Ablative recording process

Abstract: A laser dye-ablative recording element comprising a support having thereon a dye layer comprising a yellow dye dispersed in a polymeric binder, the dye layer having an infrared-absorbing material associated therewith, the yellow dye comprising curcumin.

Description: This invention relates to use of a certain image dye in a single-sheet laser dye-ablative recording element. 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 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. In one ablative mode of imaging by the action of a laser beam, an element with a dye layer composition comprising an image dye, an infrared-absorbing material, and a binder coated onto a substrate is imaged from the dye side. The energy provided by the laser drives off the image dye at the spot where the laser beam hits the element and leaves the binder behind. In ablative imaging, the laser radiation causes rapid local changes in the imaging layer thereby causing the material to be ejected from the layer. This is distinguishable from other material transfer techniques in that some sort of chemical change (e.g., bond-breaking), rather than a completely physical change (e.g., melting, evaporation or sublimation), causes an almost complete transfer of the image dye rather than a partial transfer. Usefulness of such an ablative element is largely determined by the efficiency at which the imaging dye can be removed on laser exposure. The transmission Dmin value is a quantitative measure of dye clean-out: the lower its value at the recording spot, the more complete is the attained dye removal. In U.S. Patent 5,330,876, a single-sheet laser dye-ablative recording element is described in the Examples which employs a certain yellow dye. As will be shown by comparative tests hereinafter, the yellow dye employed in accordance with this invention has several improved properties thereover. WO-A-92/06410 describes a laser dye-ablative recording element. In particular this reference describes the transferring of an image pattern from an imaging medium to a receptor element in continuous relationship therewith. In all instances in this reference the process employed is a transfer process employing a receiving element. It is an object of this invention to provide a single sheet process of forming a dye ablation image in the absence of a receiving element. These and other objects are achieved in accordance with the invention which comprises a single sheet process of forming a dye ablation image in the absence of a receiving element comprising imagewise-heating by means of an infrared laser, a dye-ablative recording element comprising a support having thereon a dye layer comprising an image dye dispersed in a polymeric binder having an infrared-absorbing material associated therewith, said laser exposure taking place through the dye side of said support having thereon said dye layer, said imagewise-heating causing imagewise dye ablation, and removing the ablated image dye material by means of an air stream to obtain said image in said dye-ablative recording element, wherein said image dye comprises a yellow dye, said yellow dye comprising curcumin. The yellow dye curcumin, also known as Brilliant Yellow S, is a natural product dye found in the spice turmeric. It has long been used in the making of curry and is therefore generally regarded as being safe. The structure is large for a molecule intended to be ablated, but surprisingly it was found to be readily decomposed to colorless products when subjected to a laser beam and thereby allowing one to achieve very good dye clean-out at modest laser powers. It has also been found that, upon decomposition through laser-ablative imaging, the compound vanillin is produced. Vanillin is the active compound in vanilla which gives rise to the odor of vanilla. Therefore, the presence of even extremely small quantities of this compound is readily detected. The dye curcumin is believed to be 1,7-bis(4-hydroxy-3-methoxyphenyl)-1,6-heptadiene-3,5-dione. While isomers of this compound are believed to exist in the natural compound, the formula is believed to have the following structure: The dye ablation elements used in this invention can be used to obtain medical images, reprographic masks, printing masks, etc. The image obtained can be a positive or a negative image. The Dmin obtained with this invention is important for graphic arts applications where the Dmin/Dmax of the mask controls the exposure latitude for subsequent use. The dye removal process can be by either continuous (photographic-like) or halftone imaging methods. The invention is especially useful in making reprographic masks which are used in publishing and in the generation of printed circuit boards. The masks are placed over a photosensitive material, such as a printing plate, and exposed to a light source. The photosensitive material usually is activated only by certain wavelengths. For example, the photosensitive material can be a polymer which is crosslinked or hardened upon exposure to ultraviolet or blue light but is not affected by red or green light. For these photosensitive materials, the mask, which is used to block light during exposure, must absorb all wavelengths which activate the photosensitive material in the Dmax regions and absorb little in the Dmin regions. For printing plates, it is therefore important that the mask have high UV Dmax. If it does not do this, the printing plate would not be developable to give regions which take up ink and regions which do not. Any polymeric material may be used as the binder in the recording element employed in the invention. For example, there may be used cellulosic derivatives, polycarbonates; polyurethanes; polyesters; poly(vinyl acetate); polystyrene; poly(styrene-co-acrylonitrile); a polysulfone; a poly(phenylene oxide); a poly(ethylene oxide); a poly(vinyl alcohol-co-acetal); or mixtures or copolymers thereof. The binder may be used at a coverage of from about 0.1 to about 5 g/m 2 . In a preferred embodiment, the polymeric binder used in the recording element employed in the process of the invention has a polystyrene equivalent molecular weight of at least 100,000 as measured by size exclusion chromatography, as described in U.S. Patent 5,330,876. A barrier layer may be employed in the laser ablative recording element of the invention if desired, as described in EP-A-0 636 490 (prior art document according to Art. 54(3) EPC). To obtain a laser-induced, dye ablative image according to the invention, a diode laser is preferably employed since it offers substantial advantages in terms of its small size, low cost, stability, reliability, ruggedness, and ease of modulation. In practice, before any laser can be used to heat a dye-ablative recording element, the element must contain an infrared-absorbing material, such as cyanine infrared-absorbing dyes as described in EP-A-0 636 493 (prior art document according to Art. 54(3) EPC) or other materials as described in the following U.S. Patent Numbers: 4,948,777, 4,950,640, 4,950,639, 4,948,776, 4,948,778, 4,942,141, 4,952,552, 5,036,040, and 4,912,083. The laser radiation is then 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, transferability and intensity of the image dyes, but also on the ability of the dye layer to absorb the radiation and convert it to heat. The infrared-absorbing dye may be contained in the dye layer itself or in a separate layer associated therewith, i.e., above or below the dye layer. The laser exposure in the process of the invention takes place through the dye side of the dye ablative recording element, which enables this process to be a single-sheet process, i.e., a separate receiving element is not required. The curcumin dye in the recording element of the invention may be used at a coverage of from about 0.01 to about l g/m 2 . The dye layer of the dye-ablative recording element used in the invention 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-ablative recording element used in the invention provided it is dimensionally stable and can withstand the heat of the laser. Such materials include polyesters such as poly(ethylene naphthalate); poly(ethylene terephthalate); polyamides; polycarbonates; cellulose esters; fluorine polymers; polyethers; polyacetals; polyolefins; and polyimides. The support generally has a thickness of from about 5 to about 200 µm. In a preferred embodiment, the support is transparent. The following example 2 is provided to illustrate the invention. Example 1 (illustrating the UV Dmax of curcumin) The following materials are employed below: Monocolor media sheets were prepared by coating 100 µm bare poly(ethylene terephthalate) support with 0.47 g/m 2 of 100 s. cellulose nitrate (Aqualon Co.), 0.24 g/m 2 IR-1 and 0.65 g/m 2 of yellow dye (Y-1 and curcumin, respectively). Light filtration was measured by an X-Rite Densitometer (Model 3-0T for Visible and Model 361T for UV, X-Rite Corp.) Table 1 shows the absorption densities obtained. UV Dmax Red Dmax Green Dmax Blue Dmax Y-1 0.7 0.14 0.44 6.1 Curcumin 3.2 0.14 0.24 6.6 As can be seen from the data in Table 1, the Blue Dmax is 8% higher and the UV Dmax is 360% higher for curcumin relative to yellow dye Y-1 at equal laydowns. This allows less dye to be used for similar filtrations. Example 2 Monocolor media sheets were prepared by coating 100 µm bare poly(ethylene terephthalate) support with 0.22 g/m 2 of 1000 s. cellulose nitrate (Aqualon Co.), 0.11 g/m 2 UV-1, 0.09 g/m 2 C-1, 0.04 g/m 2 C-2, 0.11 g/m 2 IR-1 and the quantity of yellow dye indicated in Table 2. The samples were ablation-written using Spectra Diode Labs Laser Model SDL-2432, having integral, attached fiber for the output of the laser beam with a wavelength range of 800-830 nm and a nominal power output of 250 mW. at the end of the optical fiber. The cleaved face of the optical fiber was imaged onto the plane of the dye ablative element with a 0.5 magnification lens assembly mounted on a translation stage giving a nominal spot size of 25 µm. The drum, 53 cm in circumference, was rotated at varying speeds and the imaging electronics were activated to provide the exposures given in Table 2. The translation stage was incrementally advanced across the dye ablation element by means of a lead screw turned by a microstepping motor, to give a center-to-center line distance of 10 µm (945 lines per centimeter (2400 lines per inch)). An air stream was blown over the donor surface to remove the ablated dye. The ablated dye and other effluents are collected by suction. The measured total power at the focal plane was 100 mW. Densitometer readings were obtained as in Example 1 with the following results: Yellow Dmax Dmin @ 755 mJ/cm 2 Dmin @ 566 mJ/cm 2 Dmin @ 378 mJ/cm 2 Dmin @ 283 mJ/cm 2 Y-1 (Control) (0.22 g/m 2 ) 1.6 0.17 0.21 0.27 0.40 Curcumin (0.13 g/m 2 ) 1.1 0.15 0.15 0.17 0.23 Table 2 shows that the clean-out in the visible region is comparable for the two dyes even with the lower laydown of the curcumin dye. UV Dmax Dmin @ 755 mJ/cm 2 Dmin @ 566 mJ/cm 2 Dmin @ 378 mJ/cm 2 Dmin @ 283 mJ/cm 2 Y-1 (Control) (0.22 g/m 2 ) 2.5 0.16 0.19 0.25 0.33 Curcumin (0.13 g/m 2 ) 3.0 0.26 0.27 0.33 0.45 Table 3 shows that curcumin provides comparable near UV protection as yellow dye Y-1, when used in combination with Liquid UV-Absorbing Dye UV-1, but at a lower laydown. Dye UV-1 was used in both cases to allow better spectral coverage of the UV spectral region. Without the use of Dye UV-1, Y-1 would have little UV absorption (see Table 1). The sample data shown in Tables 2 and 3 reflect a useful masking film where multiple dyes would be needed to effectively cover all activating wavelengths. The thermal decomposition of curcumin to vanilla could be easily smelled when the filters were removed from the air suction nozzle which collect any effluents from the ablation process. With the suction collection system off, the smell of vanilla can be detected in less than a few seconds allowing quick identification of a problem with the adequate collection of dye ablation effluents. When the smell of vanilla is present, it is clear that other gas phase ablation products are not being collected adequately. The ability to quickly detect the presence of a small quantity of gas phase ablation products is an advantage as a safety backup for assessing the efficacy of the dye collection system and thereby minimize worker exposure to dye ablation products.

Claims: A single sheet process of forming a dye ablation image in the absence of a receiving element comprising imagewise-heating by means of an infrared laser, a dye-ablative recording element comprising a dimensionally stable support able to withstand the heat of the laser having thereon a dye layer comprising an image dye dispersed in a polymeric binder having an infrared-absorbing material associated therewith, said laser exposure taking place through the dye side of said support having thereon said dye layer, said imagewise-heating causing imagewise dye ablation, and removing the ablated image dye material by means of an air stream to obtain said image in said dye-ablative recording element, wherein said image dye comprises a yellow dye, said yellow dye comprising curcumin. The process of Claim 1 wherein said yellow dye is 1,7-biS(4-hydroxy-3-methoxphenyl)-1,6-heptadiene-3,5-dione. The process of Claim 1 wherein said yellow dye has the formula: The process of Claim 1 wherein said infrared-absorbing material is a dye which is contained in said dye layer.

Inventors: DOMINH THAP, KASZCUK LINDA, TUTT LEE WILLIAM, DOMINH, THAP, KASZCZUK, LINDA, TUTT, LEE WILLIAM, DoMinh, Thap, c/o Eastman Kodak Company, Kaszcuk, Linda, c/o Eastman Kodak Company, TUTT, LEE WILLIAM, C/O EASTMAN KODAK COMPANY
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1995
Main classification: B41M5
IPC codes: B41M5, G03F1