Method for improving photoimage quality

Abstract: The instant invention pertains to a method of improving the quality and resolution of photoimages by incorporating into the photocurable resin composition to be used a selected amount of a polymerization inhibitor so that photopolymerization of the photocurable resin is inhibited in those areas not directly impinged by light.

Description: The present invention pertains to a method of improving the quality and resolution of photoimages by incorporating into the photocurable resin composition to be used a selected amount of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine) sebacate as a polymerization inhibitor so that photopolymerization of the photocurable resin is inhibited in those areas not directly impinged by light. The light may be visible, infrared, actinic or laser light. United States Patent Nos. 4,264,705; 4,427,759; 4,431,723; 4,442,302; 4,517,279; 4,540,649 and 4,716,094; Canadian Patent No. 1,267,475 and EP 335,247 describe multilayered elastomeric printing plates, flexographic printing plates and related photopolymerizable compositions used to prepare such plates. It is clear from these representative patents that there are many requirements for the preparation of acceptable printing plates, but chief among such requirements is that the quality of the photoimage be of the highest quality. That is, good resolution or a sharply defined image is essential along with durability and resistance to degradation or erosion by water or solvent based inks. EP 335,247 discloses that a hindered amine should also be present to provide stability to the cured product. United States Patent No. 4,216,019; EP 252,150 and WO 95/12148 describe the preparation of screen printing stencil compositions giving stencils with solvent/water resistance. These stencils are intended for use to give screen printing images of good resolution and quality. The general method of using a stencil composition includes applying or coating a photosensitive stencil composition on a screen, drying the composition, exposing the stencil appropriately through a photomask to actinic radiation to form an image, optionally drying the image, treating the stencil with an alkaline developing solution or treating the dried stencil with an aqueous, alkaline ink and printing a substrate. United States Patent No. 4,517,279 teaches the use of high molecular weight butadiene /acrylonitrile copolymers with a selected carboxyl and acrylonitile content, an photopolymerizable ethylenically unsaturated monomer and photoinitiator as the photopolymerizable unsaturated prepolymers, ethylenically unsaturated monomers, a photoinitiator and a surface tack modifier (to give a tack-free surface) as the photopolymerizable composition. United States Patent No. 4,666,821 discloses the preparation of hot melt solder masks using photopolymerizable compositions. United States Patent No. 4,824,765 describes the use of water-soluble photoinitiators in general photoimaging processes useful to prepare printing plates, screen printing stencils, solder masks, litho and letterpress printing plates, etch resists, UV cured inks, overcaoting lacquers and abrasion or mar resistant coatings. United States Patent No. 5,501,942 give a typical procedure for the preparation of solder masks or resists which include applying a photosensitive composition to a substrate, removing water from the composition to form a photosensitive film on the substrate, exposing the coated substrate with actinic light in a desired pattern, removing the unexposed areas of said coating with an aqueous or aqueous-alkaline solution to uncover the substrate in the non-exposed areas, and subjecting the coating on the substrate to a thermal or option UV cure. EP 261,910 and EP 295,944 both describe the water developable photosensitive resin plate suitable for making relief printing plates with high resistance to water-based inks. The UK Patent Application GB 2 198 736 describes a photopolymerisable material comprising a light-sensitive layer that contains compounds with N-oxyl structural units as polymerisation inhibitors. Especially disclosed are 1-oxyl-2,2,6,6,-tetramethyl-4-acetamido-piperidine, 1-oxyl-2,2,6,6,-tetramethyl-4-acetato-piperidine, 1-oxyl-2,2,6,6,-tetramethylpiperidin-4-yl benzoate and maleic acid 4-(2,2,6,6,-tetramethylpiperidino-N-oxyl)semiamide. Chemical Abstract Vol. 103, page 589, Abstract No. 186812 refers to a Russian Conference contribution analyzing light induced processes in liquid photopolymeric layers for holographic recording. As radical acceptor in photopolymeric layers 1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine is used. US Patent 4,279,986 describes a radiation sensitive composition comprising a high polymer compound and 1,1-diphenyl-2-picrylhydrazyl as radical scavenger of preventing post-irradiation. For comparative purposes 4-(1-oxyl-2,6-di-tert-butyl-benzylidene)-2,6-di-tert-butyl-cyclohexa-2,5-dienone free radical which is the known galvinoxyl stable free radical is used. From each of these references and the art generally, it is clear that steps for producing printing plates, solder masks or any other of the end-use application mentioned above involve a photopolymerizable composition having the following components: (a) a polymer or prepolymer containing some polymerizable or crosslinkable groups; (b) an ethylenically unsaturated monomer; (c) a photoinitiator or light activated cationic catalyst; and optionally (d) other compounds aimed at modifying some aspect of the ultimate polymerized or cured final product. These references note that actinic radiation is used to polymerize the liquid photopolymerizable resin composition for making the stencil, printing plate, etch resist or solder mask, but none of the references teaches or suggests that the quality or the stability of the photoimage can be greatly enhanced by inclusion of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine sebacate as a polymerization inhibitor in the photopolymerizable resin composition The photoimaging technique is used in many fields such as printing plates, etch resists and solder mask applications. Photomasks have always been used in such applications to transfer an image onto a light sensitive or photopolymerizable material. The process begins with the irradiation of actinic light onto the light sensitive material placed under a photomask. Where the incident light passes through the transparent or open part of the photomask onto the light sensitive material, said material hardens via polymerization or crosslinking steps. Where the irradiated light is blocked by the photomask, the light sensitive material beneath the photomask should receive no incident actinic light and should remain in an unpolymerized state. During development of said photoimage, the unpolymerized material is then removed from the polymerized material which latter material becomes the photoimage. Theoretically, such an image should be clear, sharp and of the highest quality. However, in practice there is a problem caused by scattering of the light while it passes through the photomask or where the laser beam impinges causing said light to diffuse out when it exits the photomask. This result is caused by the fact that any photomask has a finite thickness leading to some diffusion of incident light. Also, impurities or fillers in the formulation itself may cause some scattering of the incident light. The diffused incident light causes some polymerization to occur outside of the discrete dimensions of the open portions of the photomask where no polymerization is desired. In the case of printing plates, the unwanted polymerization will cause the reverse image to fill in with excessive polymer so that the printed image will lose its definition and clarity. In the case of electronic applications, the unwanted polymerization will fill the space between two lines also reducing the resolution of the desired image. It is noted that the instant process pertains to both positive and negative resists since each type of resists requires high resolution images. The instant invention pertains to a method to prevent or at least mitigate the unwanted polymerization of photopolymerizable material caused by diffused incident light. Said method involves the addition of an effective inhibiting amount of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine sebacate as a monomer polymerization inhibitor into the photopolymerizable material. This inhibitor is sufficient to prevent polymerization when the incident light is diffuse and not directly incident on the material, but is not enough to prevent polymerization when the incident light impinges the material directly. The effective inhibiting amount ranges from 0.1 to 20% by weight of the photoinitiator concentration or between 0.0001 and 0.2% by weight of the resin composition. More specifically, the instant invention is to a process to reduce the undesired polymerization caused by scattered and diffused light in a photopolymerizable material and to improve the quality and resolution of the final developed image formed by the irradiation of said photopolymerizable material by light, wherein the process comprises adding to the photopolymerizable material an effective inhibiting amount of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine sebacate as an inhibitor, wherein the amount of said inhibitor is sufficient to prevent or mitigate polymerization by diffused or scattered light, but is insufficient to prevent polymerization of the photopolymerizable material irradiated directly by light. The composition useful in the instant process may also contain an effective stabilizing amount of a hindered amine which is different from the N-oxyl inhibitor described above. This hindered amine and any residue from the N-oxyl inhibitor can also improve the storage stability of the printing plate made by the instant process. The residual radical inhibitor in the plate can act as a radical scavenger to prevent the plate from undergoing deterioration by oxidation and/or photodegradation. It is noted that the instant N-oxyl inhibitor may scavenge a radical to form a NOR-hindered amine. The NOR-hindered amines are known to be effective stabilizers in their own right for organic substrates. Thus, there is an added bonus with the use of the instant N-oxyl polymerization inhibitor since it may impart some additional stabilization efficacy to the instant products. It is noted that most printing presses are run at high speed which generates heat from friction between the printing plate and the printing substrate. Thus, oxidation can readily occur. Any residual radical inhibitor or added hindered amine stabilizer will be advantageous for providing protection against plate degradation. The addition of the radical inhibitor also increases the water resistance of the printing plate. Thus, it is possible to maintain its image resolution when a water-based ink is used since the image swells less. In like manner, the addition of the radical inhibitor also increases the chemical resistance of the printing plate. The presence of an additional hindered amine allows the printing plate improved resistance against both thermal and actinic induced degradation. The polymerization inhibitor is present in an effective inhibiting amount of 0.0001 to 0.2% by weight of the total composition. The polymerization inhibitor is bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) sebacate. Prefered is a process wherein the light is actinic light. Also preferred is a process wherein irradiation occurs through a photomask. The instant invention involves a photosensitive resin composition for preparing a relief printing plate which comprises (A) from 5 to 98 % by weight, based on the total weight of the components (A), (B), (C) and (D), of a polymer selected from the group consisting of a prepolymer, a binder polymer and a mixture thereof, (B) from 1.0 to 94 % by weight, based on the total weight of components (A), (B), (C) and (D), of an ethylenically unsaturated monomer or mixture thereof, (C) from 0.001 to 10% by weight, based on the total weight of components (A), (B), (C) and (D), of a photopolymerization initiator selected from the group consisting of acetophenone and a derivative thereof, benzoin and a derivative thereof, benzophenone and a derivative thereof, anthraquinone and a derivative thereof, xanthone and a derivative thereof, thioxanthone and a mixture thereof, and a mixture of one or more of these initiators, and (D) from 0.0001 to 0.2% by weight, based on the total weight of components (A), (B), (C) and (D), of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine sebacate as a polymerization inhibitor, An especially preferred embodiment is when the composition described above additional contains component (E) which is from 0.05 to 10 % by weight, based on the total weight of the composition, of a hindered amine containing a 2,2,6,6-tetramethylpiperidine moiety. The ethylenically unsaturated monomers or oligomers which can be used in the instant process include natural rubber, synthetic rubber, epoxy (meth)acrylate, urethane (meth)acrylate, polyester (meth)acrylate, unsaturated polyester styrene, vinyl ethers and vinyl functional resins and derivatives of the above named classes of monomers or oligomers or copolymers thereof. The different classes of photoinitiators which can be used in the instant process include benzoin and benzoin ether derivatives, benzil ketal derivatives, α,α-dialkoxyacetophenone derivatives, α-hydroxyalkylphenone derivatives, α-aminoalkylphenone derivatives, acylphosphine oxides, acyl phosphine sulfides, phenylglyoxylate derivatives, O-acyl-α-oximino ketone derivatives, benzophenone and its derivatives, Michler's ketone, thioxanthone and derivatives, metallocene compounds, bisimidazole and derivatives and all the polymer-bound compounds of the type mentioned above. More specifically, suitable examples of photoinitiator systems are aromatic carbonyl compounds such as benzoin, benzoin alkyl ethers, such as the isopropyl or n-butyl ether, α-substituted acetophenones, preferably benzil ketals, such as benzil dimethyl ketal, or α-halogen-substituted acetophenones, such as trichloromethyl-p-tert-butylphenyl ketone or morpholinomethyl phenyl ketone, or dialkoxyacetophenones, such as diethoxyacetophenone, or α-hydroxyacetophenones, such as 1-hydroxycyclohexyl phenyl ketone; or benzophenones, such as benzophenone or bis(4-dimethylamino)benzophenone; or metallocene initiators, such as titanocene initiators, for example bis(π-methylcyclopentadienyl)bis(σ-pentafluorophenyl)titanium (IV); or a stannan in conjunction with a photoreducible dye, for example dimethylbenzylstannan in conjunction with methlene blue or Bengal pink; or a quinone or a thioxanthone in conjunction with an amine which carries at least one hydrogen atom at an α-carbon atoms, such as antraquinone, benzoquinone or thioxanthone in conjunction with bis(4-dimethylamino)benzophenone or triethanolamine; or a thioxanthone, for example an alkyl- or halogen-substituted thioxanthone, such as 2-isopropylthioxanthone or 2-chlorothioxanthone; or acyl phosphides; or electron transfer systems such as borates in combination with electron acceptors that absorb light; or photoreducible dyes in combination with amines or other coinitiators. Suitable photopolymerizable acrylate or methacrylate monomers and oligomers are also known as described in EP 115,354. Very suitable are diethylene glycol diacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate or epoxy acrylates, bisphenol A, phenol or cresol novolaks, urethane acrylates or polyester acrylates. The epoxy acrylates can also be modified in a conventional manner with a carboxylic anhydride. In addition to the stabilizer which is a hindered amine of component (E), any number of other additives may also be present such as dyes, plasticizers, adhesion promoters, emulsifiers, pigments, chain transfer agents, sensitizers, cure enhancers such as amines, solvents, flow control agents and the like. In respect to radiation sources, any source capable of giving appropriate light irradiation is suitable such as Hg lamps, fluorescent lamps, lasers and the like. Although photoinitiators are chiefly used, hybrid systems involving free radical and cationic initiators or photo/thermal initiators are also useable in the instant invention. Although the scattering of light through photomasks is a common problem, light can be also be scattered by impurities of fillers which may be present in the formulation. This is especially the case in thick printing plates. Additionally, there are imaging techniques where no photomask is needed. For example, imaging can be done by scanning a laser across the photopolymerizable formulation or by focusing a laser on a solid photopolymerizable material to form a three-dimensional image. This is used in application such as stereo lithography and holography. A further object of the present invention is the use of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine sebacate as a polymerization inhibitor, to reduce the undesired polymerization caused by scattered and diffused light in a photopolymerizable material and to improve the quality and resolution of the final developed image formed by the irradiation of said photopolymerizable material by light. The following examples are meant to illustrate the instant invention and are not to be construed to limit the scope of the instant invention in any manner whatsoever. Example 1 Printing Plate Application A liquid photopolymer mixture comprising 70 parts of an aliphatic diacrylate, 20 parts of epoxidized soya oil acrylate and 10 parts of 1,6-hexanediol diacrylate is used as the light sensitive material to make a printing plate. The light source is NAPP Model 9000 Napprinter unit equipped with 12 VHO black light lamps. The photomask is Sayce Logarithmic Test Chart (SLTC). The SLTC gives a series of bars after the photopolymer is imaged and later developed. The depth between two relief bars is measured and compared between various test formulations with and without a radical polymerization inhibitor. The space between two bars is progressively narrower when the bar's identification number becomes larger. Consequently, the depth between two relief bars becomes shallower. A Flexo Plate test chart is also utilized as a test target to evaluate image quality. The Flexo Plate test chart consists of several reverse bars that are progressively narrower when its identification line number becomes smaller. Table I below shows that under the same exposure conditions, the reverse image quality can be improved by adding a small quantity of radical polymerization inhibitor to the test formulation. Without the radical inhibitor in the formulation, the reverse image depth for space #15 is 0.61 mm; by adding 0.001% by weight of Inhibitor A to the test formulation to prevent scattered light from initiating undesirable polymerization, the reverse image depth for the same space #15 is 0.71 mm. This represents a 17.4% improvement in image quality obtained by use of the radical inhibitor. This means that there is less fill-in between bars so that the image is neater, cleaner, deeper and with better resolution. In the case where 0.001% by weight of Inhibitor B is used, the reverse image depth for space #15 is now 1.26 mm or an 107% improvement over the image depth when no inhibitor was present in the formulation. Use of Different Inhibitors Space[mm] Inhibitor Inhibitor Conc.% # 15 # 16 # 17 # 18 # 19 # 20 None 0 0.61 0.56 0.53 0.47 0.44 0.40 A 0.0001 0.88 0.78 0.73 0.65 0.62 0.53 A 0.001 0.71 0.67 0.59 0.59 B 0.0001 0.67 0.58 0.55 0.52 0.48 0.43 B 0.001 1.26 1.24 1.20 1.11 0.95 1.04 C 0.0001 0.64 0.57 0.53 0.49 0.45 0.43 C 0.001 0.79 0.73 0.68 0.65 0.58 0.54 D 0.0001 0.39 0.63 0.59 0.51 0.49 0.42 D 0.001 0.57 0.51 0.48 0.44 0.42 0.37 D 0.01 0.59 0.53 0.50 0.49 0.43 0.39 E 0.0001 0.37 0.35 0.32 0.30 0.30 0.30 E 0.001 0.39 0.36 0.38 0.28 0.34 0.34 E 0.01 0.49 0.41 0.45 0.40 0.38 0.35 F 0.0001 0.50 0.47 0.44 0.39 0.38 0.34 F 0.001 0.50 0.46 0.44 0.40 0.39 0.34 F 0.01 0.49 0.40 0.41 0.39 0.35 0.32 Under different test conditions, it is possible to adjust exposure time so the test formulations with or without the inhibitor will give the same floor thickness as is seen in Table II. It is clear that even when different photoinitiator concentrations are used, the addition of a polymerization inhibitor to the formulation enhances the depth of the reverse images formed. Use of Different Photoinitiators Space[mm] Photo-Initiator Inhibitor A Conc. % # 15 # 16 # 17 # 18 # 19 # 20 1 0 0.61 0.56 0.53 0.47 0.44 0.40 1 0.0001 0.88 0.78 0.73 0.65 0.62 0.53 1 0.001 0.71 0.67 0.59 0.59 2 0 0.32 0.30 0.28 0.25 0.22 2 0.0001 0.36 0.36 0.34 0.31 0.26 0.26 3 0 0.32 0.32 0.24 0.26 0.24 3 0.0001 0.33 0.36 0.29 0.28 0.24 0.25 In summary, the data given in Example 1 show that under the same exposure condition one can have different floor thickness or can adjust exposure time to obtain the same floor thickness. In either case, the reverse image quality can be improved by the addition of a small effective amount of polymerization inhibitor into the photocurable formulation and this improvement is independent of floor thickness. Example 2 Electronic Application A two-pack solder mask formulation is prepared according to the following procedure. A first composition is prepared by mixing 25.4 parts by weight of a partial ester of hydroxyethyl methacrylate and a styrene-maleic anhydride copolymer [SMA 1000 (Arco Chemical); ratio 45:55]; 6.44 parts of ethylene glycol monobutyl ether acetate; 4.97 parts of an acid modified acrylate ester of bisphenol-A based epoxy resin (Novacure' 3800, Interez Inc.)); 1.84 parts of ethoxylated trimethylolpropane triacrylate; 2.0 parts of trimethylolpropane triacrylate; 0.93 parts of Modaflow flow promoting agent; 0.92 parts of a release agent; 7.37 parts of 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropanone-1 (Irgacure® 907, Ciba-Geigy Corp.) and 1.33 parts of thioxanthone photoinitiator at room temperature. A second composition is prepared by mixing 14.89 parts of an epoxy cresol novalac resin (Epon® DPS 164, Shell); 7.35 parts of phenolic novolac (Araldite® EPN 1138, Ciba-Geigy); and 9.10 parts of ethylene glycol monobutyl ether acetate. The mixture is then melted to reduce viscosity for easy processing. Finally 3.66 parts of fume silica (Carbosil® M-5, Cabot) is added. The two composition are mixed at room temperature with stirring and are then ground using a three-roll mill. A 1-2 mil thick coating of the resultant mixture is deposited onto a copper plate using a #3 rod. After the coating is dried at 80°C for about 25 minutes and then cooled to room temperature, a tack-free coating is obtain. The coated board is then placed on a vacuum plate with a negative photo mask placed on top. The board is then covered with a thin, clear polyethylene film and subjected to about 400 millijoules of UV radiation. The image is developed by washing with a 1% aqueous sodium carbonate solution for one minute at 50°C. The resulting image of cured polymer on the board is given a post cure of 2.4 joules using a medium pressure Hg lamp and finally baked in an oven at 150°C for one hour. A "Microcopy Resolution Test Chart" is used as a photo mask to evaluate the image resolution. The test chart consists of 18 patterns with different number assigned to each pattern. Each number represents the resolution of the pattern next to it. The higher the number that is obtained, the better is the image resolution that is achieved. The results are seen in Table III below. Effect of Inhibitor on Solder Mask Resolution Inhibitor A (conc. %) Resolution step 0 2.5 0.005 2.5 0.01 2.5 0.05 4 0.1 9 0.15 9 0.2 10 0.3 10 0.5 10 *Inhibitor A is bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) sebacate. From the results given in Table IV, it is clear that adding a small quantity of free radical inhibitor to the solder mask formulation significantly improves the image resolution. The best image resolution that can be obtained for the formulation without an inhibitor is 2.5, but by adding 0.05% or 0.1% of inhibitor A to the formulation, the image resolution becomes 4 and 9 respectively.

Claims: A process to reduce the undesired polymerization caused by scattered and diffused light in a photopolymerizable material and to improve the quality and resolution of the final developed image formed by the irradiation of said photopolymerizable material by light, wherein the process comprises adding to the photopolymerizable material an effective inhibiting amount of 0.0001 to 0.2% by weight of the total composition of an inhibitor, which inhibitor is bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine)sebacate. A process according to claim 1, wherein the light is actinic light. A process according to claim 1, wherein irradiation occurs through a photomask. A photosensitive resin composition for preparing a relief printing plate, an etch resist, a solder mask or a screen printing stencil which comprises (A) from 5 to 98 % by weight, based on the total weight of the components (A), (B), (C) and (D), of a polymer selected from the group consisting of a prepolymer, a binder polymer and a mixture thereof, (B) from 1.0 to 94 % by weight, based on the total weight of components (A), (B), (C) and (D), of an ethylenically unsaturated monomer, (C) from 0.001 to 10% by weight, based on the total weight of components (A), (B), (C) and (D), of a photopolymerization initiator selected from the group consisting of acetophenone and a derivative thereof, benzoin and a derivative thereof, benzophenone and a derivative thereof, anthraquinone and a derivative thereof, xanthone and a derivative thereof, thioxanthone and a mixture thereof, and a mixture of one or more of these initiators, and (D) from 0.0001 to 0.2 % by weight, based on the total weight of components (A), (B), (C) and (D), of an inhibitor which is bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine)sebacate. A composition according to claim 4, which additionally contains component (E) which is from 0.05 to 10 % by weight, based on the total weight of the composition, of a hindered amine containing a 2,2,6,6-tetramethylpiperidine moiety. Use of bis(1-oxyl-2,2,6,6-tetramethyl-4-hydroxypiperidine)sebacate to reduce the undesired polymerization caused by scattered and diffused light in a photopolymerizable material and to improve the quality and resolution of the final developed image formed by the irradiation of said photopolymerizable material by light.

Inventors: CHANG CHIA-HU, EVERS HARRY JOSEPH, LAVER HUGH STEPHEN, MAR ANDREW, NGUYEN THAI HONG, CHANG, CHIA-HU, EVERS, HARRY JOSEPH, LAVER, HUGH STEPHEN, MAR, ANDREW, NGUYEN, THAI HONG
Applicants: CIBA SC HOLDING AG, CIBA SPECIALTY CHEMICALS HOLDING INC.
Application year: 1997
Main classification: G03F7
IPC codes: C08F2, G03F7