerized form such as
isopropenyl toluene, phenylisobutene, phenylhexadiene and
isopropenyl naphthalene.
Natural and synthetic polymeric materials containing unreacted
carbon-to-carbon double bonds therein may also be used as the
photooxidizable substrate material in practicing this invention.
The carbon-to-carbon unsaturation may be intralinear, e.g.,
--CH.sub.2 --CH=CH--CH.sub.2 --, a vinylene linkage, terminal,
e.g., --CH.sub.2 --CH=CH.sub.2 vinyl, ##SPC1##
vinylidene and the like. Attached groups to the aforedescribed
entities may be linear or branched. In general, the polymeric
backbone will be hydrocarbon in structure with any halide, ester,
ether, hydroxyl, nitrile, phenyl or other group present in the
polymer molecule appended to the polymeric backbone.
It will be understood that the vinyl compounds are a species of
vinylidene compounds since they contain the characteristic CH.sub.2
CH-- group, the indicated free carbon valence being satisfied by
another atom in the polymer molecule. The term "vinylidene" is used
herein to include both vinylidene and vinyl unsaturation.
Illustrative examples of these olefinically unsaturated polymers
useful in photooxidation include natural rubbers; homopolymers,
copolymers, and polymers from three or more monomers, prepared from
diolefins such as butadiene, isoprene, 2,3-dimethyl- 1,3
-butadiene, piperylene, chloroprene, bromoprene,
2-acetoxy-butadiene - 1,3,2-methyl-pentadiene, 2-ethylhexadiene;
and polymers prepared from diolefins such as those aforementioned
and compounds containing a vinyl or a vinylidene group such as
a. Vinyl ethers, e.g. vinyl alkyl ethers such as vinyl ethyl ether,
vinyl butyl ether, vinyl octyl ether, vinyl dodecyl ether, vinyl
tetradecyl ether, vinyl hexadecyl ether, viny octadecyl ether and
vinyl alkenyl ethers, e.g., vinyl ether, vinyl octenyl ether, vinyl
tetradecenyl ether, vinyl octadecenyl ether;
b. Vinyl esters, e.g. vinyl acetate, vinyl butyrate, vinyl
caprylate, vinyl caprate, vinyl laurate, vinyl myristate, vinyl
palmitate, vinyl stearate;
c. Vinyl halides, e.g. vinyl chloride, vinyl bromide;
d. Vinyl ketones, e.g. vinyl methyl ketone;
e. Vinyl sulfides, sulfoxides and sulfones, e.g. vinyl ethyl
sulfide; vinyl propyl sulfoxide, vinyl tert-butyl sulfone;
f. Vinylidene compounds, e.g. vinylidene chloride;
g. Acrylic, methacrylic acids or crotonic acids and their
derivatives, e.g. acrylic acid, acrylonitrile, methacrylamide,
crotonamide;
h. Acrylic, methacrylic esters or crotonic esters, e.g. methyl
methacrylate, ethyl acrylate, propyl acrylate, amyl acrylate,
heptyl acrylate, octyl methacrylate, nonyl acrylate, undecyl
acrylate,tetradecyl acrylate, hexadecyl acrylate, octadecyl
acrylate, ethenyl acrylate, hexenyl methacrylate, dodecenyl
acrylate, octadecenyl acrylate, ehtyl crotonate;
i. Allyl esters, e.g. allyl acetate, allyl butyrate, allyl
caprylate, allyl caprate, allyl laurate, allyl myristate, allyl
palmitate, allyl stearate;
j. Allyl alkyl ethers, e.g. allyl ethyl ether, allyl octyl ether,
allyl dodecyl ether, allyl tetradecyl ether, allyl hexadecyl ether,
allyl octadecyl ether, and vinyl alkenyl ethers, e.g. allyl ethenyl
ether, allyl octenyl ether, allyl tetradecenyl ether, allyl
octadecenyl ethers;
k. Cycloaliphatic vinyl compounds, e.g. vinyl cyclohexane;
l. Aryl vinyl compounds, e.g. styrene, vinyltoluene, vinylbiphenyl,
vinyl naphthalene and the ar-chloro substituted styrenes;
m. Heterocyclic vinyl compounds, e.g. vinyl pyridine and vinyl
dihyropyrane;
n. Alpha-olefins, e.g. ethylene, propylene, butene-1, octene-1,
dodecene-1, tetradecene-1, hexadecene-1 and heptadecene-1,
dichloroethylenes, tetrafluoroethylene; and
o. Branched olefins, e.g. isobutylene, isoamylene, 2,3,3
-trimethyl-1-butene.
It is to be understood that the unsaturated polymers which are used
in the practice of this invention can also be prepared by
copolymerization of two or more different diolefins, e.g. from a
mixture of butadiene and piperylene, either in the presence or
absence of one or more non-dienic copolymerizable monomers.
The physical characteristics of the olefinically unsaturated
polymers which can be photooxidized in accordance with the present
invention may vary from low molecular weight polymer oils
containing relatively few olefinic bonds to high molecular weight
rubbers and resins such as those resulting from the polymerization
or copolymerization of diolefins in the presence or absence of one
or more non-dienic copolymerizable monomers.
The photoimaging by photooxidation utilized in the present
invention depends upon the change in properties caused by addition
of oxygen to molecular structures of the photosensitive substrate,
and appears to a considerable extent to be due to the polarity of
hydroperoxy groups in such molecules. The photooxidation makes
possible differentially profound point-by-point property changes in
a film due to differential distribution of non-migrating
hydroperoxy groups in such film. The differential distribution of
hydroperoxide accurately reproduces the intensity of light to which
each differential area was exposed and the difference in chemical
and physical properties of the hydroperoxidized regions compared to
the non-exposed regions results in a latent image which can be
rendered visible by difference in dye sorption, solubility, surface
tack or other properties. For the differences caused by the
photooxidation to be most evident, it is desirable that the
original photosensitive composition not have groups with properties
similar to hydroperoxides, although some such groups can be
tolerated, even though contributing to an objectionable background
in some photoimaging procedures. Such polar groups as carboxy,
hydroxyl, nitrile, etc. may mask the photoimaging effect of
hydroperoxy groups to some extent. For this reason some of the
preferred polymers for use herein are hydrocarbon polymers with
residual unsaturation, e.g., styrene/ butadiene copolymers, etc.
However, for the effect upon the original solvent solubility, or
upon mechanical film properties it may at times be desirable to use
polymers having various substituents, such as halogen, nitrile,
carboxyalkyl, etc, and polymers containing such substituents can be
used if some loss in photoimaging sensitivity can be tolerated in
the particular application in view. In general it will be preferred
that polar monomers not constitute more than three-fourths of the
monomer content of a copolymer used as the photooxidizable
substrate in the present invention.
Aside from characteristics of the photosensitive compositions for
forming latent photoimages in accordance herewith, various other
mechanical or other properties of the polymers will have
significance with respect to ease of coating application,
durability and handling properties of the film, but in general
those skilled in the art will be able to select appropriate
materials for particular applications, particularly in view of the
present disclosure.
In general solid polymers having carbon-to-carbon double bonds with
allylic hydrogen adjacent thereto are suitable for photooxidation
usse herein. Such polymers will preferably be substantially linear
and have a weight average molecular weight of at least 50,000, and
at least one such carbon-to-carbon double bond for about every 50
carbon atoms; a more limited class of such polymers are hydrocarbon
in structure to avoid possible adverse effects of polar or other
substituents.
Photosensitizers used herein for catalyzing the preferred
photooxidation type of reaction are referred to generally as being
of the porphyrin type. The porphyrin type of photosensitizer may be
described as any compound having the porphin structure, i.e., four
pyrrole rings connected by single carbon or nitrogen atoms, which
includes related compounds such as the porphyrazines,
phthalocyanines or chlorophylls.
Particular photosensitizers useful in practicing photooxidation in
the present invention are the aromatic group mesosubstituted
porphin compounds. Among such aromatic substituted porphins are the
ms-tetraarylporphins (ms-meso). These compounds are those porphins
in which aryl groups having from 6 to 24 carbon atoms are
substituted on the bridging carbon atoms of the porphin ring
structure which contains four pyrrole nuclei linked together in a
circular pattern by four bridging carbon atoms to form a great
ring. Examples of aryl groups which may be substituted in the
meso-position of these compounds are phenyl, chlorophenyl,
dichlorophenyl, methylphenyl, N,N-dimethylaminophenyl,
hydroxyphenyl, naphthyl, biphenyl, anthracyl, phenanthryl, etc. In
addition to the substituents in the aryl group substituents noted
above, the aryl groups can also have any or a combination of such
substituents, e.g., as alkyloxy (1 to 20 carbon atoms) substituents
such as methoxy, ethoxy, isopropoxy, butoxy, hexyloxy, etc., as
well as other substituents, particularly those which do not change
the fundamental aromatic character of the groups. These porphin
sensitizers including the above exemplified arylporphin, can have
various other substituents, particularly at the beta and beta'
positions of the pyrrole rings, e.g., such substituents as lower
alkyl (1-20 carbon atoms) such as vinyl or allyl or alkanoic acid
groups such as methylcarboxy or ethylcarboxy.
Examples of porphin compounds which are useful as photochemical
sensitizers in practicing this invention are the arylporphins such
as the tetraphenyltetrazoporphins and the complexes thereof, such
as diamagnetic complexes, e.g., magnesium
tetraphenyltetrazoporphin, tetraphenyl tetrazoporphin acetate,
tetraphenyltetrazoporphin sufate, zinc tetraphenyltetrazoporphin;
the meso-aryl porphins including alpha, beta, gamma,
deltanaphthylporphin and the diamagnetic metal chelates thereof,
e.g.,
tetraphenylporphin
tetrakis( 2,4 -dichlorophenyl)porphin
tetrakis( 2-furyl)porphin
tetrakis( 4-methoxyphenyl)porphin
tetrakis( 4-methylphenyl)porphin
tetrakis( 2-thienyl)porphin
tetraphenylporphin zinc complex
tetrakis( 4-nitrophenyl)porphin
tetrakis( 4-dimethylaminophenyl)porphin
zinc complex;
the tetrabenzomonoazo- and tetrabenzodiazo porphins, the
1,2,3,4,5,6,7,8 -octaphenylporphins and azoporphins such as
octaphenylporphyrazine, the tetrabenzoporphins, e.g.,
tetrabenzoporphin and the zinc complex of tetrabenzoporphin.
Other useful porphin types of photosensitizing materials which may
be used include chlorophyll, such as chlorophyll a and chlorophyll
b, hemin, the tetrazoporphins, chlorophyllin salt derivatives such
as the reaction product of an alkaline metal chlorophyllin salt and
sodium bisulfite, hematoporphin, mercury proto- and
hemato-porphins, vitamin B.sub.12 and its derivative tetrakis
(1-naphthyl) porphin, porphin, ms-tetraethylporphin,
ms-tetramethylporphin, and other ms-alkyl and alkoxy prophins.
Related porphin type materials which may be used include the
phthalocyanines including the metal-free phthalocyanine and metal
complexes of phthalocyanine such as the zinc and magnesium,
complexes of phthalocyanine, as well as phthalocyanine derivatives
such as the barium or calcium salts of the phthalocyanine sulfonic
acid, acetylated phthalocyanine, alkoxy- and
aryloxy-benzosubstituted phthalocyanines, 5,5' , 5",
5'"tetraamino-metal phthalocyanine- 4, 4', 4', 4'"-tetrasulfonic
acid; magnesium tetra(4) methylthiophthalocyanine, arylthioethers
of phthalocyanines, vinyl group containing tetraazoporphins and
polymers thereof, mercaptoamino phthalocyanine derivatives and
phthalocyanine.
Other useful photosensitizers which can be used include fluorescein
type dyes and light absorber materials based on a triarylmethane
nucleus. Such compounds are well known and include Crystal Violet,
Malachite green, Eosin, Rose Bengal and the like.
Another group of photosensitizers particularly useful in the
ultraviolet region include the aromatic compounds such as
acetophenone, benzophenone, benzoin, benzil and triphenylene.
Light necessary in the practice of this invention can vary
considerably in wave lengths, depending on the sensitizer in this
system. The light can be monochromatic or polychromatic. Light of
wave lengths in the range of 3600 to 8000 Angstroms has been found
very suitable.
Light sources suitable for use in the practice of this invention
include carbon arcs, tungsten and mercury-vapor arcs, fluorescent
lamps, argon glow lamps, electronic flash units, photographic flood
lamps and sunlight.
The present invention is particularly concerned with imaging
procedures utilizing photosensitized oxygen transfer reactions in
which light in the presence of a sensitizer causes the oxygen to
oxidize the carbon-to-carbon unsaturated substrate by being added
to one carbon atom of a double bond with shift of the double bond
to the allyl position and movement of the allylic hydrogen atom to
the oxygen atom of the oxygen molecule which is not attached to the
carbon atom. The reaction can be postulated: ##SPC2##
The aforesaid oxygen transfer reaction does not include
autooxidations, proceeding by a free radical mechanism in which
irradiation with light serves to initiate free radicals and cause
the formation of free radical sites in the substrate by hydrogen
abstraction. The true photosensitized oxidation or oxygen transfer
reactions used herein are characterized by the fact that they can
proceed using wavelengths of light which may be ineffective for
autooxidation and by the fact that in general ordinary oxidation
inhibitors do not retard the reaction.
The photosensitized oxygen utilized herein involves what is
referred to be Gollnick and Schenck (K. Gollnick and G. O. Schenck,
Pure and Applied Chemistry, Vol. 9, 507 [1964]) as a Type 2
reaction, or "photosensitized oxygen transfer." The reaction
involves some excited oxygen species, whether pictured as an oxygen
molecule itself in an excited singlet state, or an excited
sensitizer-oxygen adduct. Irradiation with light appears to
transform the sensitizer to an excited state, such as a triplet
state: ##SPC3##
The sensitizer then transfers its energy to oxygen. This can be
postulated as ##SPC4##
and the excited singlet delta oxygen can then add to the double
bond as pictured above. It should be understood that if the triplet
energy of the sensitizer is above 37 kcal singlet sigma oxygen may
also be produced. It may react directly or decay to the lower
energy delta species. The reaction involves light energy to excite
the sensitizer and produce an excited state oxygen which reacts
with the substrate to cause addition of oxygen to one of the
doubly-bonded carbons thereof. The reaction ordinarily does not
include any chain propagation, but only one oxygen addition per
photon absorbed at quantum yield of unity. The photosensitized
reaction can proceed using wave lengths of light other than
ultraviolet, and ordinary oxidation inhibitors do not inhibit the
reaction. A sensitizer-oxygen adduct is presumably formed but is
apparently short-lived; however it should be understood that the
oxidation is effective regardless of what the mechanism and exact
contribution of the adduct to the oxidation of the olefin may
be.
In another aspect, the present invention can utilize an oxidation
reaction in which a hydrogen atom is abstracted to give a radical
and oxygen is then added. For example the Type 1 reaction in the
foregoing Gollnick and Schenck article involves a reaction in which
the allylic hydrogen atom at C-3 is abstracted to give a mesomeric
mono-radical ##SPC5##
and oxygen is then attached at either of radical sites C.sub.1 or
C.sub.3, and the peroxyradicals thus formed extract hydrogen from
the C-3 position of the olefin to give hydroperoxides and a new
mesomeric radical, thus permitting chain propagation. Sensitizers
which are voracious hydrogen abstractors when excited by light
energy are suitable for use in such reaction. One group in such a
class is the carbonyl compounds, as for example, benzophenone,
acetophenone, etc. Aside from olefins containing allyl hydrogen,
other types of materials containing labile hydrogen can undergo
reactions similar to that of Type 1 to produce materials containing
hydroperoxy groups, and such materials can be used for photoimaging
in accordance with this aspect of the invention, for example, such
materials as ditetrahydrofurfuryl phthalate, di-2-ethylhexyl
phthalate, compounds containing tertiary hydrogen, etc. If such
materials are liquid they will generally be used in conjunction
with a polymer or some other high molecular weight binder to
provide a suitable matrix. In oxidations involving abstraction of
labile hydrogen to generate free radicals, other reactions such as
crosslinking can also occur and may interfere with the desired
photoimaging reaction, and such oxidations, while part of the
present invention and useful to some extent, are not in accord with
the preferred aspects of the present invention.
Sensitizers which can function in both Type 1 and Type 2 reactions
include benzophenone, acetophenone, benzil, benzoin, etc. These
carbonyl type sensitizers require ultraviolet light of suitable
wave length for excitation. Sensitizers which also function in both
Type 1 and Type 2 reactions, but are active in the visible region
as well as the ultraviolet region of the spectrum include eosin,
fluorescein, rose bengal, etc. Sensitizers which are not hydrogen
abstracters and which function largely or wholly by energy
interchange as in Type 2 reactions, include the various porphyrin
type photosensitizers. In general photosensitizers capable of Type
2 sensitization are much preferred, and ordinarily the better ones
of this Type are not very effective as Type 1 photosensitizers.
Moreover, the absence of Type 1 activity may make it easier to
minimize side reactions. There will be variations in the
effectiveness of sensitizers with the physical type of phase
involved and it will be understood that the sensitizers utilized
herein will be those effective under the conditions of use. The
sensitizers described above are known to function in liquid phase.
In the practice of this invention some systems have involved the
post-application of a sensitizer solvent system to an already
pre-formed film. the resulting system can be called a quasi-solid
phase as it consists of a solid polymer lightly swollen with a
swelling solvent system. In such a quasi-solid phase, the
sensitizers listed above and similar photosensitizers are found to
effect photochemical addition of oxygen, although with great
variation in effectiveness. In the practice of the invention it is
also feasible to use solid phase systems in which the sensitizer
has been incorporated into a polymeric film composition which has
not been swollen by solvent. In the solid phase such sensitizers as
rose bengal, fluorescein, eosin, methylene blue, etc. did not
exhibit significant photoimaging capability in reasonable exposure
times. Benzophenone, acetophenone, benzil, etc., were found to
require high level of application, circa 10 percent, and prolonged
exposure, circa 30 minutes at ultraviolet flux of 7 .times.
10.sup.5 ergs/cm.sup.2 /sec. in order to show substantial
photoimaging capability. In contrast to this, porphyrins, such as
tetraphenyl porphin are very active at levels as low as 0.1 percent
at a flux of 2.5 .times. 10.sup.5 ergs/cm.sup.2 /sec. for 1 to 2
minutes. Triphenylene in the solid phase seems to function largely
by crosslinking, making it of little value for continuous tone
image production.
The photosensitizers can be placed in solid phase by incorporation
into a coating solution, emulsion, melt, or suspension etc. and
application to support. After evaporation, drying, or other means
of removing volatile solvents or other liquid medium, the
photosensitizer remains in the residual coating composition
dispersed in solid form in the solid composition. Even if the
photosensitizer is incorporated by post-application with a solvent,
it can be converted to the solid state by permitting the solvent to
evaporate. For ease of handling and reproducibility, it is
preferred that the photosensitive compositions be dry at the time
of photoimaging. It will be recognized that in referring to the
photosensitizer as being in a solid medium, it is not meant to
exclude such resilience, elasticity or other properties as may be
desirable in photosensitive films for various purposes, and that
plasticizers or low molecular weight materials may be present for
such purposes. Thus the solid state contrasts with the quasi solid
state in which liquid is present to swell the polymer structure as
in a plastisol or organosol and to provide a liquid medium in which
the photosensitizer can be present, aside from how much of the
photosensitizer is actually present in such medium.
The photosensitizer as employed will generally be of a type
suitable for producing a desired amount of oxygen addition in the
particular photosensitive composition upon degrees of light
exposure within ranges of practicality for some photoimaging
applications. For most applications it will be desirable that a
required energy absorption be no greater than 10.sup.7
ergs/cm.sup.2, or possibly 10.sup.8 ergs/cm.sup.2, in some
applications, and preferred that such absorption be sufficient with
a concentration of photosensitizer no greater than 1% by weight of
the photosensitive composition, for example with a flux sufficient
to obtain such absorption over a 2-minute exposure period. The
energy required for imaging will generally lie in the range of 1 to
10 .times. 10.sup.6 ergs/cm.sup.2. Absorptions with usual imaging
procedures are frequently of the order of 2.5 .times. 10.sup.4
ergs/cm.sup.2 /sec. The foregoing energy ranges are those generally
employed with the concentrations of photosensitizer generally used,
but increasing the concentration makes it possible to use lower
energy input for the photoimaging as the imaging requirements are
approximately in inverse proportion to the photosensitizer
concentration. The use of various amplifying means also makes it
possible to lower the energy requirements. In order to have
practical value in a photoimaging system, a photosensitizer as used
should produce an oxygen uptake of at least about 10.sup.-.sup.9
moles/cm.sup.2 with an absorbed energy of 10.sup.7 ergs. A
styrene-butadiene polymer (40 wt. parts styrene/60 wt. parts
butadiene) film can suitably be used for determining oxygen uptake
at particular energy absorptions.
Only a portion of the applied light flux will be absorbed by the
photoimaging substrate, with that portion varying with the
absorption characteristics of such substrate, as well as with the
wave length of the light. Absorptions may, for example, be less
than 10 percent, or of the order of 7 percent in some cases.
Visible light can effectively be used in the present invention, and
this is a definite advantage as it avoids the cost and loss in
efficiency which results from having to produce light in particular
ranges, such as the ultra violet range. In the present invention it
is not necessary to utilize the ultra violet range, and in fact,
the range of 4000 to 4500 angstroms appears most efficient. If
desired, light in ranges above 4000 angstroms can be used to avoid
possible ultra violet catalysis of competing reactions, although
this is not ordinarily necessary. While visible light is effective,
the present materials can generally be handled in ordinary
daylight, such as by removing the photosensitive material from the
intense light used for exposure, and carrying out development or
other steps without special precaution to avoid further exposure to
ordinary ambient light.
The preferred sensitizers for use herein belong to the class of
porphyrins which are compounds with pyrrole rings linked together
by carbon atoms to form a conjugated double bond structure, and in
which one or more of the carbon atoms, i.e. methine groups, can be
replaced by a nitrogen atom, and which class also includes the
phthalocyanines and benzoporphyrins, as well as the
meso-arylporphyrins, or other compounds having various substituents
on the basic porphyrin structure. The tetraaryl porphyrins,
particularly tetraphenyl porphyrin, are characterized by the
capability to utilize energy from three of the main areas of the
visible light spectrum, i.e., the violet, yellow and red areas and
therefore to make efficient use of light energy. Such sensitizers
can be termed panchromatic photooxidation sensitizers and are
particularly valuable. Some other sensitizers are active only in
limited areas of the spectrum, for example chlorophyll absorbs
mainly in the red region. Aside from efficiency, the panchromatic
sensitizers are advantageous for multi-color work in that it makes
it possible to use a single sensitizer for exposures to reproduce
different colors from an original, rather than having to change
sensitizers for each of the main segments of the color spectrum.
Tetraphenyl porphyrin absorbs most strongly in the violet, and less
in the yellow and least in the red, which is advantageous in that
visible light is the reverse, being strong in the red, etc., and
therefore the sensitizer compensates for the variation in
light-intensity and tends to equalize the effect of different
intensities. Utilizing the panchromatic sensitizers, the present
invention produces images from multi-color transparencies. If
polychromatic light is used with a single exposure, the resultant
image will not ordinarily exhibit appreciable differentiation
between the colors, but the image produced will have parts
corresponding to the various colors. The image can be developed by
applying a single dye to give a monochromatic image e.g., red and
white, or by using a solvent to remove areas either corresponding
to the colored regions or the non-colored regions.
In preparing 4-color proofs in accord with the present invention,
color separation exposures are formed on photosensitive polymeric
coatings on supports. The coated supports are prepared by coating
supports with a material comprising polymer, photosensitizer and
pigment. Various procedures can be employed for coating the
support, but the following exemplifies a suitable procedure.
Mastergrinds of pigments are prepared containing in parts by
weight, 30 parts pigment solids, 170 parts toluene, 0.2 part of a
surfactant and 25 parts of a 20 percent solution of
styrene/butadiene copolymer in benzene. The pigments are ground for
a number of hours with ceramic balls. The polymer to be employed is
placed in solution as a 20 percent solution in benzene by rolling
pieces of the polymer in benzene on a ball mill. The polymer
solution is sensitized by adding sensitizer thereto, e.g.
tetraphenylporphin for photooxidation photoimaging. The desired
amount of sensitizer can be added dissolved in 60 parts by weight
of chloroform which is added to 50 parts of the polymer solution,
along with 50 additional parts benzene. Varying amounts of
sensitizer can be used, for many applications a suitable amount is
0.25 percent by weight of tetraphenylporphin on the total polymer
for the yellow, magenta and cyan coatings, and 0.5 percent for the
black coating. Coating slurries are made from the pigment grinds
and sensitizer, polymer solution, coveniently by adding the polymer
solution slowly with stirring to the pigment grind in a brown
bottle, and adding benzene to obtain the desired solids content.
The slurries can conveniently be used as 6 percent solids
concentrations (polymer and pigment). Suitable pigment loadings,
are, for example, 25 parts per hundred yellow and cyan, and 20
parts per hundred of magenta and black, the parts being by weight
on the polymer. It may be desirable to filter the slurry to insure
absence of large particles, e.g. through a seven micron opening
nylon screen. The coating slurries are then used to coat a support
appropriate for transfer, e.g., a release paper. The coating can be
accomplished by usual procedures for applying liquid coatings, for
example by using wire wound rods, such as a No. 10 for yellow and
cyan, No. 14 for magenta, and a No. 12 for the black coating. If
the coated papers are to be stored before use, they can be faced
with another sheet of release paper to prevent damage to the
coating.
The color separation exposures are formed on the coated release
papers using the appropriate color separation transparency. A 4000
watt pulsed Xenon light can conveniently be used. During the
exposure when a photooxidation is involved, the photosensitive
coating must have access to oxygen. This can conveniently be
provided for by having an air gap between the transparency and the
photosensitive surface. For example, the coated support can be held
flat on a vacuum plate. The transparency is on top of the coated
support and held in register by register pins. The transparency is
topped by a glass plate which is supported by spacers one-half mil
thicker than the transparency. An air stream is then forced between
the transparency and the coated support, forcing the transparency
against the glass plate, thereby providing uniform spacing from the
photosensitive coating, and providing oxygen for the photoxidation
reaction. With the above light coil held 32 inches from the coated
film, the flux as measured by a radiometer was 5.2 .times. 10.sup.5
ergs/cm.sup.2 /sec. Typical exposure times for photooxidation
imaging with this flux are 2.5 minutes for yellow and magenta
coatings, 2.75 minutes for cyan coatings, and 7 minutes for black
coatings.
For development of the images, areas of the image are selectively
removed by treatment with fluids. For negative working, the
non-exposed areas are removed. This is generally accomplished by
applying a liquid having some affinity for the polymeric coating
but not very great solvent power for it, such as an aliphatic
hydrocarbon when the polymer is a styrene/butadiene copolymer. For
example, a varnish makers and painters naphtha with a KB value of
36 (Skellysolve V) can be used with a styrene/butadiene copolymer.
Any type of washing procedure with such fluids can be employed,
provided that care is exercised to avoid excessive mechanical
stress on the coating. Spraying with the liquid has been found
suitable, whether by hand with a nozzle, or mechanically with a
gang of nozzles. Spray nozzles can, for example, be about 5 inches
from the coating and operated from a tank under 25 psi. Passing
back and forth before the nozzles for about 20 seconds is usually
sufficient. In general the fluids employed in the development step
will be liquids. However, materials having the proper affinity for
the coating can also be employed in gaseous or vapor form,
employing mild heating if desired. The spray nozzles can also
employ air or other gases under pressure as an aid in spraying, or
various other expedients employed in spraying paints or cleaning
solutions. It is also feasible to employ other washing methods,
such as immersing or dipping the coatings in the solutions, with
mild agitation. This can at times be combined with blotting or
wiping dry, although care must be exercised to avoid damaging the
image and it is generally advisable to avoid rubbing the coating.
In the dipping procedure the wash solvent becomes discolored with
the pigment, and presents some redeposition problem, but this can
ordinarily be overcome by changing the wash solution in the later
stages.
The support utilized herein from which the image is to be
transferred should have a surface to which the photosensitive
coating has low to moderate adherence. Release papers used in
casting of plastics in general have suitable surfaces if they can
be coated with the photosensitive material. Such papers can have
matt, dull, gloss or patent finishes, so long as the proper release
properties are present. In paper or other materials, the release
properties are generally provided by release or parting agents,
such as waxes, silicones, fluorocarbons, metallic stearates, or
other soaps, paraffins or other hydrocarbons, e.g., polyethylenes,
or inorganic materials such as silica or silicates, e.g., calcium
silicate. Such materials can be applied as a solution or suspension
in a volatile solvent which evaporates, leaving a film of the
release material on the surface. Such materials need not
necessarily be a completely contiguous film as such materials can
frequently be effective if incorporated into the body of the
support material, as practiced with anti-blocking materials in
plastics manufacture, or of various agents in paper manufacture.
There are a number of proprietary silicones used as release agents,
some of which are dimethyl siloxane resins. In general such resins,
or lower molecular weight materials, having alternating silicon and
oxygen atoms, with hydrocarbon substituents on the silicon, have
release properties. The series of silicones manufactured by Dow
Corning as release agents give release surfaces, including those of
the 200 series, e.g., Dow Corning 203 fluid, or Dow Corning 230
Fluid, which is an alkylaryl polysiloxane fluid, or emulsions such
as Dow Corning HV-490 emulsion which is a silicone emulsion
prepared from 100,000-centistoke dimethyl polysiloxane fluid.
Possibly the foregoing will be modified by additives, e.g., as
Dow-Corning No. 23 silicone release coating has its release
properties degraded by Dow-Corning C-4-2109 release additive. The
desirable release coatings will vary somewhat with the properties
of the photosensitive coatings employed, the surface properties of
the support to which the image is to be transferred, and the
development liquids and washing procedure employed. However in
general the release surface will have a relatively low surface
energy so that the developed image can be transferred to the higher
surface energy receptive support. At the same time the
photosensitive coating has to be sufficiently adherent to the
release surface that it is not completely removed therefrom in the
washing development. Any surface can be used for the receptive,
i.e., transfer support, provided only that the photosensitive
coating can be bonded to it. Paper, including paperboard, can be
conveniently used for the transfer surface, either as uncoated
paper stock, or coated paper. For example, high quality papers,
bond paper, etc. are suitable, and in general most papers having a
glossy surface. Cast coat, a high quality paper provided by the
Albermarle Paper Company is satisfactory. Papers having the usual
titanium dioxide, clay and synthetic binder, e.g. styrene-butadiene
resin, coatings are suitable. Various other surfaces can be used
for transfer surfaces, e.g., plastic film, metals in general, etc.
For reasons of economy and convenience, paper surfaces will
generally be preferred.
After development, the images are dried and transferred. When a
composite proof is made, a number of images are separately
transferred in register from their supports to a single transfer
support, and the images superimposed thereon constitute the
composite proof. The transfer is accomplished by contacting the
second support with the image, and stripping the original support
from the image. Simple lamination procedures can be employed for
the contacting, such as pressing the materials together, and, if
desired, applying heat. A platen press can conveniently be employed
with pressures of the order of 100 to 500 lbs/in.sup.2. Heat can
conveniently be used by heating the platen upon which the receptive
transfer support rests, while the upper platen is cooled by tap
water. Temperatures employed will be well below the melting point
of the coating materials, but can make the surface more tacky or
soften it to promote bonding to the receptive surface. A rubber
blanket or other resilient material may be used between the upper
platen and the release support to aid in equal distribution of the
pressure. For styrene/butadiene copolymer materials, a bottom
platen temperature, for example, around 80.degree. C. is
satisfactory. A short sojourn under pressure is sufficient, say
five seconds or so. The sheets are then cooled and the original
support is separated, leaving the image on the receptive transfer
support. Ordinarily a clean transfer is obtained and no residue on
the release support is observed. At times there may be some
residual color left, or even some background color in areas where
the coating has been removed by development, but this is ordinarily
not harmful as it does not usually transfer. In the transfer the
heating is ordinarily very brief and limited. Heating can affect
the photoreaction products, e.g., hydroperoxy groups, and promote
further reactions thereof, or affect the colorants, and this should
be taken into consideration when employing heat in the development
or transfer steps. In some cases such further efforts may be
desirable, but if not, only mild heating conditions should be used.
Platen temperatures are usually in the range of 50.degree. to
150.degree.C.
When half-tone images are transferred, the coating is being
transferred in the form of dot areas. There may be some large areas
in which dots are contiguous, but in general there will be
discontinuities and individual discrete dots being transferred. As
the dots in an image of one color will not necessarily be in the
same areas as those of another image, some parts of one of the
images may rest on a previously transferred lower image, while
other parts rest directly upon the receptive support. Thus the
composite proofs do not necessarily have several discrete
superimposed layer images, but some portions of the upper layer may
penetrate into or through lower layers. Also, when continuous tone
images are involved, the selective removal in developing such
images includes removal of portions to varying depth of the
coating, so the transferred layers may vary in thickness. Other
devices can be used to effect transfer, such as a heated platen and
a rubber roll, or the nip between two opposing rolls, such as a
heated metal roll and a metal roll or rubber roll, or various other
laminating devices. While the heated platen will generally be next
to the support to which the image is being transferred, transfers
can also be effected when the platen is adjacent to the release
support. Also, if desired, the original support can be removed
without permitting the laminate to cool first.
EXAMPLE 1
Photosensitized coated papers were prepared in accordance with the
procedure described above utilizing a heterogeneous
styrene/butadiene copolymer of 48 parts styrene to 52 parts
butadiene (Solprene 303 from Phillips Petroleum Company) with 25
parts per hundred loadings of the yellow and cyan pigments and 20
parts per hundred for magenta and black pigments, based on the
polymer. The sensitizer concentration was 0.25% for the colored
coatings and 0.5 percent for the black coatings. The coatings were
formed on release paper, Transkote ER (S. D. Warren Co.) release
paper for yellow, magenta and black, and Transkote FER (S. D.
Warren Co.) release paper for cyan. The coated release papers were
separately exposed utilizing a 4000 watt pulsed Xenon light 32
inches from the coatings, utilizing color separation negatives with
an air gap between the negative and the coating surface. The yellow
pigmented coating was exposed through a color separation half-tone
negative obtained by use of a blue filter, the magenta through such
a negative from a green filter and the cyan through a negative from
the red filter, with the black coating being exposed through a
negative appropriate for printing black areas. The exposure times
were 2.5 minutes for yellow and magenta, 2.75 minutes for cyan and
7 minutes for black. The images were developed by passing in front
of a gang of three spray nozzles spraying an aliphatic naphtha
(Skellysolve V, KB value 36), with 9 passes for a total of about 20
seconds. The images were individually transferred by pressing in a
platen press onto a sheet of paperboard (Castcoat), employing a
press pressure of 200 psi. and a bottom platen temperature of
80.degree.C. The release supports were stripped from the resulting
sandwiches after cooling. The four color images were superimposed
in register to give a good four color print. The images were
transferred in the order, yellow, magenta, cyan, and black but this
order can be changed as the images of one color do not prevent
viewing those of the other colors to obtain the overall effect. A
picture was obtained with good reproduction of blue, red, and
yellow colors and combinations thereof, as well as blacks, with
good highlight and shadow areas. Either of the above release papers
can be used with any of the colored coatings.
In the foregoing Example 1 the pigments employed were as follows.
The yellow was Diarylide Yellow OT YT-564-D, brand of duPont. The
magenta was 13-3150 Hostaperm Carmine FBB Powder brand of Farbwerke
Hoescht Ag. The cyan was 9 to 1 mixture of Monastral Blue B
BT-284-D/Monostral Green Y GT-805-D brands of duPont. The black was
Black Shield No. 8537 carbon black marketed as a 20 percent solids
dispersion in toluene by Carbon Dispersions, Incorporated.
EXAMPLE 2
Sensitized pigment polymer mixtures were coated on a release paper
(Transkote ER). The coating slurries were made by mixing sensitized
polymer solutions with 15 percent pigment slurries in toluene. For
the magenta, cyan and black coatings, the polymer solution was 100
grams of 10 percent styrene/butadiene copolymer in benzene, 25 mg.
of tetraphenyl porphin in 25 ml. chloroform, and an additional 22.5
grams chloroform. For 25 grams of the solution, 1.4 grams of the
magenta pigment slurry was used for the magenta coating while 0.8
gram of the cyan slurry was used, and 1.25 gram of the black. For
the yellow coating, the polymer solution varied by using only 10
mg. of tetraphenylporphin in 10 ml. chloroform, and having an
additional 45 grams chloroform, and 1.4 grams of the yellow
pigmented slurry was used with 25 grams of the solution. The
coatings were imaged with appropriate color separation negatives
with a flux of 2.5 ergs/cm.sup.2 /sec. The exposure times were 1.75
minutes for yellow, 1.25 minutes for magenta, 0.75 minutes for
cyan, and 3 minutes for black. The resulting latent images were
developed by spraying with a V, M and P naphtha (Skellysolve C) to
wash away non-exposed area and transferred individually in register
to a receptive paperboard to give a good, colored image.
EXAMPLE 3
An isoprene/acrylonitrile copolymer was dissolved to form a 10
percent solution of benzene. A 20 percent amount of iodoform, based
on polymer, was added, and 10 percent of a pigment, based on the
polymer. The pigments were added as 10-15 percent slurries in
hydrocarbon solvent. A polyethyl terephthalate film (Mylar) was
coated with a fluorocarbon resin, and separate pieces were coated,
the coatings employing yellow, magenta, cyan and black pigments.
The coated films were separately exposed through appropriate color
separation negatives employing a flux of about 2.5 ergs/cm.sup.2
/sec. for about one minute. The exposed films were developed by
washing with toluene to remove non-exposed areas of the coatings.
The resulting images were transferred in register to a coated
Bristol board to provide successfully a four-color proof.
EXAMPLE 4
A polyethyl terephthalate film (Mylar) was coated with a trans
polyisoprene polymer containing 0.26 percent tetraphenyl porphyrin
and 10 percent pigment, based on the polymer. Both yellow and cyan
pigments were used. Exposures were made through negatives for 6
minutes, and development was by immersion in a tray of
cyclohexane-toluene. An image was obtained. The procedure was
repeated employing a medium viscosity polybutadiene as polymer.
Cyclohexane development produced a fair image by removing unexposed
parts, while toluene tended to remove exposed areas also. With a
40/60 styrene/butadiene black copolymer, the procedure was repeated
as above with four pigments, and transfers were made in register to
give a full color print. An aliphatic VM and P naphtha was used for
development (Skellysolve L).
In the present invention it is feasible to use relatively thin
coatings. This has some slight advantage in economy of materials.
Also, since in half-tone procedures it is necessary to effect
complete selective removal of the coatings during development to
achieve the dot structure, it is desirable to have the coating
relatively thin to contribute to ease of removal and to minimize
exposure times, etc., to achieve reaction through the depth of the
coating, although surface reaction may be sufficient to give the
desired protection against the development fluids. The coatings are
usually of the order of 1 to 2 microns, say 0.5 to 3 microns, and
seldom exceed 5 microns. However, thicker coatings, such as up to
10 or 20 microns or more can be used. Relatively thick coatings may
be easier to transfer and handle. For a balance, one can select the
thicker coating having suitable developability, and employ lower
pigment loadings to compensate for the thicker image.
Utilizing a slurry as above, with a styrene/butadiene random
copolymer (48 styrene to 52 butadiene) and 6 percent solids
content, in which the pigment was 15 parts of yellow pigment for
100 parts of polymer, coatings were drawn with different rods and
thickness calculated from weight and density values. The
thicknesses were in the range of about 1 micron for a No. 8 rod, to
about 2 microns for a No. 16 rod, and about 4.5 microns for a No.
40 rod. In general, exposure and development did not change the
film thickness appreciably.
The pigments employed herein can in general be any pigments which
have the desired colors. For the most part the pigments will be
organic compounds and these are most suitable although inorganic
colorants, for example chrome yellows, can also be used. As used
herein the term pigment refers to solid, colorant materials which
are insoluble, or at least of very limited solubility, in the
polymer solvent systems employed in coating and development. The
term dye is used to designate colorant materials employed in
solution. The pigments as used are generally in very finely
divided, non-agglomerated form, such as in ranges up to 0.5 micron,
say 0.1 to 0.5 micron, and seldom exceed 1 micron in diameter. The
advantage of the small particle size can be seen with reference to
obtaining fine resolution, and also for production of thin, smooth
coatings. If not already in fine particle size, the pigments should
be reduced to such size, and it may be necessary to break up any
agglomerates in preparing the coating formulations. The pigment
loading will be regulated to give the desired color depth with the
particular coating thickness and other factors. However, the
pigment also has an effect upon the developability of the coatings
as it tends to make the coatings fracture upon washing with
appropriate liquids. A 5 to 10 percent by weight amount of pigment,
based on polymer, is usually sufficient for this purpose, and
loadings up to the amount the polymer can bind can be employed, but
it will generally be convenient to operate in the range of 10 to 50
percent by weight, based on polymer. If for some reason a
particular coating is to have little or no color, it may be
advisable to add some insoluble solids to the coatings for the
effect upon developability, the amounts possibly being sufficient
to provide 5 to 10 percent or so of solids, taking any pigments
into account as well as any white, colorless, or low-color solids.
For example, various amounts of silica or other fillers can be
added along with pigments.
EXAMPLE 5
A magenta pigmented styrene-butadiene copolymer slurry in benzene,
containing 0.25% tetraphenylporphin on the polymer was coated on a
release paper. The coated sheet was imaged 2.5 minutes through a
magenta half-tone color separation with a 4000 watt pulsed Xenon
light 32 inches from the surface. The exposed coating was then
immersed in a yellow dye solution for 2 minutes, and the dye was
wiped off, and the image developed by spraying with a V, M and P
Naphtha (Skellysolve V), washing away the non-exposed area. The
usual magenta image had been shifted to red to orange by the yellow
dye. The image was transferred to a receptive paper support. The
use of a dye makes possible the shifting of hues in the images. The
magenta pigment used above was at a loading of 20 parts per
hundred, based on polymer, and was a commercially available magenta
(13-3150 Perm Carmine FBB (Hoechst)). The yellow dye was a 2
percent (weight/volume) solution of a yellow dye, Alcian Yellow GX
(Imperial Chem. Ind.) in a 3:7 solution of ethanol and dodecyl
alcohol, with 5 percent by weight of added butanediol. Dyes can be
used in this manner to modify the colors of any of the color
separations images, or even of a composite formed therefrom. After
modification of the magenta image as shown above, the images from
the other color separations can be transferred in register to the
same support as the magenta image to form the composite colored
picture. This procedure may be particularly convenient for
modifying the magenta image, since some printers inks are more red
than magenta, and this procedure makes it possible to use pure
magenta and to obtain the desired match by dye modification.
Modification of a cyan image with a yellow dye may also have
frequent use.
EXAMPLE 6
A magenta-pigmented coating was used for imaging. The coating
contained 12.5 parts per hundred loading of the magenta pigment,
Monastral Red B, and had been drawn on a release paper with a No. 8
rod. The coating was exposed through a green record (magenta)
half-tone color separation negative and developed with an aliphatic
naphtha (Skellysolve C) to wash away non-exposed areas. The image
was transferred to a coated paper. An image so obtained had
measured optical densities of 0.08 through a red filter, 0.50
through a green filter, and 0.34 through a blue filter. Another
image, after development, was soaked in a blue dye solution for 30
seconds, followed by a wash with the same naphtha used for
development. The image was transferred and had optical densities of
0.31 through a red filter, 0.61 through a green filter and 0.36
through a blue filter. Another image was similarly treated with the
blue dye, but ethanol was used for the wash, with results of
optical density 0.1 through the red, 0.48 through the green, and
0.31 through the blue. It is apparent that the blue dye has shifted
the hue, especially when the naphtha wash was used, causing greater
absorption of the light which had passed the red and green filters,
i.e., higher density, because of the shift of the magenta toward
the blue. The dye solution used in the dye treatments was a 1%
(weight/volume) solution of blue dye (Victoria Blue R) in ethanol.
Images were similarly treated with 1 percent red dye solution
(Neozapon RED GE 216) in ethanol. A 30 second soak followed by
washing with aliphatic naphtha gave optical densities of the
transferred image of, 0.11 through the red, 0.61 through the green,
and 0.43 through the blue. With a 1 minute soak the values were
0.11 through the red, 0.64 through the green, and 0.45 through the
blue. The higher density in the green and blue shows greater red
absorption and that the dye has made the hue more red.
EXAMPLE 7
A polymer solution was prepared from 100 grams of chloroform, 100
grams of a 20% solution of a butadiene/styrene random copolymer
(Solprene 303) in benzene and 100 mg. tetraphenyl porphyrin. A
finely divided silica (Santocel Z brand of Monsanto Company) was
dispersed in benzene at a rate of 0.75 grams to 45 grams.
Approximately equal parts of the polymer solution and silica
dispersion were mixed, and a release paper was coated with the
slurry. Coatings were exposed through color separation negatives,
dyed, and then developed by washing with VM and P naphtha
(Skellysolve V) to give images. The exposure times with a 4000 watt
pulsed Xenon light 32 inches away were 2.5 minutes for yellow and
magenta, and 1.5 minutes for cyan. The images were transferred in
register to make a good composite picture, but with too much yellow
tone. A repeat of the procedure, but with a 1.5 minute exposure for
all color separations produced a picture with much truer color.
Utilizing the latter procedure above, but with omission of the
silica in the coating solution, produced a good composite picture,
but the transfers were more difficult to accomplish. In the above
procedures, the yellow dye was a 2 percent (weight-volume) solution
of a yellow dye, Alcian Yellow GX, in a 3:7 solution of ethanol and
dodecyl alcohol, with 5 percent by weight of added butanediol. The
magenta was 85 grams of a 2 percent solution of magenta dye (Sevron
Brilliant Red D (duPont)) in 7:3 hexadecyl alcohol and ethanol,
with 15 grams of a 2 percent solution of yellow dye (Maxilon
Brilliant Yellow 7 GLA (Geigy Chemical)) in the same solvents, and
10 grams of butanediol. The cyan dye was 44 grams of a 2 percent
solution of a cyan dye (Genacryl Blue 5B (General Aniline and
Film)) in 7:3 hexadecyl alcohol and ethanol, with 40 additional
grams of the solvent mixture and 4 grams butanediol. The black was
120 grams of a 2% solution of black (Nigrosin SS J (duPont)) in 100
ml 7:3 hexadecyl alcohol and ethanol with 50 grams of the dye
solution used for yellow, except the butanediol was omitted. The
soak for the dye application was 2 minutes. Colorless "pigments"
such as silica can be used in this procedure for their effect upon
the physical properties of the coatings, particularly with respect
to developability and transferability.
EXAMPLE 8
A release paper (Transkote FER) was coated with a styrene/butadiene
copolymer containing a 25 parts per hundred loading of blue green
pigment comprised of 9 parts blue (Monastral Blue B BT 284D) to one
part green (Monastral Green Y GT 805D). Coated samples were imaged
through a chrome tint and treated by aerosol sprays of liquids with
different KB values. The coating was resistant to n-hexane having a
KB value of 30.5. A VM and P naphtha (Skellysolve V) of KB value
36, and a similar aliphatic (Quick Solution H) of KB value 33.8,
both developed good dot structures, although the latter gave
somewhat higher print density. Another VM and P naphtha (Shell V),
KB value 39, was fairly strong for the conditions of use, tending
to cause loss of some of the dot structure.
EXAMPLE 9
A variation of the usual procedure employs a transferable polymer
film having a high energy surface. The pigmented, sensitized
coating is exposed and developed on the film, and the film is then
transferred along with the developed image. For example a release
paper is coated with a polar polymer solution to give a thin film,
and this is then overcoated with a coating solution containing as
polymer 95 parts styrene/butadiene (Solprene 303) to 5 parts
cis-polybutadiene. The coating had a 20 parts per hundred loading
of magenta pigment and 0.5 percent tetraphenylporphin. The coating
was exposed through a screen tint transparency, and developed with
an aliphatic naphtha, KB value 39. The image was then laminated to
an acceptor paper at 10,000 psi and 120.degree. for 15 seconds in a
6 inch by 6 inch press. The release paper was removed, leaving the
image covered by the transparent covered film. Fair quality images
can be obtained and transferred in this manner, although there is
some problem of background from the film. a carboxylated polymethyl
methacrylate (Lucite 6012) gave lower background than either a low
molecular weight polymethyl methacrylate (Elvacite 2008) or high
molecular weight polymethyl metharcylate (Elvacite 2041). The
development of cyan, yellow and black images in similar manner can
be followed by their transfer in register to the same support to
obtain a four color composite. The background presents some
difficulty, but film backings can be selected and other adjustments
made to overcome or minimize this problem.
EXAMPLE 10
A magenta-pigmented styrene/butadiene copolymer containing 0.25
percent tetraphenylporphin was coated on release paper (Transkote
ER) in the usual manner. It was imaged with a positive half-tone,
transparency, and developed with a solvent mixture having effective
polarity, a 1:1 mixture of methanol and a VM & P naphtha
(Skellysolve V). The exposed areas were washed away, and the image
was transferred with heat and pressure to a paperboard. Similar
results are obtained with butyl cellosolve as the developing
liquid. Images can be prepared in similar manner from the other
color separation half-tones, and transferred in register to form a
four color positive replica. In general the solvents used herein
for development by coating removal will be relatively poor solvents
for the polymer substrate involved, as a selective removal is
desired. For selective removal of non-exposed areas, solvents will
be selected which are effective to soften or dissolve the
non-exposed areas, but which are not sufficiently effective to
remove exposed areas in which hydroperoxy groups or other groups
affecting solubility are present. Solubility parameters present a
suitable guide for choosing appropriate solvents, although there
will be some variance with individual members of such classes. Such
parameters .delta. based on cohesive energy density, are described
in Solubility Parameters by Harry Burrell, Parts I and II,
Interchemical Review, Vol. 14, No. 1, pages 3-16, and Vol. 14, No.
2, pages 31- 46 (1955). As the hydroperoxy groups increase the
solubility parameter, the solvent will generally be selected to
have a parameter slightly less than that of the polymer employed.
Thus with a diene rubber having a solubility parameter around 8.5,
a suitable solvent would probably have a solubility parameter less
than 8. Many of the hydrocarbon diene polymers suitable for use
herein have solubility parameters in the range of 8 to 9.5, and
accordingly the developing solvents usually will have solubility
parameters below 8, although higher parameters may at times be
suitable. Most of the solvents suitable for use herein for removal
of non-exposed areas will have solubility parameters in the range
of 7 to 8 or 8.2. Poorer solvents when used sometimes require
longer development times, but this may not be objectionable in some
applications. Aliphatic hydrocarbons, including cycloaliphatics,
provide a number of suitable solvents for use with particular
polymer systems, e.g., kerosene, VM and P naphthas,
methylcyclohexane, octane etc. Some aliphatic, i.e., non-benzenoid,
unsaturation may be present in such solvents, but aromatic solvents
generally have too high a solubility parameter for use with the
preferred polymer systems herein. Solvents such as benzene,
toluene, etc. will ordinarily dissolve both the exposed and
non-exposed areas in a photooxidation imaging system. Thus it is
not desirable to use really good solvents for the polymer for the
development purposes, but to select solvents of lowe solubility
parameter than the polymer, e.g. 0.2 to 0.5 or more units lower. If
the starting polymer is readily soluble in toluene or benzene, as
is usually the case herein, the exposed areas after photooxidation
imaging are still readily soluble as the imaging does not crosslink
or otherwise change such polymer so as to render it insoluble in
such solvents. It will be recognized that the suitability of
particular development solvents will vary with such factors as the
molecular weight of polymers in the film substrate, characteristics
of other additives of components in the film, desired speed of
development, film thickness and strength, etc. The hydroperoxy
groups are strongly polar, and therefore to avoid dissolution of
the exposed areas, solvents lacking strong polar groups are
ordinarily employed. Hydroxy, keto, etc. groups tend to increase
the solubility parameter, and are therefore not generally used
unless with a high solubility parameter polymer system, or if such
groups are present in such proportions in the solvent as not to
unduly affect the parameter. Similarly strongly halogenated
solvents tend to have higher solubility parameters, and are not
ordinarily employed as development solvents herein.
For the development of images by dissolution of the exposed
photooxidized areas, solvents of higher solubility parameter, such
as polar solvents, are employed. In broad terms, solvents will
dissolve polymers if the solubility parameters match. Thus if a
high solubility parameter solvent is used, it can dissolve the
hydroperoxidized region having a similar solubility parameter, but
has too high a parameter to dissolve the non-exposed regions of the
polymer. The precise relationship between the number of hydroperoxy
groups and the solubility parameter is not known, but the solvents
chosen should have a solubility parameter above that of the
original polymer so as not to dissolve non-exposed areas. Polar
solvents, such as hydroxyl containing compounds, e.g., various
alcohols, glycols, cellosolves, etc. can be used. Solvents will be
selected so as to give the desired degree of solubility without
unduly affecting the non-exposed area, and may at times have
solubility parameters considerably above that of the original
polymer substrate. It is to be recognized that the solvents herein
can include mixtures of various solvents, and that descriptions
herein are mainly concerned with the overall characteristics of
solvents, rather than with characteristics of individual components
thereof. For example, a particular naphtha may be considered as a
low solubility parameter aliphatic hydrocarbon solvent even though
it has some aromatics content. With some of the solvent for the
hydroperoxidized areas it may be desirable to use small amounts of
bases, for example, alkalies such as sodium hydroxide, or chemical
reagents to aid in the removal.
Another useful guide in choice of development fluids is the KB
value. The KB value, i.e., Kauri-butanol value, is a measure of the
solvent power of a solvent as determined by dissolving Kauri resin
in butanol, and titrating the amount of a given solvent necessary
to titrate to incipient insolubility. In general, with
hydrocarbons, the stronger the solvent, the higher the KB value.
The KB value has a fairly good correlation with solubility
parameter for aliphatic solvents. Reported KB values are available
for many solvents. When a solvent of particular KB value has been
found suitable for developing a particular photosensitive coating,
with a particular application method, other solvents of similar KB
value will also be suitable. The initial selection can be made by
trying solvents on a scale of gradually changing KB value,
generally in half-tone work using one which is just sufficiently
effective to remove non-exposed areas well, but without disturbing
the exposed areas. In the case of mixed solvents of vastly
different character, e.g., hydrocarbons and polar solvents,
effective KB value must be used, as dependent upon the KB values
and relative amounts, as the ordinary method of determining KB
values would not give the proper value in such case. With the
unsaturated hydrocarbon resins preferred herein, particularly
styrene/butadiene polymers, useful KB values are usually in the
range of about 32 to 38, or up to 39 to 40 with some application
methods.
* * * * *