Dye-receiving element containing spacer beads in a laser-induced thermal dye transfer

Abstract: A dye-receiving element comprising a support having thereon a dye-receiving layer containing a laser-induced thermal dye transfer image, the element containing spacer beads of such particle size and concentration that effective contact between the dye-receiving element and a dye-donor element is prevented during transfer of the laser-induced thermal dye transfer image, the spacer beads being located either in the dye-receiving layer or in a layer thereover.

Description: This invention relates to dye-receiver elements used in laser-induced thermal dye transfer which contain spacer beads. 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. Another way to thermally obtain a print using the electronic signals described above is to use a laser instead of a thermal printing head. In such a system, the donor sheet includes a material which strongly absorbs at the wavelength of the laser. When the donor is irradiated, this absorbing material converts light energy of the laser to thermal energy and transfers the heat to the dye in the immediate vicinity, thereby heating the dye to its vaporization temperature for transfer to the receiver. The absorbing material may be present in a layer beneath the dye and/or it may be admixed with the dye. The laser beam is modulated by electronic signals which are representative of the shape and color of the original image, so that each dye is heated to cause volatilization only in those areas in which its presence is required on the receiver to reconstruct the color of the original object. Further details of this process are found in GB 2,083,726A. There is a problem with using the laser system described above in that the transfer of dye tends to be nonuniform. In many instances, the dye-binder melts and sticks to the receiver, creating an effect called image mottle. Further, when the dye-donor is in direct contact with the dye-receiving layer, heat is lost to the dye-receiving layer from the dye-donor, cooling the dye-donor with a resultant loss in density being transferred. It is an object of this invention to find a way to improve the uniformity and density of dye transfer using a laser. U.S. Patent 4,541,830 and EPA 163,145 describe a dye-donor for thermal dye transfer wherein the dye layer contains non-sublimable particles which protrude from the surface. Although there are no examples, there is a disclosure in these references that their donor could be used for high speed recording by a laser beam. There is no disclosure in these references, however, that the non-sublimable particles could be used in a dye-receiver element. There is an advantage in having particles in the dye-receiver instead of the dye-donor in that image mottle is reduced and a matte viewing surface is provided. From JP-A- 63-1592 an image receiving paper is known. The image receiving paper is obtained by applying the image receiving layer consisting of particles of Al₂O₃ and the matrix resin having styrene acryl as material to a base film. In order to protrude the particles from the coating layer of the matrix resin the image receiving layer is so constructed as to have a void when it is superimposed on an ink sheet. Because the particle is contacted with the ink sheet and its heat conductivity is high, it becomes especially of high temperature in the image receiving paper and the ink is transferred by fusion from the contact point with the particle. These and other objects are achieved in accordance with this invention which comprises a dye-receiving element comprising a support having thereon a dye-receiving layer containing a laser-induced thermal dye transfer image, the element containing spacer beads of such particle size and concentration that effective contact between the dye-receiving element and a dye-donor element is prevented during transfer of the laser-induced thermal dye transfer image, the spacer beads being located either in the dye-receiving layer or in a layer thereover. Any spacer beads may be employed in the invention provided they have the particle size and concentration as described above. In general, the spacer beads should have a particle size ranging from 3 to 50 µm, preferably from 5 to 25 µm. The coverage of the spacer beads may range from 5 to 2,000 beads/mm². As the particle size of the beads increases, then proportionally fewer beads are required. In a preferred embodiment of the invention, the spacer beads have a particle size from of 3 to 5 µm and are present at a concentration of from 750 to 2,000/mm². In another preferred embodiment of the invention, the spacer beads have a particle size from of 5 to 15 µm and are present at a concentration of from 10 to 1,000/mm². In still another preferred embodiment of the invention, the spacer beads have a particle size from of 15 to 50 µm and are present at a concentration of from 5 to 200/mm². The spacer beads do not have to be spherical and may be of any shape. The spacer beads may be formed of polymers such as polystyrene, phenol resins, melamine resins, epoxy resins, silicone resins, polyethylene, polypropylene, polyesters, polyimides, etc.; metal oxides, inorganic salts, inorganic oxides, silicates, salts, etc. In general, the spacer beads should be inert and insensitive to heat at the temperature of use. The support of the dye-receiving element of the invention may be a transparent film such as a poly(ether sulfone), a polyimide, a cellulose ester such as cellulose acetate, a poly(vinyl alcohol-coacetal) or a poly(ethylene terephthalate). The support for the dye-receiving element may also be reflective such as baryta-coated paper, polyethylene-coated paper, white polyester (polyester with white pigment incorporated therein), an ivory paper, a condenser paper or a synthetic paper such as duPont Tyvek®. The dye image-receiving layer which is coated on the support of the dye-receiving element 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 spacer beads are incorporated into the dye image-receiving layer. However, the spacer beads may also be coated as a separate layer over the dye image-receiving layer in a binder such as higher polysaccharides e.g., starch, dextran, dextrin, corn syrup, etc.; cellulose derivatives; acrylic acid polymers; polyesters; polyvinylacetate; etc. Any dye can be used in the dye layer of the dye-donor element employed in certain embodiments of the invention provided it is transferable to the dye-receiving layer by the action of heat. Especially good results have been obtained with sublimable 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 described above is dispersed in a polymeric binder such as a cellulose derivative, e.g., cellulose acetate hydrogen phthalate, 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 described above provided it is dimensionally stable and can withstand the heat generated by the laser beam. Such materials include polyesters such as poly(ethylene terephthalate); polyamides; polycarbonates; glassine paper; condenser paper; cellulose esters; fluorine polymers; polyethers; polyacetals; polyolefins or methylpentane polymers. The support generally has a thickness of from 2 to 250 µm. It may also be coated with a subbing layer, if desired. Any material may be used as the infrared-absorbing material in the dye-donors employed in certain embodiments of the invention such as carbon black or non-volatile infrared-absorbing dyes or pigments which are well known to those skilled in the art. Cyanine infrared absorbing dyes may also be employed as described in EP-A-0 321 923, filed December 20, 1988, entitled "Infrared Absorbing Cyanine Dyes for Dye-Donor Element Used in Laser-Induced Thermal Dye Transfer." EP-A-0 321 923 belongs to the prior art according to Article 54(3)(4) EPC. As noted above, dye-donor elements are used to form a laser-induced thermal dye transfer image according to the invention. Such a process comprises imagewise-heating a dye-donor element as described above using a laser, and transferring a dye image to a dye-receiving element as described above to form the laser-induced thermal dye transfer image. After the dyes are transferred to the receiver, the image may be thermally fused to stabilize the image. This may be done by radiant heating or by contact with heated rollers. The fusing step aids in preventing fading of the image upon exposure to light and also tends to prevent crystallization of the dyes. Solvent vapor fusing may also be used instead of thermal fusing. Several different kinds of lasers could conceivably be used to effect the thermal transfer of dye from a donor sheet to a receiver, such as ion gas lasers like argon and krypton; metal vapor lasers such as copper, gold, and cadmium; solid-state lasers such as ruby or YAG; or diode lasers such as gallium arsenide emitting in the infrared region from 750 to 870 nm. However, in practice, the diode lasers offer substantial advantages in terms of their small size, low cost, stability, reliability, ruggedness, and ease of modulation. In practice, before any laser can be used to heat a dye-donor element, the laser radiation must be absorbed into the dye layer and converted to heat by a molecular process known as internal conversion. Thus, the construction of a useful dye layer will depend not only on the hue, sublimability and intensity of the image dye, but also on the ability of the dye layer to absorb the radiation and convert it to heat. A thermal dye transfer assemblage of 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 adjacent to and overlying the 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. 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 using the laser beam. 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 examples are provided to illustrate the invention. Example 1 A) A cyan dye-donor element was prepared by coating on a 100 µm gelatin-subbed poly(ethylene terephthalate) support: a dye layer containing the cyan dye illustrated above (0.33 g/m²), the bis indolylcyanine dye illustrated below (0.16 g/m²), and Dow Corning DC-510® surfactant (0.10 g/m²) in a cellulose acetate propionate (2.5% acetyl, 45% propionyl) binder (0.30 g/m²) coated from a cyclohexanone, butanone and dimethylformamide solvent mixture. A dye-receiving element was prepared by coating on a poly(methyl acrylate-co-vinylidene chloride-co-itaconic acid) (0.11 g/m²) subbed polyethylene terephthalate support a layer of poly(methyl-methacrylate-co-divinylbenzene) (97:3 wt. ratio) (8-12 µm diameter spherical beads) at the coverage indicated in Table 1 below, Dow Corning DC-510® surfactant (0.10 g/m²) in a Lexan® 101 (General Electric) bisphenol-A polycarbonate binder (1.7 g/m²) from a chlorobenzene and dichloromethane solvent mixture. The number of beads per square millimeter in each coating was estimated by counting under a microscope. The dye-receiving element containing the polymeric spacer beads was overlaid with the dye-donor, placed on the drum of a laser exposing device and a vacuum to 600 mm pressure was applied to hold the donor to the receiver. The assembly was then exposed on the 180 rpm rotating drum to a focused 830 nm laser beam from a Spectrodiode Labs Laser Model SDL-2420-H2® using a 30 µm spot diameter and an exposure time of approximately 100 microsec. to transfer areas of dye to the receiver. The power level was 86 milliwatts and the exposure energy was 44 microwatts/sq. micron. After dye transfer, the receivers were inspected for non-uniformities and relative grainy surface caused by sticking of the donor to the receiver. The following results were obtained: Dye Receiver Bead Conc. (g/m²) Beads per mm² Donor/Rec. Sticking Graininess Control 0 0 Yes Unacceptable Control 0.002 7 Yes Unacceptable Invention 0.010 31 No Moderate Invention 0.020 50 No Acceptable Invention 0.13 300 No Acceptable Invention 0.26 490 No Acceptable Unacceptable - - Graininess and mottle were so severe as to make the image commercially valueless. Moderate - - Graininess and mottle were noticeable over substantial areas. Acceptable - - Observed mottle was minimal. The above results indicate that at least 30 beads/mm² of 8-12 µm diameter are required in the dye-receiver layer to prevent sticking and obtain good image quality. Infrared absorbing indolyl dye: This dye is the subject of EP-A-0 321 923 filed December 20, 1988, entitled "Infrared Absorbing Cyanine Dyes for Dye-Donor Element Used in Laser-Induced Thermal Dye Transfer", referred to above. Example 2 Dye-donors were prepared as in Example 1. Dye-receivers were prepared as in Example 1 except that the polymeric beads were poly(styrene-co-divinylbenzene) (90:10 wt. ratio) (19-21 µm in diameter). Imaging and evaluation were as in Example with the following results: Dye Receiver Bead Conc. (g/m²) Beads per mm² Donor/Rec. Sticking Graininess Control 0 0 Yes Unacceptable Control 0.002 2 Yes Unacceptable Control 0.010 3 Yes Unacceptable Invention 0.020 12 No Acceptable Invention 0.13 80 No Acceptable Invention 0.26 96 No Acceptable The above results indicate that at least 10 beads/mm² of 20 µm diameter are required in the dye-receiver layer to prevent sticking and obtain good image quality. Example 3 Dye-donors were prepared as in Example 1. Dye-receivers were prepared as in Example 1 except that the polymeric beads were divinylbenzene crosslinked polystyrene (3 µm in diameter). Imaging and evaluation were as in Example with the following results: Dye Receiver Bead Conc. (g/m²) Beads per mm² Donor/Rec. Sticking Graininess Control 0 0 Yes Unacceptable Control 0.002 22 Yes Unacceptable Control 0.010 97 Yes Unacceptable Control 0.020 560 Yes Unacceptable Invention 0.10 970 No Acceptable The above results indicate that at least 750 beads/mm² of 3 µm diameter are required in the dye-receiver layer to prevent sticking and obtain good image quality.

Claims: A dye-receiving element comprising a support having thereon a dye-receiving layer containing a laser-induced thermal dye transfer image, said element containing spacer beads of such particle size and concentration that effective contact between said dye-receiving element and a dye-donor element is prevented during transfer of said laser-induced thermal dye transfer image, said spacer beads being located either in said dye-receiving layer or in a layer thereover. The element of Claim 1 characterized in that said spacer beads have a particle size of from 3 to 50 µm. The element of Claim 1 characterized in that said spacer beads are present at a concentration of from 5 to 2,000/mm². The element of Claim 1 characterized in that said spacer beads have a particle size from of 3 to 5 µm and are present at a concentration of from 750 to 2,000/mm². The element of Claim 1 characterized in that said spacer beads have a particle size from of 5 to 15 µm and are present at a concentration of from 10 to 1,000/mm². The element of Claim 1 characterized in that said spacer beads have a particle size from of 15 to 50 µm and are present at a concentration of from 5 to 200/mm². The element of Claim 1 characterized in that said spacer beads are poly(methyl methacrylate-co-divinylbenzene) or poly(styrene-co-divinylbenzene). A process of forming a laser-induced thermal dye transfer image comprising a) imagewise-heating by means of a laser a dye-donor element comprising a support having thereon a dye layer and an infrared-absorbing material, and b) transferring a dye image to a dye-receiving layer of a dye-receiving element to form said laser-induced thermal dye transfer image, characterized in that said dye-receiving element comprises a support having thereon spacer beads of such particle size and concentration that effective contact between said dye-receiving element and said dye-donor element is prevented during transfer of said laser-induced thermal dye transfer image, said spacer beads being located either in said dye-receiving layer or in a layer thereover. A thermal dye transfer assemblage comprising: a) a dye-donor element comprising a support having a dye layer and an infrared absorbing material, and b) a dye-receiving element comprising a support having thereon a dye image-receiving layer, said dye-receiving element being in a superposed relationship with said dye-donor element so that said dye layer is adjacent to said dye image-receiving layer, characterized in that said dye image-receiving layer contains spacer beads of such particle size and concentration that effective contact between said dye-receiving element and said dye-donor element is prevented during transfer of a laser-induced thermal dye transfer image, said spacer beads being located either in said dye-receiving layer or in a layer thereover.

Inventors: DEBOER CHARLES DAVID C O EASTM, DEBOER, CHARLES DAVID C/O EASTMAN KODAK COMPANY
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1989
Main classification: B41M5
IPC codes: B41M5