Printing – Stenciling – Stencils
Reexamination Certificate
2000-12-08
2002-05-28
Funk, Stephen R. (Department: 2854)
Printing
Stenciling
Stencils
C101S128400, C347S103000
Reexamination Certificate
active
06393980
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to a method of forming an image by imagewise crosslinking a polymeric substance by ink jet printing a crosslinker onto it.
BACKGROUND OF THE INVENTION
It has been known to form images by selectively crosslinking materials by applying light to a crosslinkable resin. The technique has been used for forming photoresists where, after uncrosslinked material has been removed, etching of metal or glass is carried out. The technique has also been used to form silk-screen or screen-printing materials where the uncrosslinked material is washed out of the screen to create the finished printing screen. Such techniques are disclosed in “Light Sensitive Systems” by J. Kosar, published by John Wiley and Sons, Inc., New York, 1965, and in “Screen Process Printing” by J. Stephens, published by Blueprint (an imprint of Chapman and Hall), London, 1996.
These techniques, while successful, are expensive as they require expensive light imaging apparatus. Further they require expensive resins that will crosslink when exposed to light. There is difficulty in forming thick coats of crosslinked polymer as the light can not penetrate through thick crosslinkable resins, particularly when they are colored. Further, only very expensive imaging equipment could accurately produce fine quality images.
U.S. Ser. No. 09/089,903, filed Jun. 3, 1998, now abandoned, by Simons et al and entitled Method of Forming an Image describes a method of forming an image which comprises providing a coating of a crosslinkable polymeric substance on a substrate, applying a pattern of crosslinker to the coated substrate by ink jet printing to crosslink the polymeric substance in the pattern of the crosslinker, and washing the coated substrate to remove crosslinkable polymer in the area not having the pattern of crosslinker applied thereto. The substrate may be a screen printing screen.
There is a need for alternative methods of providing hardened polymeric images in layers of crosslinkable materials that are accurate and low in cost.
A particular problem with the method of the noted U.S. Ser. No. 09/089,903 is that transporting some substrates, for example, a screen mesh through an ink jet printer is difficult.
SUMMARY OF THE INVENTION
The invention provides a method of forming an image comprising:
providing a coating of a crosslinkable polymeric substance on a first substrate,
applying a pattern of a first crosslinker to the coated first substrate by ink jet printing to crosslink the polymeric substance,
washing the coated first substrate to remove the crosslinkable polymer in the areas not having the first crosslinker applied thereto, and
transferring the crosslinked polymer on the first substrate to a second substrate.
Another embodiment of this invention provides a method of forming an image comprising:
providing a coating of a crosslinkable polymeric substance on a first substrate,
applying a pattern of a first crosslinker to the first coated substrate by ink jet printing to crosslink the polymeric substance in the applied pattern of the crosslinker,
washing the coated first substrate to remove the crosslinkable polymer in the areas not having the pattern of the first crosslinker applied thereto,
patternwise transferring crosslinked polymeric substance to a foraminous substrate,
bringing the foraminous substrate into contact with a receiving material,
applying an ink to the foraminous substrate, and
removing the foraminous substrate to leave a pattern on the receiving material.
This invention can provide accurate low cost silk screens and colored relief images on a variety of substrates using materials that are not light sensitive.
The invention has numerous advantages over previous processes of forming crosslinked images in crosslinkable materials. The invention is low in cost and can use a common ink jet printer to create accurate and low cost images. This printing technique allows images to be formed by printing from a computer onto a substrate that does not have to be kept in the dark. The substrate may be formed of a dry material that may be easily handled in the light and then washed with water to remove uncrosslinked polymer. The material does not need to be flat during imaging as in many light exposing techniques.
The method is much simpler to operate than existing decoration or fabrication techniques using light-induced hardening of polymeric layers by light exposure through an optical pattern. It does not involve light-sensitive materials, nor toxic materials like potassium dichromate. It provides a versatile decoration and fabrication technique to anyone with a computer and ink-jet printer fitted with a suitable cartridge, and has the potential to open a wide range of craft applications involving decoration and images to a large number of people. These and other objects will become apparent from the detailed description below.
DETAILED DESCRIPTION OF THE INVENTION
The invention comprises a process for printing, marking or fabricating images, patterns or marks from electronic information by writing by means of ink-jet printing means which deposits in a pattern a first crosslinker onto a first substrate which bears a layer of crosslinkable or hardenable polymeric material, and then treating the first substrate to cause a distribution of hardened or crosslinked polymeric material according to the deposited pattern. The crosslinked polymeric material pattern is then transferred to a second substrate, for example, a screen printing screen.
The pattern of crosslinked polymeric material may constitute the desired image, or may be subsequently treated, for example, by dyeing to give the desired image. The image may then be used as a mask for a subsequent process, such as printing or etching.
The first substrate may be regarded as a temporary support as the pattern of hardened or crosslinked polymer is transferred from the first substrate to the desired second substrate.
Transfer may be achieved by contacting the second substrate with the pattern of crosslinked polymer on the first substrate, arranging for the crosslinked polymer to adhere preferentially to the second substrate, and then separating the first and second substrates.
A number of ways of arranging for the crosslinked polymer to adhere preferentially to the second substrate are available. For example, it may be possible to choose appropriate materials such that the second substrate has a natural affinity for the crosslinked polymer that is greater than the crosslinked polymer affinity for the first substrate.
Alternatively, transfer may be achieved by contacting the second substrate with the pattern of crosslinked polymer in the presence of an agent which promotes adhesion of the crosslinked polymer to the second substrate. For example, the adhesion promoting agent may comprise a layer of polymeric material attached to the second substrate which has a higher affinity for the crosslinked polymer. Alternatively, the second substrate may bear a second crosslinker agent (either a second quantity of the first crosslinker or a different type of crosslinker) that causes the crosslinked polymeric material in contact with the second substrate to crosslink further and thereby become attached preferentially to the second substrate. The second quantity or type of crosslinker may be applied to the first substrate after washing instead of or in addition to its application to the second substrate. Additionally, the second substrate may be pre-treated with polymeric or other materials that increase the effect of the adhesion promoting agent.
The first substrate may be any suitable material for printing with an ink jet printer. Suitable materials include cloth, metal, paper and plastic sheets. If a plastic sheet is used for the substrate it may be any of the common polymer sheet materials such as polyethylene, polypropylene, cellulose acetate and polyester.
The second substrate may comprise a foraminous material such as a permeable woven or fibrous material, such as silk fabric, polyester or polyamide mesh, or open-weave paper. In
Eastman Kodak Company
Funk Stephen R.
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