Thermal transfer with a plasticizer-containing transfer layer

Details Thermal transfer with a plasticizer-containing transfer layer Thermal transfer with a plasticizer-containing transfer layer

1999-09-09

2001-05-08

Schilling, Richard L. (Department: 1752)

Radiation imagery chemistry: process, composition, or product th

Imaged product

Nonsilver image

C430S200000, C430S270100, C430S271100, C430S280100, C430S281100, C430S964000

Reexamination Certificate

active

06228543

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to thermal transfer elements and methods of transferring layers from the thermal transfer elements, as well as the articles formed by these methods. In particular, the invention relates to thermal transfer elements having plasticizer-containing transfer layers and methods of transferring layers from the thermal transfer elements, as well as the articles formed by these methods.
BACKGROUND OF THE INVENTION
The thermal transfer of layers from a thermal transfer element to a receptor has been suggested for the preparation of a variety of products. Such products include, for example, color filters, spacers, black matrix layers, polarizers, printed circuit boards, displays (for example, liquid crystal and emissive displays), polarizers, z-axis conductors, and other items that can be formed by thermal transfer including, for example, those described in U.S. Pat. Nos. 5,156,938; 5,171,650; 5,244,770; 5,256,506; 5,387,496; 5,501,938; 5,521,035; 5,593,808; 5,605,780; 5,612,165; 5,622,795; 5,685,939; 5,691,114; 5,693,446; and 5,710,097 and PCT Patent Applications Nos. 98/03346 and 97/15173, incorporated herein by reference.
For many of these products, resolution and edge sharpness are important factors in the manufacture of the product. Another factor is the size of the transferred portion of the thermal transfer element for a given amount of thermal energy. As an example, when lines or other shapes are transferred, the linewidth or diameter of the shape depends on the size of the resistive element or light beam used to pattern the thermal transfer element. The linewidth or diameter also depends on the ability of the thermal transfer element to transfer energy. Near the edges of the resistive element or light beam, the energy provided to the thermal transfer element may be reduced. Thermal transfer elements with better thermal conduction, less thermal loss, more sensitive transfer coatings, and/or better light-to-heat conversion typically produce larger linewidths or diameters. Thus, the linewidth or diameter can be a reflection of the efficiency of the thermal transfer element in performing the thermal transfer function. To address these issues of the thermal transfer process, new methods of thermal transfer and new thermal transfer element configurations are developed.
SUMMARY OF THE INVENTION
Generally, the present invention relates to thermal transfer elements having plasticizer-containing transfer layers and methods of transferring layers from the thermal transfer elements, as well as the articles formed by these methods. One embodiment is a method of making an article. In this method, a receptor is brought into contact with a thermal transfer element that includes a transfer unit having at least one layer with a binder composition and a plasticizer. A portion of the transfer unit is thermally transferred to the receptor. This thermal transfer can be accomplished by, for example, using a thermal print head or radiative (e.g., light or laser) thermal transfer. After transfer, the binder composition and the plasticizer (in the portion of the transfer unit that is transferred to the receptor) is reactively coupled.
Another embodiment is a thermal transfer element that includes a substrate and a transfer unit. The transfer unit includes at least one layer having a binder composition and a plasticizer that are capable of co-reacting after transfer of a portion of the transfer unit to a receptor.
Yet another embodiment is an article that includes a substrate and a thermally transferred layer. The thermally transferred layer includes a binder composition and a plasticizer that have been co-reacted subsequent to the transfer of the thermally transferred layer from a thermal transfer element.
In these embodiments, the plasticizer is typically selected to facilitate transfer to a receptor. For example, a plasticizer or plasticizers having a glass transition temperature of no more than 25° C. can be chosen. As another example, a plasticizer of plasticizers can be chosen to give the plasticizer-containing layer a glass transition temperature that is at least 40° C. less than the same layer without the plasticizer.
The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures and the detailed description which follow more particularly exemplify these embodiments.


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