Resin-coated paper support for receiving element used in thermal dye transfer

Abstract: A dye-receiving element for thermal dye transfer comprising a resin-coated paper support having thereon a polymeric dye image-receiving layer, the resin coating having a surface roughness measurement of 7.5 Ra microinches-AA or less.

Description: This invention relates to dye-receiving elements used in thermal dye transfer, and more particularly to the use of a resin-coated paper support having a certain surface roughness. In recent years, thermal transfer systems have been developed to obtain prints from pictures which have been generated electronically from a color video camera. According to one way of obtaining such prints, an electronic picture is first subjected to color separation by color filters. The respective color-separated images are then converted into electrical signals. These signals are then operated on to produce cyan, magenta and yellow electrical signals. These signals are then transmitted to a thermal printer. To obtain the print, a cyan, magenta or yellow dye-donor element is placed face-to-face with a dye-receiving element. The two are then inserted between a thermal printing head and a platen roller. A line-type thermal printing head is used to apply heat from the back of the dye-donor sheet. The thermal printing head has many heating elements and is heated up sequentially in response to the cyan, magenta and yellow signals. The process is then repeated for the other two colors. A color hard copy is thus obtained which corresponds to the original picture viewed on a screen. Further details of this process and an apparatus for carrying it out are contained in U.S. Patent No. 4,621,271 by Brownstein entitled "Apparatus and Method For Controlling A Thermal Printer Apparatus," issued November 4, 1986. In JP 60/236,794, polyethylene-coated paper supports are disclosed for use in thermal dye transfer systems. A problem exists with using those supports, however, in that the appearance of the thermally-transferred print is not always uniform. EP-A-0 234 563 discloses laminating a synthetic paper to a paper core material and then forming a receptive layer on top. While cast-coated papers or those subjected to a supercalendering treatment having a surface smoothness (Bekk smoothness) of 1,000 sec are disclosed, there is no teaching in this reference of extrusion overcoating a paper support with a polyolefin coating, or that such coating having a surface roughness measurement of 0.19 µm or less can be obtained by using a chill roller. It is an object of the invention to provide a resin-coated paper support for use as a dye-receiving element for thermal dye transfer systems which would have a more uniform surface appearance. These and other objects are achieved in accordance with this invention which comprises a dye-receiving element for thermal dye transfer comprising a paper support extrusion overcoated with a polyolefin, said polyolefin coating having thereon a polymeric dye image-receiving layer, characterized in that said polyolefin coating has a surface roughness measurement (R a ) of 0.19 µm (7.5 microinches-AA) or less, said R a being obtained by extrusion coating said polyolefin coating using a chill roller having the appropriate smoothness. Surface roughness measurements are made by the ANSI/ASME B46.1-1985 test on page 30, Sect. C3.l.l, described in the "1985 Catalog of American National Standards", published by the American Society of Mechanical Engineers (jointly with the American National Standards Institute): United Engineering Center, 345 E. 47th Street, New York, N.Y. 10017. The definition for Ra (Roughness average) and microinches-AA (Arithmetic Average) is also described in the above article. It was found that the appearance of the print of a thermally-transferred image varied depending upon the surface roughness of the resin-coted paper stock. A paper stock having a very matte resin-coated surface with a high Ra surface roughness produces a dye-transfer image that appears glossy in maximum density areas. This is caused by the greater heating in those areas which transforms the inherent matte receiver surface to a glossy surface. In the minimum density areas, however, where there is less heating, the inherent matte receiver surface remains matte. The difference in gloss is very noticeable and objectionable. In accordance with this invention, a relatively smoother resin-coated support is obtained which provides a dye-transfer image which retains its glossy surface regardless of whether one looks at the minimum or maximum density areas. The inherent roughness of the paper stock and the density of the paper fibers were not found to be critical. Thus, the surface appearance of images obtained in accordance with this invention is less variable than that of the prior art. In a preferred embodiment of the invention, a subbing layer is present between the resin-coated surface and the dye image-receiving layer. For example, a subbing layer may be used which is a vinylidene chloride copolymer, such as one comprising from 5 to 35 percent by weight of recurring units of an ethylenically unsaturated monomer, from 0 to 20 percent by weight of recurring units of an ethylenically unsaturated carboxylic acid, and from 55 to 85 percent by weight of recurring units of vinylidene chloride. Further examples of these subbing layers are found in U.S. Patent 4,748,150 of Vanier and Lum, issued May 31, 1988. The resin coating for the paper support may be any polymeric material which has been used in the art to provide a smooth coating on paper, and which has a sufficiently high heat deflection so as to not soften appreciably by a thermal print head or a heated finishing roller. In a preferred embodiment of the invention, polyolefins are used such as polyethylene, polypropylene, etc. In another preferred embodiment, white pigments such as titanium dioxide, zinc oxide, etc., may by added to the resin coating to provide reflectivity. The polymeric dye image-receiving layer of the dye-receiver of the invention may comprise, for example, a polycarbonate, a polyurethane, a polyester, polyvinyl chloride, poly(styrene- co -acrylonitrile), poly(caprolactone) or mixtures thereof. The dye image-receiving layer may be present in any amount which is effective for the intended purpose. In general, good results have been obtained at a concentration of from 1 to 5 g/m². In a preferred embodiment of the invention, the dye image-receiving layer is a polycarbonate. The term "polycarbonate" as used herein means a polyester of carbonic acid and a glycol or a dihydric phenol. Examples of such glycols or dihydric phenols are p -xylylene glycol, 2,2-bis(4-oxyphenyl)propane, bis(4-oxyphenyl)methane, 1,1-bis(4-oxyphenyl)ethane, 1,1-bis(oxyphenyl)butane, 1,1-bis(oxyphenyl)cyclohexane, 2,2-bis(oxyphenyl)butane, etc. In another preferred embodiment of the invention, the polycarbonate dye image-receiving layer is a bisphenol-A polycarbonate having a number average molecular weight of at least 25,000. In still another preferred embodiment of the invention, the bisphenol-A polycarbonate comprises recurring units having the formula wherein n is from 100 to 500. Examples of such polycarbonates include General Electric Lexan® Polycarbonate Resin #ML-4735 (Number average molecular weight app. 36,000), and Bayer AG Makrolon #5705® (Number average molecular weight app. 58,000). The later material has a T g of 150°C. A dye-donor element that is used with the dye-receiving element of the invention comprises a support having thereon a dye later. Any dye can be used in such a layer provided it is transferable to the dye image-receiving layer of the dye-receiving element of the invention by the action of heat. Especially good results have been obtained with sub-limable dyes such as or any of the dyes disclosed in U.S. Patent 4,541,830. The above dyes may be employed singly or in combination to obtain a monochrome. The dyes may be used at a coverage of from 0.05 to 1 g/m² and are preferably hydrophobic. The dye in the dye-donor element is dispersed in a polymeric binder such as a cellulose derivative, e.g., cellulose acetate hydrogen phtalate, cellulose acetate, cellulose acetate propionate, cellulose acetate butyrate, cellulose triacetate; a polycarbonate; poly(styrene-co-acrylonitrile), a poly(sulfone) or a poly(phenylene oxide). The binder may be used at a coverage of from 0.1 to 5 g/m². The dye layer of the dye-donor element may be coated on the support or printed thereon by a printing technique such as a gravure process. Any material can be used as the support for the dye-donor element provided it is dimensionally stable and can withstand the heat of the thermal printing heads. Such materials include polyesters such as poly(ethylene terephthalate); polyamides; polycarbonates; glassine paper; condenser paper; cellulose esters; fluorine polymers; polyethers; polyacetals; polyolefins; and polyimides. The support generally has a thickness of from 2 to 30 µm. It may also be coated with a subbing layer, if desired. The reverse side of the dye-donor element may be coated with a slipping layer to prevent the printing head from sticking to the dye-donor element. Such a slipping layer would comprise a lubricating material such as a surface active agent, a liquid lubricant, a solid lubricant or mixtures thereof, with or without a polymeric binder. As noted above, dye-donor elements are used to form a dye transfer image. Such a process comprises imagewise-heating a dye-donor element and transferring a dye image to a dye-receiving element as described above to form the dye transfer image. The dye-donor element employed in certain embodiments of the invention may be used in sheet form or in a continuous roll or ribbon. If a continuous roll or ribbon is employed, it may have only one dye thereon or may have alternating areas of different dyes such as cyan, magenta, yellow, black, etc., as disclosed in U.S. Patent 4,541,830. In a preferred embodiment of the invention, a dye-donor element is employed which comprises a poly(ethylene terephthalate) support coated with sequential repeating areas of cyan, magenta and yellow dye, and the above process steps are sequentially performed for each color to obtain a three-color dye transfer image. Of course, when the process is only performed for a single color, then a monochrome dye transfer image is obtained. A thermal dye transfer assemblage using the invention comprises a) a dye-donor element as described above, and b) a dye-receiving element as described above, the dye-receiving element being in a superposed relationship with the dye-donor element so that the dye layer of the donor element is in contact with the dye image-receiving layer of the receiving element. The above assemblage comprising these two elements may be preassembled as an integral unit when a monochrome image is to be obtained. This may be done by temporarily adhering the two elements together at their margins. After transfer, the dye-receiving element is then peeled apart to reveal the dye transfer image. When a three-color image is to be obtained, the above assemblage is formed on three occasions during the time when heat is applied by the thermal printing head. After the first dye is transferred, the elements are peeled apart. A second dye-donor element (or another area of the donor element with a different dye area) is then brought in register with the dye-receiving element and the process repeated. The third color is obtained in the same manner. The following example is provided to illustrate the invention. Example A) A dye-receiver in accordance with the invention was prepared by obtaining a commercially produced paper stock 6.5 mil (165 µm) thick 40 lb/1000 ft² (195 g/m²) mixture of hard woodkraft and soft wood-sulfite bleached pulp. The paper stock was then extrusion overcoated with an approximately 1:4 ratio of medium density : high density polyethylene (2.5 lb/1000 ft²) (12 g/m²) with approximately 6 wt. percent anatase titanium dioxide and 1.5 wt. percent zinc oxide (layer thickness 12 µm). The extrusion overcoating operation used separate chill rollers each of different smoothness to produce coated paper stock receivers of different smoothness as described in the table. The support was then coated with the following layers: (a) Subbing layer of poly(acrylonitrile)- co -vinylidene chloride- co -acrylic acid (14:79:7 wt. ratio) (0.54 g/m²) coated from a butanone and cyclopentanone solvent mixture; and (c) Dye-receiving layer of Makrolon 5705® polycarbonate (Bayer AG) (2.9 g/m²), 1,4-didecoxy-2,5-dimethoxybenzene (0.38 g/m²), and FC-431® surfactant (3M Co.) (0.016 g/m²) coated from methylene chloride. The back side of the receiver was coated with a polyethylene layer and an overcoat layer. A dye-donor element was prepared by coating on a 6 µm poly(ethylene terephthalate) support dye layers containing the dyes as identified above (0.77 mmoles/m²), and FC-431® (3M Corp.) surfactant (2.2 mg/m²) in a cellulose acetate propionate (40% acetyl and 17% propionyl) binder (at 1.8 times that of the dye) coated from a toluene, methanol and cyclopentanone solvent mixture. On the back side of the element was coated a slipping layer of the type disclosed in U.S. Patent 4,737,485 of Henzel et al, issued April 12, 1988. The dye side of the dye-donor element strip one inch (25 mm) wide was placed in contact with the dye image-receiving layer of the dye-receiver element of the same width. The assemblage was fastened in the jaws of a stepper motor driven pulling device. The assemblage was laid on top of a 0.55 (14 mm) diameter rubber roller and a TDK Thermal Head L-133 (No. C6-0242) and was pressed with a spring at a force of 8 pounds (3.6 kg) against the dye-donor element side of the assemblage pushing it against the rubber roller. The imaging electronics were activated causing the pulling device to draw the assemblage between the printing head and roller at 0.123 inches/sec (3.1 mm/sec). Coincidentally, the resistive elements in the thermal print head were heated at increments from 0 up to 8.3 msec to generate a graduated density test pattern. The voltage supplied to the print head was approximately 21 v representing approximately 1.7 watts/dot (12 mjoules/dot). The dye-receiving element was separated from the dye-donor element. The receiving elements were then examined and measured for surface glass. The following results were obtained: Paper Stock Ra (µm) Differential Gloss Upon Printing Smooth Glossy 0.03 No Rough Glossy 0.17 No V. Rough Glossy 0.19 No Matte 1.26 Yes The above results indicate that the receiving elements having a surface roughness of 7.5 Ra microinches-AA or less do not have a differential gloss upon printing, and thus are superior prints.

Claims: A dye-receiving element for thermal dye transfer comprising a paper support extrusion overcoated with a polyolefin, said polyolefin coating having thereon a polymeric dye image-receiving layer, characterized in that said polyolefin coating has a surface roughness measurement (R a ) of 0.19 µm (7.5 microinches-AA) or less, said R a being obtained by extrusion coating said polyolefin coating using a chill roller having the appropriate smoothness. The element of Claim 1 characterized in that a subbing layer is present between said resin-coated surface and said dye image-receiving layer. The element of Claim 2 characterized in that said subbing layer comprises a vinylidene chloride copolymer. The element of Claim 1 characterized in that said polyolefin is polyethylene. The element of Claim 4 characterized in that said polyethylene layer also contains titanium dioxide. The element of Claim 1 characterized in that said dye image-receiving layer is a bisphenol-A polycarbonate having a number average molecular weight of at least 25,000. The element of Claim 6 characterized in that said bisphenol-A polycarbonate comprises recurring units having the formula wherein n is from 100 to 500.

Inventors: CAMPBELL ROBERT BENTON C O EAS, CAMPBELL, ROBERT BENTON C/O EASTMAN KODAK COMPANY
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY (A NEW JERSEY CORPORATION)
Application year: 1988
Main classification: B41M5
IPC codes: B41M5