Thermal dye transfer system with a dye-receiving element containing a reactive keto moiety

Abstract: A thermal dye transfer assemblage comprising: (a) a dye-donor element comprising a support having thereon a dye layer comprising a dye dispersed in a polymeric binder, the dye being substituted with a reactive primary or secondary aliphatic or primary aromatic amino group, and (b) a dye-receiving element comprising a support having thereon a dye image-receiving layer, the dye-receiving element being in a superposed relationship with the dye-donor element so that the dye layer is in contact with the dye image-receiving layer, the dye image-receiving layer comprising a polymer containing a plurality of β-diketone, β-ketoester or β-ketoamide functional groups.

Description: This invention relates to a thermal dye transfer system, and more particularly to the use of a thermal dye transfer assemblage wherein the receiver contains a polymer containing a plurality of reactive β-diketone, β-ketoester or β-ketoamide groups which react with amino-substituted dyes transferred from a dye-donor 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 one of the cyan, magenta or yellow signals, and 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. Dyes for thermal dye transfer imaging should have bright hue, good solubility in coating solvents, good transfer efficiency and good light stability. A dye receiver polymer should have good affinity for the dye and provide a stable (to heat and light) environment for the dye after transfer. In particular, the transferred dye image should be resistant to damage caused by handling, or contact with chemicals or other surfaces such as the back of other thermal prints and plastic folders, generally referred to as retransfer. Many of the deficiencies of thermal dye transfer systems with regard to the above features can be traced to insufficient immobilization of the dye in the receiver polymer. It would be desirable to provide a dye/receiver polymer system in which the dye is capable of undergoing reaction with the receiver polymer to form a dye species with reduced mobility, preferably via covalent attachment to the polymer chain. U.S. Patent 4,614,521 relates to a reactive dye-polymer system for thermal dye transfer imaging. Specifically, this patent discloses a variety of dyes having substituents capable of reacting with receiver polymers having epoxy or isocyanate groups. However, there is a problem with receivers containing epoxy- or isocyanate-containing polymers in that they are potentially prone to poor keeping, especially in humid environments. Japanese Patent Application JP05-238174 relates to the thermal transfer of dyes, substituted with groups having "alkaline" properties, to an image receiving material containing an "acidic" substance. Dye-receiver binding is the result of an acid-base reaction between the basic dye and the acidic substance in the receiver, which yields a dye salt (ion-pair) rather than a covalent reaction product. However, there is a problem with these dyes in that they are potentially unstable in acidic environments, especially in combination with atmospheric moisture. Japanese Patent Application JP05-212981 relates to the thermal transfer of dyes having an "active hydrogen", such as a primary amino group, to a receiver layer having a basic catalyst and an "active olefin", such as an acrylate or acrylamide polymer. The basic catalysts include metal alkoxides and Grignard compounds. A Michael-type addition of the active hydrogen-containing group of the dye to the olefinic group in the receiver yields a covalently bound dye. However, there is a problem with acrylate-type materials in that they are potentially prone to light and dark chemical changes which could reduce the effectiveness of the binding reaction. It is an object of this invention to provide a thermal dye transfer system having improved retransfer properties. In the following copending applications of even priority, application and publication date, EP-A-0 733 485 discloses a thermal dye transfer assemblage comprising a dye donor element comprising a dye with a reactive primary or secondary aliphatic amino group, and a dye receiving element comprising an image-receiving layer comprising a polymer with a plurality of specific carbonyl-containing functional groups, and EP-A-0 733 486 discloses a thermal dye transfer assemblage comprising a dye donor element comprising a dye with a reactive primary or secondary aliphatic amino group, and a dye receiving element comprising an image-receiving layer comprising a polymer with a pendant alkyl acrylamidoglycolate alkyl ether group. This and other objects are achieved in accordance with this invention which relates to a thermal dye transfer assemblage comprising: (a) a dye-donor element comprising a support having thereon a dye layer comprising a dye dispersed in a polymeric binder, the dye being substituted with a reactive primary or secondary aliphatic or primary aromatic amino group, and (b) a dye-receiving element comprising a support having thereon a dye image-receiving layer, the dye-receiving element being in a superposed relationship with the dye-donor element so that the dye layer is in contact with the dye image-receiving layer, the dye image-receiving layer comprising a polymer containing a plurality of reactive β-diketone, β-ketoester or β-ketoamide functional groups. In a preferred embodiment of the invention, the dyes employed have the general formula: A-L-NHR 1 wherein: A represents a thermally transferable dye residue, e.g., any of the dye classes described in the art for use in thermal transfer imaging such as azo, methine, merocyanine, indoaniline, anthraquinone, etc.; L represents a divalent alkylene linking group of 1-10 carbon atoms, which may be substituted or interrupted with other divalent moieties such as oxygen atoms, carbonyl groups, etc. or a divalent arylene group of 1-10 carbon atoms which may be substituted; and R 1 represents H or a substituted or unsubstituted alkyl group of 1 to 10 carbon atoms, which may also optionally be bonded to either A or L; with the proviso that when L is arylene, R 1 must be H. Dyes according to the above formula are disclosed in Japanese Patent Application JP05-212981. In another preferred embodiment of the invention, the β-diketone, β-ketoester or β-ketoamide group has the formula: R 2 -COCH 2 CO-X-R 3 wherein: R 2 represents a substituted or unsubstituted alkyl group having from 1 to 6 carbon atoms or a substituted or unsubstituted aryl group having from 6 to 10 carbon atoms; X represents a direct bond, O or NR 4 ; R 3 represents a substituted or unsubstituted alkyl group having from 1 to 6 carbon atoms or a substituted or unsubstituted aryl group having from 5 to 10 carbon atoms; R 4 represents H or R 2 ; and R 2 and/or R 3 is linked to the polymer backbone. Any type of polymer may be employed in the receiver e.g., condensation polymers such as polyesters, polyurethanes, polycarbonates, etc.; addition polymers such as polystyrenes, vinyl polymers, etc.; block copolymers containing large segments of more than one type of polymer covalently linked together and having the β-diketone/ketoester/ketoamide group in any or all of the segments such as a poly(dimethylsiloxane)-polyacrylate block copolymer with the reactive groups located in the acrylate block, the poly(dimethylsiloxane) block or in both segments, etc. It has been found that dyes substituted with reactive primary or secondary aliphatic or primary aromatic amino groups give much improved retransfer performance, as compared to dyes without such substituents, when transferred to receiving elements based on polymers containing β-diketone, β-ketoester or β-ketoamide functional groups. The reaction of the dye and polymer leads to polymer bound dyes of the structure: R 3 -X-COCH=C(R 2 )-NR 1 -L-A where A, L, R 1 , R 2 , R 3 and X are as described above. When R 1 is H, a tautomeric imine form is also possible, e.g., R 3 -X-COCH 2 C(R 2 )=N-L-A. The following dyes may be used in accordance with the invention: The following receiver polymers may be used in accordance with the invention: Polymer ID Tg, °C X, (wt %) Y, (wt %) Z, (wt %) Polymer 12 -60°C 50 5 45 Polymer 13 -4°C 50 15 35 Polymer 14 41°C 50 35 15 Polymer 15 47°C 60 35 5 The polymer in the dye image-receiving layer may be present in any amount which is effective for its intended purpose. In general, good results have been obtained at a mordant concentration of from about 0.5 to about 10 g/m 2 . The polymers may be coated from organic solvents or water, if desired. Polymers 2-8 and 10-15 described above were prepared by conventional free radical polymerizations. Polymers 1 and 9 were prepared from commercially available hydroxyl polymers [PKHJ, Union Carbide Corp. and poly(vinyl acetal) KS-1 (Sekisui Co) (24 mole% hydroxyl, 76 mole% acetal)], by procedures similar to those described in J. Org. Chem., 50, 2431 (1985). The support for the dye-receiving element of the invention may be transparent or reflective, and may comprise a polymeric, a synthetic paper, or a cellulosic paper support, or laminates thereof. Examples of transparent supports include films of poly(ether sulfone)s, poly(ethylene naphthalate), polyimides, cellulose esters such as cellulose acetate, poly(vinyl alcohol-co-acetal)s, and poly(ethylene terephthalate). The support may be employed at any desired thickness, usually from about 10 µm to 1000 µm. Additional polymeric layers may be present between the support and the dye image-receiving layer. For example, there may be employed a polyolefin such as polyethylene or polypropylene. White pigments such as titanium dioxide, zinc oxide, etc., may be added to the polymeric layer to provide reflectivity. In addition, a subbing layer may be used over this polymeric layer in order to improve adhesion to the dye image-receiving layer. Such subbing layers are disclosed in U.S. Patents 4,748,150, 4,965,238, 4,965,239, and 4,965,241. The receiver element may also include a backing layer such as those disclosed in U.S. Patents 5,011,814 and 5,096,875. Resistance to sticking during thermal printing may be enhanced by the addition of release agents to the dye-receiving layer or to an overcoat layer, such as silicone-based compounds, as is conventional in the art. Dye-donor elements that are used with the dye-receiving element of the invention conventionally comprise a support having thereon a dye-containing layer as described above. 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. 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 a cyan, magenta and yellow dye, as described above, and the dye transfer 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. Thermal print heads which can be used to transfer dye from dye-donor elements to the receiving elements of the invention are available commercially. Alternatively, other known sources of energy for thermal dye transfer may be used, such as lasers as described in, for example, GB No. 2,083,726A. When a three-color image is to be obtained, the assemblage described above 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. After thermal dye transfer, the dye image-receiving layer contains a thermally-transferred dye image. The following examples are provided to further illustrate the invention. Example 1 Dyes The following control dyes were synthesized and evaluated: 1. Control dyes with basic substituents other than primary or secondary aliphatic or primary aromatic amines. These dyes are typical of those described in Japanese Patent Application JP05-238174. 2. Control dye with a hydroxy substituent. This dye is similar to those described in Japanese Patent Application JP05-212981 and U.S. Patent 4,614,521. 3. Control dyes with substituents having no basic properties or active hydrogens. Polymeric Dye-receiving Layers. The following control polymers which do not contain reactive groups conforming to the invention structure were coated and evaluated as dye receiver layers as described below: Preparation of Dye-Donor Elements Dye-donor elements 1-15 and Control Dye-donor elements C-1 to C-10 were prepared by coating on a 6 µm poly(ethylene terephthalate) support: 1) a subbing layer of Tyzor TBT®, a titanium tetrabutoxide, (DuPont Company) (0.16 g/m 2 ) coated from 1-butanol; and 2) a dye layer containing dyes 1-15 of the invention and control dyes C-1 to C-10 described above, and FC-431® fluorocarbon surfactant (3M Company) (0.01 g/m 2 ) in a cellulose acetate propionate binder (2.5% acetyl, 45% propionyl) coated from a toluene, methanol and cyclopentanone mixture. Details of dye and binder laydowns are tabulated in Table 1 below. On the back side of the dye-donor element was coated: 1) a subbing layer of Tyzor TBT®, a titanium tetrabutoxide, (DuPont Company) (0.16 g/m 2 ) coated from 1-butanol; and 2) a slipping layer of Emralon 329® (Acheson Colloids Co.), a dry film lubricant of poly(tetrafluoroethylene) particles in a cellulose nitrate resin binder (0.54 g/m 2 ) and S-nauba micronized carnauba wax (0.016 g/m 2 ) coated from a n-propyl acetate, toluene, isopropyl alcohol and n-butyl alcohol solvent mixture. Dye Donor Element Dye λ-max Dye Laydown (g/m 2 ) CAP (g/m 2 ) 1 552 0.20 0.22 2 551 0.22 0.25 3 534 0.23 0.25 4 547 0.23 0.27 5 460 0.48 0.63 6 632 0.23 0.17 7 653 0.54 0.39 8 463 0.23 0.30 9 446 0.31 0.41 10 459 0.32 0.42 11 449 0.65 0.47 12 438 0.51 0.68 13 552 0.21 0.23 14 553 0.23 0.25 15 635 0.27 0.19 C-1 551 0.23 0.25 C-2 543 0.23 0.25 C-3 549 0.20 0.22 C-4 539 0.24 0.26 C-5 549 0.18 0.20 C-6 542 0.23 0.27 C-7 458 0.44 0.59 C-8 459 0.26 0.34 C-9 448 0.49 0.36 C-10 629 0.23 0.17 Preparation and Evaluation of Dye-Receiver Elements Dye-receiver elements according to the invention were prepared by first extrusion laminating a paper core with-a 38 µm thick microvoided composite film (OPPalyte 350TW®, Mobil Chemical Co.) as disclosed in U.S. Patent No. 5,244,861. The composite film side of the resulting laminate was then coated with the following layers in the order recited: 1) a subbing layer of Polymin Waterfree® polyethyleneimine (BASF, 0.02 g/m 2 ), and 2) a dye-receiving layer composed of the polymers 2-8 and 12-15 (3.23 g/m 2 ) and a fluorocarbon surfactant (Fluorad FC-170C®, 3M Corporation, 0.022 g/m 2 ) coated from 2-butanone, except 1) polymers 1 and 9 were coated from dichloromethane and utilized Fluorad FC-431® (3M Corporation, 0.022 g/m 2 ) as surfactant, and 2) polymers 10 and 11 were coated from methanol. The receiver element prepared from polymer 9 also contained 0.32 g/m 2 each of dibutyl- and diphenylphthalate. Preparation and Evaluation of Thermal Dye Transfer Images Eleven-step sensitometric thermal dye transfer images were prepared from the above dye-donor and dye-receiver elements. The dye side of the dye-donor element approximately 10 cm X 15 cm in area was placed in contact with a receiving-layer side of a dye-receiving element of the same area. This assemblage was clamped to a stepper motor-driven, 60 mm diameter rubber roller. A thermal head (TDK No. 8I0625, thermostatted at 31° C) was pressed with a force of 24.4 newtons (2.5 kg) against the dye-donor element side of the assemblage, pushing it against the rubber roller. The imaging electronics were activated causing the donor-receiver assemblage to be drawn through the printing head/roller nip at 11.1 mm/s. Coincidentally, the resistive elements in the thermal print head were pulsed (128 µs/pulse) at 129 µs intervals during a 16.9 µs/dot printing cycle. A stepped image density was generated by incrementally increasing the number of pulses/dot from a minimum of 0 to a maximum of 127 pulses/dot. The voltage supplied to the thermal head was approximately 10.25 V resulting in an instantaneous peak power of 0.214 watts/dot and a maximum total energy of 3.48 mJ/dot. After printing, the dye-donor element was separated from the imaged receiving element and the appropriate (red, green or blue) Status A reflection density of each of the eleven steps in the stepped-image was measured with a reflection densitometer. The reflection density at the highest power is listed in Table 2. A second eleven-step image adjusted to yield a maximum density of approximately 2.5-3.0 by varying the printing voltage over the range of 9.0 V - 11.5 V was prepared as above. The imaged side of the stepped image was placed in intimate contact with a similarly sized piece of a poly(vinyl chloride) (PVC) report cover, a 1 kg weight was placed on top and the whole assemblage was incubated in an oven held at 50° C for 1 week. The PVC sheet was separated from the stepped image and the appropriate Status A transmission density in the PVC (a measure of the amount of dye transferred to the PVC) at the highest density step was measured with a transmission densitometer. The results of these measurements are collected in Table 2. In addition, the appearance of the stepped image with regard to uniformity and sharpness was noted and given a rating of 0-5. The ratings for these criteria are collected in Table 2. In each case 0 represents no image degradation and 5 represents nearly total image degradation. The following results were obtained: As the results in Table 2 clearly show, the use of dyes substituted with reactive amino groups and dye receiver elements based on polymers containing β-diketone, β-ketoester or β-ketoamide groups yields thermal dye transfer images with good transferred density and superior resistance to damage from contact with other surfaces. Example 2 : Thermal dye transfers were prepared and evaluated as in Example 1, except that the donor-receiver assemblage was drawn through the printing head/roller nip at 40.3 mm/s while the resistive elements of the thermal head were pulsed (128 µs/pulse) at 131 µs intervals during a 4.6 µs/dot printing cycle (including a 0.4 µs/dot cool down interval). In addition, the number of pulses/dot was varied from 0 to 32 and the printing voltage was 12.8 volts resulting in an instantaneous peak power of 0.334 watts/dot and a maximum total energy of 1.49 mJ/dot. A second eleven-step image (used for the retransfer test) adjusted to yield a maximum density of approximately 1.2-2.5 was prepared by varying the printing voltage over the range of 12.8-13.1 V. The following results were obtained: Dye Donor Element Dye Receiver Polymer Transfer D-max (Reflect.) Dye Transferred to PVC (Transm.) Image Uniformity After Incubation 1 1 2.4 0.10 0 5 8 1.2(B) 0.04(B) 0 6 8 1.8(R) 0.08(R) 0 1 C-2 2.3 0.99 5 C-4 1 2.5 1.30 5 As the results in Table 3 clearly show, the use of dyes substituted with reactive amino groups and dye receiver elements based on polymers containing β-diketone, β-ketoester or β-ketoamide groups yields thermal dye transfer images with good transferred density and superior resistance to damage from contact with other surfaces.

Claims: A thermal dye transfer assemblage comprising: (a) a dye-donor element comprising a support having thereon a dye layer comprising a dye dispersed in a polymeric binder, the dye being substituted with a reactive primary or secondary aliphatic or primary aromatic amino group, and (b) a dye-receiving element comprising a support having thereon a dye image-receiving layer, the dye-receiving element being in a superposed relationship with the dye-donor element so that the dye layer is in contact with the dye image-receiving layer, said dye image-receiving layer comprising a polymer containing a plurality of reactive β-diketone, β-ketoester or β-ketoamide functional groups. The assemblage of Claim 1 wherein said dye has the general formula: A-L-NHR 1 wherein: A represents a thermally transferable dye residue; L represents a divalent alkylene linking group of 1-10 carbon atoms, which may be substituted or interrupted with other divalent moieties or a divalent arylene group of 1-10 carbon atoms which may be substituted; and R 1 represents H or a substituted or unsubstituted alkyl group of 1 to 10 carbon atoms, which may also optionally be bonded to either A or L; with the proviso that when L is arylene, R 1 must be H. The assemblage of Claim 2 wherein A is the residue of an azo dye, an indoaniline dye or a merocyanine dye. The assemblage of Claim 2 wherein L is an alkylene group of from 2 to 4 carbon atoms. The assemblage of Claim 2 wherein R 1 is hydrogen. The assemblage of Claim 1 wherein said β-diketone, β-ketoester or β-ketoamide functional group has the formula: R 2 -COCH 2 CO-X-R 3 wherein: R 2 represents a substituted or unsubstituted alkyl group having from 1 to 6 carbon atoms or a substituted or unsubstituted aryl group having from 6 to 10 carbon atoms; X represents a direct bond, O or NR 4 ; R 3 represents a substituted or unsubstituted alkyl group having from 1 to 6 carbon atoms or a substituted or unsubstituted aryl group having from 5 to 10 carbon atoms; R 4 represents H or R 2 ; and R 2 and/or R 3 is linked to the polymer backbone. A process of forming a dye transfer image comprising imagewise-heating the dye-donor element described in Claim 1 and imagewise transferring said dye to the dye-receiving element described in Claim 1 to form said dye transfer image. The process of Claim 7 wherein said dye has the general formula as described in Claim 2. The process of Claim 7 wherein said β-diketone, β-ketoester or β-ketoamide group has the formula as described in Claim 6. The process of Claim 7 wherein polymer bound dyes are formed having the structure: R 3 -X-COCH=C(R 2 )-NR 1 -L-A wherein A represents a thermally transferable dye residue; L represents a divalent alkylene linking group of 1-10 carbon atoms, which may be substituted or interrupted with other divalent moieties or a divalent arylene group of 1-10 carbon atoms which may be substituted; R 1 represents H or a substituted or unsubstituted alkyl group from 1 to 10 carbon atoms, which may also optionally be bonded to either A or L; with the proviso that when L is arylene, R 1 must be H. R 2 represents a substituted or unsubstituted alkyl group having from 1 to 6 carbon atoms or a substituted or unsubstituted aryl group having from 6 to 10 carbon atoms; X represents a direct bond, O or NR 4 ; R 3 represents a substituted or unsubstituted alkyl group having from 1 to 6 carbon atoms or a substituted or unsubstituted aryl group having from 5 to 10 carbon atoms; R 4 represents H or R 2 ; and R 2 and/or R 3 is linked to the polymer backbone.

Inventors: BAILEY DAVID BENEDICT, BOWMAN WAYNE ARTHUR, EVANS STEVEN, LAWRENCE KRISTINE B, NOONAN JOHN MICHAEL, BAILEY, DAVID BENEDICT, BOWMAN, WAYNE ARTHUR, EVANS, STEVEN, LAWRENCE, KRISTINE B., NOONAN, JOHN MICHAEL, BAILEY, DAVID BENEDICT, C/O EASTMAN KODAK COMPANY, BOWMAN, WAYNE ARTHUR, C/O EASTMAN KODAK COMPANY, EVANS, STEVEN, C/O EASTMAN KODAK COMPANY, Lawrence, Kristine B., c/o Eastman Kodak Company, NOONAN, JOHN MICHAEL, C/O EASTMAN KODAK COMPANY
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1996
Main classification: B41M5
IPC codes: B41M5