Radiation imagery chemistry: process – composition – or product th – Stripping process or element – Element
Reexamination Certificate
2002-06-11
2003-09-23
McPherson, John A. (Department: 1756)
Radiation imagery chemistry: process, composition, or product th
Stripping process or element
Element
C430S262000, C430S263000
Reexamination Certificate
active
06623904
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a photosensitive transfer recording material. More specifically, it relates to a photosensitive transfer recording material appropriate for dry transfer onto an uneven support, and to a process for producing a color filter using the photosensitive transfer recording material.
2. Description of the Related Art
Photosensitive transfer recording materials that are used in the production of color filters for liquid crystal cells and that comprise a temporary support having successively disposed thereon a thermoplastic resin layer, an alkali-soluble intermediate layer, and an alkali-soluble, pigment-containing photosensitive resin layer are conventionally known. Such materials are disclosed in, for example, Japanese Patent Application Laid-open Publication (JP-A) Nos. 5-173320 and 11-149008. In these publications, a photosensitive resin layer of a photosensitive transfer recording material is adhered to a substrate by ordinary lamination, and then the temporary support is peeled away to form an image on the substrate without exposing and developing the substrate.
Conventionally, there has been the problem that, when the surface of the substrate is uneven, air bubbles come between the photosensitive resin layer and the substrate when the two are adhered, whereby defects in transfer are caused. However, it has become possible to obtain a good transfer image, even if the substrate is uneven, by disposing a thermoplastic resin layer to prevent the formation of air bubbles.
Nevertheless, air bubbles have again become easily formable due to an increase in the production rates of color filters in recent years and an attendant increase in the speed at which lamination is conducted. Thus, defects in transfer have again become a problem.
In order to prevent air bubbles from forming when lamination is conducted at high speed, it is necessary to soften the thermoplastic resin layer. However, softening the thermoplastic resin layer causes reticulation. Reticulation means that when the intermediate layer expands due to moisture absorption or the like, the soft thermoplastic resin buckles and fine wrinkles appear in the surface of the photosensitive transfer recording material, which results in defective transfer. What is needed in order to conduct lamination at high speed is a technique to prevent air bubbles and reticulation.
SUMMARY OF THE INVENTION
It is a first object of the present invention to provide a photosensitive transfer recording material that prevents both the formation of air bubbles and reticulation even when lamination is conducted at high speed. It is a second object of the invention to provide a process for producing a color filter using the photosensitive transfer recording material.
In order to achieve the first object, there is provided a photosensitive transfer recording material that includes a temporary support having sequentially disposed thereon a thermoplastic resin layer, an alkali-soluble intermediate layer, and an alkali-soluble pigment-containing photosensitive resin layer, with the intermediate layer containing a polymer latex.
The glass transition temperature (Tg) of the polymer latex is preferably 60° C. or less. Additionally, the amount of the polymer latex is, in terms of the solid content thereof, 5 to 70% by weight with respect to the resin of the intermediate layer.
In order to achieve the second object, there is also provided a process for producing a color filter using plural types of the photosensitive transfer recording material.
DETAILED DESCRIPTION OF THE INVENTION
Photosensitive Transfer Recording Material
A photosensitive transfer recording material of the present invention comprises a temporary support having sequentially disposed thereon a thermoplastic resin layer, an alkali-soluble intermediate layer, and an alkali-soluble pigment-containing photosensitive resin layer, with the intermediate layer containing a polymer latex. The photosensitive transfer recording material of the invention and a process for producing a color filter using the photosensitive transfer recording material are described below.
Alkali-solubility
By “alkali-soluble” is meant soluble in an aqueous solution of an alkaline substance, such as listed below, or soluble in an aqueous solution of an alkaline substance having mixed therein water and a water-miscible organic solvent.
Examples of the alkaline substance include alkali metal hydroxides (such as sodium hydroxide and potassium hydroxide), alkali metal carbonates (such as sodium carbonate and potassium carbonate), alkali metal bicarbonates (such as sodium bicarbonate and potassium bicarbonate), alkali metal silicates (such as sodium silicate and potassium silicate), alkali metal metasilicates (such as sodium metasilicate and potassium metasilicate), triethanolamine, diethanolamine, monoethanolamine, morpholine, tetraalkylammonium hydroxides (such as tetramethylammonium hydroxide) and sodium tertiary phosphate. It is preferable that the concentration of the alkaline substance is 0.01 to 30% by weight and that the pH is 8 to 14.
Examples of the water-miscible organic solvent include methanol, ethanol, 2-propanol, 1-propanol, butanol, diacetone alcohol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol mono-n-butyl ether, benzyl alcohol, acetone, methyl ethyl ketone, cyclohexane, &egr;-caprolactone, &ggr;-butyrolactone, dimethylformamide, dimethylacetamide, hexamethylphosphoramide, ethyl lactate, methyl lactate, &egr;-caprolactam and N-methylpyrrolidone. The concentration of the water-miscible organic solvent is 0.1 to 30% by weight. Known surfactants can also be added. It is preferable that the concentration of the surfactant is 0.01 to 10% by weight.
Thermoplastic Resin Layer
Examples of the resin comprising the thermoplastic resin layer include an acrylic resin, a polystyrene resin, a polyester resin, a polyurethane resin, a rubber resin, a vinyl acetate resin, a polyolefin resin, and copolymers thereof. Although it is not essential for the resin comprising the thermoplastic resin layer of the invention to be alkali-soluble, the resin is preferably alkali-soluble.
Specific examples of the resin comprising the thermoplastic resin layer include at least one of a saponified product of an ethylene/acrylic ester copolymer, a saponified product of a styrene/(meth)acrylic ester copolymer, a styrene/(meth)acrylic acid/(meth)acrylic ester three-component copolymer, a saponified product of a vinyl toluene/(meth)acrylic ester copolymer, a poly(meth)acrylic ester, a saponified product of a butyl (meth)acrylate/(meth)acrylic ester (such as vinyl acetate) copolymer, and the alkaline aqueous solution-soluble organic polymers described in
Purasuchikku seinô binran (“Manual of Plastics Properties”) (compiled by the Japan Plastics Industry Federation and Zen-Nihon Purasuchikku Seikei Kôgyô Rengôkai, Tokyo: Kôgyô Chôsakai,
1968).
It is preferably that these resins are used in combination.
In particular, resins having a weight average molecular weight of 50,000 to 500,000 and a glass transition temperature (Tg) of 0 to 140° C. (hereinafter, also referred to as resin (A)) are preferable. Resins having a weight average molecular weight of 60,000 to 200,000 and a glass transition temperature (Tg) of 30 to 110° C. are more preferable. Specific examples of these resins include the alkaline aqueous solution-soluble resins described in Japanese Patent Application Publication (JP-B) Nos. 54-34327, 55-38961, 58-12577 and 54-25957, JP-A No. 61-134756, JP-B No. 59-44615, JP-A Nos. 54-92723,54-99418, 54-137085, 57-20732, 58-93046, 59-97135 and 60-159743, Offenlegungsschrift (OLS) No. 3504254, JP-A Nos. 60-247638, 60-208748, 60-214354, 60-230135, 60-258539, 61-169829, 61-213213, 63-147159, 63-213837, 63-266448, 64-55551, 64-55550, 2-191955, 2-199403, 2-199404and 2-208602, and Japanese Patent Application No. 4-39653. Especially preferable is the methacrylic acid/2-ethylhexyl acrylate/benzyl methacrylate/methyl methacrylate copolymer
Fuji Photo Film Co. , Ltd.
McPherson John A.
Sughrue & Mion, PLLC
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