Patent Application
20060240366
This invention relates to the use of improved thermal solvents in thermally developable materials such as thermographic and photothermographic materials and to methods of imaging these materials.
Silver-containing thermographic and photothermographic imaging materials (that is, thermally developable imaging materials) that are imaged and/or developed using heat and without liquid processing have been known in the art for many years.
Silver-containing thermographic imaging materials are non-photosensitive materials that are used in a recording process wherein images are generated by the use of thermal energy. These materials generally comprise a support having disposed thereon (a) a relatively or completely non-photosensitive source of reducible silver ions, (b) a reducing composition (usually including a developer) for the reducible silver ions, and (c) a suitable binder.
In a typical thermographic construction, the image-forming layers are based on silver salts of long chain fatty acids. Typically, the preferred non-photosensitive reducible silver source is a silver salt of a long chain aliphatic carboxylic acid having from 10 to 30 carbon atoms. The silver salt of behenic acid or mixtures of acids of similar molecular weight are generally used. At elevated temperatures, the silver of the silver carboxylate is reduced by a reducing agent for silver ion such as methyl gallate, hydroquinone, substituted-hydroquinones, hindered phenols, catechols, pyrogallol, ascorbic acid, and ascorbic acid derivatives, whereby an image of elemental silver is formed. Some thermographic constructions are imaged by contacting them with the thermal head of a thermographic recording apparatus such as a thermal printer or thermal facsimile. In such constructions, an anti-stick layer is coated on top of the imaging layer to prevent sticking of the thermographic construction to the thermal head of the apparatus utilized. The resulting thermographic construction is then heated to an elevated temperature, typically in the range of from about 60 to about 225° C., resulting in the formation of an image.
Silver-containing photothermographic imaging materials (that is, photosensitive thermally developable imaging materials) that are imaged with actinic radiation and then developed using heat and without liquid processing have been known in the art for many years. Such materials are used in a recording process wherein an image is formed by imagewise exposure of the photothermographic material to specific electromagnetic radiation (for example, X-radiation, or ultraviolet, visible, or infrared radiation) and developed by the use of thermal energy. These materials, also known as “dry silver” materials, generally comprise a support having coated thereon: (a) a photocatalyst (that is, a photosensitive compound such as silver halide) that upon such exposure provides a latent image in exposed grains that are capable of acting as a catalyst for the subsequent formation of a silver image in a development step, (b) a relatively or completely non-photosensitive source of reducible silver ions, (c) a reducing composition (usually including a developer) for the reducible silver ions, and (d) a binder. The latent image is then developed by application of thermal energy.
In photothermographic materials, exposure of the photographic silver halide to light produces small clusters containing silver atoms (Ag0)n. The imagewise distribution of these clusters, known in the art as a latent image, is generally not visible by ordinary means. Thus, the photosensitive material must be further developed to produce a visible image. This is accomplished by the reduction of silver ions that are in catalytic proximity to silver halide grains bearing the silver-containing clusters of the latent image. This produces a black-and-white image. The non-photosensitive silver source is catalytically reduced to form the visible black-and-white negative image while much of the silver halide, generally, remains as silver halide and is not reduced.
In photothermographic materials, the reducing agent for the reducible silver ions, often referred to as a “developer,” may be any compound that, in the presence of the latent image, can reduce silver ion to metallic silver and is preferably of relatively low activity until it is heated to a temperature sufficient to cause the reaction. A wide variety of classes of compounds have been disclosed in the literature that function as developers for photothermographic materials. At elevated temperatures, the reducible silver ions are reduced by the reducing agent. This reaction occurs preferentially in the regions surrounding the latent image. This reaction produces a negative image of metallic silver having a color that ranges from yellow to deep black depending upon the presence of toning agents and other components in the photothermographic imaging layer(s).
Differences Between Photothermography and Photography
The imaging arts have long recognized that the field of photothermography is clearly distinct from that of photography. Photothermographic materials differ significantly from conventional silver halide photographic materials that require processing with aqueous processing solutions.
In photothermographic imaging materials, a visible image is created in the absence of processing solvent by heat as a result of the reaction of a developer incorporated within the material. Heating at 50° C. or more is essential for this dry development. In contrast, conventional photographic imaging materials require processing in aqueous processing baths at more moderate temperatures (from 30° C. to 50° C.) to provide a visible image.
In photothermographic materials, only a small amount of silver halide is used to capture light and a non-photosensitive source of reducible silver ions (for example, a silver carboxylate or a silver benzotriazole) is used to generate the visible image using thermal development. Thus, the imaged photosensitive silver halide serves as a catalyst for the physical development process involving the non-photosensitive source of reducible silver ions and the incorporated reducing agent. In contrast, conventional wet-processed, black-and-white photographic materials use only one form of silver (that is, silver halide) that, upon chemical development, is itself at least partially converted into the silver image, or that upon physical development requires addition of an external silver source (or other reducible metal ions that form black images upon reduction to the corresponding metal). Thus, photothermographic materials require an amount of silver halide per unit area that is only a fraction of that used in conventional wet-processed photographic materials.
In photothermographic materials, all of the “chemistry” for imaging is incorporated within the material itself. For example, such materials include a developer (that is, a reducing agent for the reducible silver ions) while conventional photographic materials usually do not. The incorporation of the developer into photothermographic materials can lead to increased formation of various types of “fog” or other undesirable sensitometric side effects. Therefore, much effort has gone into the preparation and manufacture of photothermographic materials to minimize these problems.
Moreover, in photothermographic materials, the unexposed silver halide generally remains intact after development and the material must be stabilized against further imaging and development. In contrast, silver halide is removed from conventional photographic materials after solution development to prevent further imaging (that is in the aqueous fixing step).
Because photothermographic materials require dry thermal processing, they present distinctly different problems and require different materials in manufacture and use, compared to conventional; wet-processed silver halide photographic materials. Additives that have one effect in conventional silver halide photographic materials may behave quite differently when incorporated in photothermographic materials where the underlying chemistry is significantly more complex. The incorporation of such additives as, for example, stabilizers, antifoggants, speed enhancers, supersensitizers, and spectral and chemical sensitizers in conventional photographic materials is not predictive of whether such additives will prove beneficial or detrimental in photothermographic materials. For example, it is not uncommon for a photographic antifoggant useful in conventional photographic materials to cause various types of fog when incorporated into photothermographic materials, or for supersensitizers that are effective in photographic materials to be inactive in photothermographic materials.
These and other distinctions between photothermographic and photographic materials are described in Unconventional Imaging Processes, E. Brinckman et al. (Eds.), The Focal Press, London and New York, 1978, pp. 74-75, in D. H. Klosterboer, Imaging Processes and Materials, (Neblette's Eighth Edition), J. Sturge, V. Walworth, and A. Shepp, Eds., Van Nostrand-Reinhold, New York, 1989, Chapter 9, pp. 279-291, in Zou et al., J. Imaging Sci. Technol. 1996, 40, pp. 94-103, and in M. R. V. Sahyun, J. Imaging Sci. Technol. 1998, 42, 23.
Problem to be Solved
Typically, thermally developable materials include one or more thermal solvents that are thought to provide a fluid medium at processing temperatures that enhances the development process, leading to greater photographic speeds and higher achievable densities. U.S. Pat. No. 3,347,675 (Henn et al.), U.S. Pat. No. 3,438,776 (Yudelson), U.S. Pat. No. 5,064,753 (Sohei et al.), U.S. Pat. No. 5,250,386 (Aono et al.), and U.S. Pat. No. 5,368,979 (Freedman et al.) describe the use of various compounds including alkylene oxide polymers, organic acids, amides, diamides, ureas, sulfonamides, carbonates, pyridines, imides, alcohols, oximes, polyols, acetamides, succinamides, thioureas, sulfoxides, and heterocycles as thermal solvents. Research Disclosure, October 1976, item 15027 describes the use of aromatic hydroxy compounds, aliphatic polycarboxylic compounds, N-heterocyclic compounds, and certain imide compounds. The combination of 1,3-dimethylurea with succinimide or salicyanilides is also described in U.S. Pat. No. 6,605,418 (Ramsden and Zou) and U.S. Pat. No. 6,790,569 (Yang, et al.).
Thus, while a number of compounds or combinations of compounds have been proposed as thermal solvents, improved materials are still needed. In particular, 1,3-dimethylurea and other compounds having a relatively high vapor pressure tend to be lost from the photothermographic material during thermal processing, leading to contamination of the processor and the environment around it. Additionally, we have found that the choice of thermal solvent can affect other photothermographic properties besides increasing photographic speed and increasing Dmax. One such property is “Natural Age Keeping” (NAK) that is also known as “Raw Stock Keeping” (RSK), that is a measure of the stability of the photothermographic material at ambient temperature and relative humidity during storage prior to imaging. Natural Age Keeping is a problem especially for photothermographic films compared to conventional silver halide photographic films because, as noted above, all the components needed for development and image formation in photothermographic systems are incorporated into the imaging element, in intimate proximity, prior to development. Thus, there are a greater number of potentially reactive components that can prematurely react during storage.
It is desirable that photothermographic materials be capable of maintaining imaging properties, including photospeed and Dmax, while exhibiting minimal increase in Dmin during storage periods.
Another challenge with photothermographic materials is the need to improve the “Dark Stability” of the imaged and processed photothermographic film upon storage. It is desirable that the Dmin not increase and that the Dmax, tint, and tone of the image not change over time.
Yet another challenge with photothermographic materials is the need to improve the resistance of film to aging when stored under conditions of high temperature and humidity prior to imaging.
Hence, there is a need to provide photothermographic materials with improved Natural Age Keeping, resistance to aging under severe conditions, and good Dark Stability without loss of other desired sensitometric properties.
This invention provides a black-and-white thermally developable material comprising a support and having thereon at least one thermally developable imaging layer comprising a polymer binder and the material further comprising, in reactive association:
a. a non-photosensitive source of reducible silver ions,
b. a reducing agent for the reducible silver ions, and
c. at least 0.0001 mol/m2 of a thermal solvent having the following Structure I, II, III, or IV:
wherein R1, R2, R3, and R4 are independently hydrogen or an alkyl, cycloalkyl, or alkenyl group, or R1 and R2, or R3 and R4 can be joined together to form a 3- to 6-membered ring, or again either R1 or R2 can be joined with either R3 or R4 to form a 6- to 8-membered ring with the >NC(═O)C(═O)N< group, provided that at least one of R1, R2, R3, and R4 is not a hydrogen atom,
wherein R5 is hydrogen or an alkyl or alkenyl group, R6 and R7 are independently hydrogen or an alkyl or alkenyl group, or R6 and R7 can be joined together to form a 3- to 6-membered ring, or again either R6 or R7 can be joined with R5 to form a 6- to 12-membered ring with the >NC(═O)(L1)- group, and L1 is an alkylene group of 2 to 8 carbon atoms that is substituted with 2 to 8 hydroxy groups,
wherein R8, R9, R10, and R11 are independently hydrogen or an alkyl or alkenyl group, or R8 and R9, or R10 and R11, can be joined together to form a 3- to 6-membered ring, L2 is an alkylene group having 1 to 8 carbon atoms, provided that when L2 is substituted with 1 or less hydroxy groups, at least one of R8, R9, R10, and R11 is an alkyl that is substituted with at least one hydroxy group, or an alkenyl group, and
wherein R12, R13, and R14 are hydroxyalkyl groups.
This invention also provides a black-and-white dry-processable photothermographic material comprising a support having on a frontside thereof,
a) one or more frontside photothermographic imaging layers comprising a hydrophilic polymer binder or a water-dispersible polymer latex binder, and the material further comprising, in reactive association, on the frontside, a photosensitive silver halide, a non-photosensitive source of reducible silver ions, and a reducing agent for the non-photosensitive source reducible silver ions,
b) the material comprising on the backside of the support, one or more backside photothermographic imaging layers and the same or different imaging composition, and
c) optionally, an outermost protective layer disposed over the one or more photothermographic imaging layers on either or both sides of the support,
wherein the material further comprises, on one or both sides of the support, at least 0.0001 mol/m2 of a thermal solvent represented by one of the Structure I, II, III, or IV noted above.
This invention also provides a method of forming a visible image comprising:
(A) imagewise exposing a photothermographic material of this invention to form a latent image,
(B) simultaneously or sequentially, heating the exposed photothermographic material to develop the latent image into a visible image.
In alternative methods of this invention, a method of forming a visible image comprises:
(A′) thermal imaging of the thermally developable material of this invention that is a thermographic material.
An imaging assembly of this invention comprises a photothermographic material of this invention that is arranged in association with one or more phosphor intensifying screens.
The images obtained using the present invention can be used for medical diagnosis as well as other purposes.
We have found that the use of certain thermal solvents that are defined by Structures I, II, III, or IV noted above and having at least one >N—C(═O)— group provide a desired increase in Natural Age Keeping and Dark Stability in photothermographic materials. These improvements are achieved without unacceptable loss in other sensitometric properties such as Dmax and photospeed.
The thermally developable materials described herein are both dry processable thermographic and photothermographic materials. While the following discussion will often be directed primarily to the preferred aqueous-based photothermographic embodiments, it would be readily understood by one skilled in the art that non-aqueous-based thermographic materials can be similarly constructed and used to provide black-and-white or color images using appropriate imaging chemistry and particularly non-photosensitive organic silver salts, reducing agents, toners, binders, and other components known to a skilled artisan.
The thermally developable materials can be used in black-and-white thermography and photothermography and in electronically generated black-and-white hardcopy recording. They can be used in microfilm applications, in radiographic imaging (for example digital medical imaging), X-ray radiography, and in industrial radiography. Furthermore, in some embodiments, the absorbance of these materials between 350 and 450 nm is desirably low (less than 0.5), to permit their use in the graphic arts area (for example, imagesetting and phototypesetting), in the manufacture of printing plates, in contact printing, in duplicating (“duping”), and in proofing.
The thermally developable materials are particularly useful for imaging of human or animal subjects in response to visible, X-radiation, or infrared radiation for use in a medical diagnosis. Such applications include, but are not limited to, thoracic imaging, mammography, dental imaging, orthopedic imaging, general medical radiography, therapeutic radiography, veterinary radiography, and autoradiography. When used with X-radiation, the photothermographic materials may be used in combination with one or more phosphor intensifying screens, with phosphors incorporated within the photothermographic emulsion, or with combinations thereof. Such materials are particularly useful for dental radiography when they are directly imaged by X-radiation. The materials are also useful for non-medical uses of X-radiation such as X-ray lithography and industrial radiography. In these and other imaging applications, it is often particularly desirable that the photothermographic materials be “double-sided.”
The photothermographic materials can be made sensitive to radiation of any suitable wavelength. Thus, in some embodiments, the materials are sensitive at ultraviolet, visible, near infrared, or infrared wavelengths, of the electromagnetic spectrum. In these embodiments, the materials are preferably sensitive to radiation greater than 100 nm, such as from about 100 nm to about 1400 nm, normally from about 300 to about 850 nm, (preferably from about 300 to about 600 nm, more preferably from about 300 to about 450 nm, even more preferably from a wavelength of from about 360 to 420 nm, and most preferably from about 380 to about 420 nm). In other embodiments they are sensitive to X-radiation. Increased sensitivity to X-radiation can be imparted through the use of phosphors.
In some embodiments of the photothermographic materials, the components needed for imaging can be in one or more imaging or emulsion layers on one side (“frontside”) of the support. The layer(s) that contain the photosensitive photocatalyst (such as a photosensitive silver halide) for photothermographic materials or the non-photosensitive source of reducible silver ions, or both, are referred to herein as the emulsion layer(s). In photothermographic materials, the photocatalyst and non-photosensitive source of reducible silver ions are in catalytic proximity and preferably are in the same emulsion layer.
Where the photothermographic materials contain imaging layers on one side of the support only, various non-imaging layers can also be disposed on the “backside” (non-emulsion or non-imaging side) of the materials, including, conductive or antistatic layers, antihalation layer(s), protective layers, and transport enabling layers.
In such instances, various non-imaging layers can also be disposed on the “frontside” or imaging or emulsion side of the support, including protective overcoat layers, primer layers, interlayers, opacifying layers, antistatic layers, antihalation layers, acutance layers, auxiliary layers, and other layers readily apparent to one skilled in the art.
For preferred embodiments, the photothermographic materials are “double-sided” or “duplitized” and have the same or different emulsion coatings (or photothermographic imaging layers) on both sides of the support. In addition to the buried conductive layers, such constructions can also include one or more protective overcoat layers, primer layers, interlayers, acutance layers, antihalation layers, auxiliary layers, and other layers readily apparent to one skilled in the art on either or both sides of support. Preferably, such photothermographic materials have essentially the same layers on each side of the support.
Similarly, in the thermographic materials of this invention, the components needed for imaging can be in one or more imaging layers. The layer(s) that contain the non-photosensitive source of reducible silver ions are referred to herein as thermographic emulsion layer(s).
When the photothermographic materials are heat-developed as described below in a substantially water-free condition after, or simultaneously with, imagewise exposure, a silver image (preferably a black-and-white silver image) is obtained.
Definitions
As used herein:
In the descriptions of the thermally developable materials, “a” or “an” component refers to “at least one” of that component (for example, the thermal solvent compounds described herein).
The term “black-and-white” refers to an image formed by silver metal.
Unless otherwise indicated, the terms “photothermographic materials,” “thermographic materials,” “photothermographic materials,” and “imaging assemblies” are used herein in reference to embodiments of the present invention.
Heating in a substantially water-free condition as used herein, means heating at a temperature of from about 50° C. to about 250° C. with little more than ambient water vapor present. The term “substantially water-free condition” means that the reaction system is approximately in equilibrium with water in the air and water for inducing or promoting the reaction is not particularly or positively supplied from the exterior to the material. Such a condition is described in T. H. James, The Theory of the Photographic Process, Fourth Edition, Eastman Kodak Company, Rochester, N.Y., 1977, p. 374.
“Aqueous-based” means that the solvent in which the imaging layer and the any additional underlayers, carrier layers, and overcoat layers are prepared and coated is predominantly (greater than 50%) water.
“Photothermographic material(s)” means a dry processable integral element comprising at least one photothermographic emulsion layer or a photothermographic set of emulsion layers (wherein the photosensitive silver halide and the source of reducible silver ions, are in one layer and the other essential components or desirable additives are distributed, as desired, in the same layer or in an adjacent coated layer) that provides a color image or preferably a black-and-white silver image. These materials also include multilayer constructions in which one or more imaging components are in different layers, but are in “reactive association.” For example, one layer can include the non-photosensitive source of reducible silver ions and another layer can include the reducing agent and/or photosensitive silver halide. By “integral”, we mean that all imaging chemistry required for imaging is in the material without diffusion of imaging chemistry or reaction products (such as a dye) from or to another element (such as a receiver element).
“Thermographic materials” are similarly defined except that no photosensitive silver halide photocatalyst is purposely added or created.
When used in photothermography, the term, “imagewise exposing” or “imagewise exposure” means that the material is imaged using any exposure means that provides a latent image using electromagnetic radiation. This includes, for example, by analog exposure where an image is formed by projection onto the photosensitive material as well as by digital exposure where the image is formed one pixel at a time such as by modulation of scanning laser radiation.
When used in thermography, the term, “imagewise exposing” or “imagewise exposure” means that the material is imaged using any means that provides an image using heat. This includes, for example, by analog exposure where an image is formed by differential contact heating through a mask using a thermal blanket or infrared heat source, as well as by digital exposure where the image is formed one pixel at a time such as by modulation of thermal print-heads or by thermal heating using scanning laser radiation.
“Catalytic proximity” or “reactive association” means that the materials are in the same layer or in adjacent layers so that they readily come into contact with each other during thermal imaging and development.
“Emulsion layer,” “imaging layer,” or “photothermographic imaging layer,” means a layer of a photothermographic material that contains the photosensitive silver halide (when used) and/or non-photosensitive source of reducible silver ions. It can also mean a layer of the material that contains, in addition to the photosensitive silver halide (when used) and/or non-photosensitive source of reducible ions, additional essential components and/or desirable additives such as the reducing agent(s). In single-sided materials, these layers are usually on what is known as the “frontside” of the support.
“Photocatalyst” means a photosensitive compound such as silver halide that, upon exposure to radiation, provides a compound that is capable of acting as a catalyst for the subsequent development of the image-forming material.
“Simultaneous coating” or “wet-on-wet” coating means that when multiple layers are coated, subsequent layers are coated onto the initially coated layer before the initially coated layer is dry.
The terms “double-sided” and “duplitized” are used to define photothermographic materials having one or more of the same or different photothermographic emulsion layers disposed on both sides (front and back) of the support. In double-sided materials the emulsion layers can be of the same or different chemical composition, thickness, or sensitometric properties.
In addition, “frontside” also generally means the side of a photothermographic material that is first exposed to imaging radiation, and “backside” generally refers to the opposite side of the photothermographic material.
“Ultraviolet region of the spectrum” refers to that region of the spectrum less than or equal to 400 nm, and preferably from about 100 nm to about 400 nm, although parts of these ranges may be visible to the naked human eye. More preferably, the ultraviolet region of the spectrum is the region of from about 190 nm to about 400 nm. The near ultraviolet region of the spectrum refers to that region of from about 300 to about 400 nm.
“Visible region of the spectrum” refers to that region of the spectrum of from about 400 nm to about 700 nm.
“Short wavelength visible region of the spectrum” refers to that region of the spectrum of from about 400 nm to about 450 nm.
“Blue region of the spectrum” refers to that region of the spectrum of from about 400 nm to about 500 nm.
“Green region of the spectrum” refers to that region of the spectrum of from about 500 nm to about 600 nm.
“Red region of the spectrum” refers to that region of the spectrum of from about 600 nm to about 700 nm.
“Infrared region of the spectrum” refers to that region of the spectrum of from about 700 nm to about 1400 nm.
“Non-photosensitive” means not intentionally light sensitive.
“Transparent” means capable of transmitting visible light or imaging radiation without appreciable scattering or absorption.
The sensitometric terms “photospeed,” “speed,” or “photographic speed” (also known as sensitivity), absorbance, contrast, Dmin, and Dmax have conventional definitions known in the imaging arts. In photothermographic materials, Dmin is considered herein as image density achieved when the photothermographic material is thermally developed without prior exposure to radiation. It is the average of eight lowest density values on the exposed side of the fiducial mark.
In photothermographic materials, the term Dmin is considered herein as image density achieved when the photothermographic material is thermally developed without prior exposure to radiation. The term Dmax is the maximum image density achieved when the photothermographic material is exposed to a particular radiation source and a given amount of radiation energy and then thermally developed. In thermographic materials, Dmin is considered herein as the image density in the areas with the minimum application of heat by the thermal print-head. In thermographic materials, the term Dmax is the maximum image density achieved when the thermographic material is thermally imaged with a given amount of thermal energy.
The terms “density,” “optical density (OD),” and “image density” refer to the sensitometric term absorbance.
Speed-2 is Log 1/E+4 corresponding to the density value of 1.0 above Dmin where E is the exposure in ergs/cm2.
Relative Speed-2 was determined at a density value of 1.00 above Dmin and was normalized against a sample that contained a known thermal solvent(s) and was assigned a relative speed value of 100.
“Aspect ratio” refers to the ratio of particle or grain “ECD” to particle or grain thickness wherein ECD (equivalent circular diameter) refers to the diameter of a circle having the same projected area as the particle or grain.
The phrase “silver salt” or “organic silver salt” refers to an organic molecule capable of forming a bond with a silver atom. Although the compounds so formed are technically silver coordination complexes or silver compounds they are also often referred to as silver salts.
As used herein in reference to conductive layers, the terms “underlayer” and “buried” conductive layer refer to the same conductive layer.
In the compounds described herein, no particular double bond geometry (for example, cis or trans) is intended by the structures drawn unless otherwise specified. Similarly, in compounds having alternating single and double bonds and localized charges their structures are drawn as a formalism. In reality, both electron and charge delocalization exists throughout the conjugated chain.
Similarly, many of the compounds described herein are drawn as the particular stereoisomer used. It is to be understood that other stereoisomers and mixtures of stereoisomers of these compounds are possible and that the usefulness of the compounds as thermal solvents is not due to the chirality of the compounds. However, a particular stereoisomer or mixtures thereof may be preferred in any given application.
As is well understood in this art, for the chemical compounds herein described, substitution is not only tolerated, but is often advisable and various substituents are anticipated on the compounds used in the present invention unless otherwise stated. Thus, when a compound is referred to as “having the structure” of, or as “a derivative” of, a given formula, any substitution that does not alter the bond structure of the formula or the shown atoms within that structure is included within the formula, unless such substitution is specifically excluded by language.
As a means of simplifying the discussion and recitation of certain substituent groups, the term “group” refers to chemical species that may be substituted as well as those that are not so substituted. Thus, the term “alkyl group” is intended to include not only pure hydrocarbon alkyl chains, such as methyl, ethyl, n-propyl, t-butyl, cyclohexyl, iso-octyl, and octadecyl, but also alkyl chains bearing substituents known in the art, such as hydroxy, alkoxy, phenyl, halogen atoms (F, Cl, Br, and I), cyano, nitro, amino, and carboxy. For example, alkyl group includes ether and thioether groups (for example CH3—CH2—CH2—O—CH2— and CH3—CH2—CH2—S—CH2—), hydroxyalkyl (such as 1,2-dihydroxyethyl), haloalkyl, nitroalkyl, alkylcarboxy, carboxyalkyl, carboxamido, sulfoalkyl, and other groups readily apparent to one skilled in the art. Substituents that adversely react with other active ingredients, such as very strongly electrophilic or oxidizing substituents, would, of course, be excluded by the ordinarily skilled artisan as not being inert or harmless.
Research Disclosure (http://www.researchdisclosure.com) is a publication of Kenneth Mason Publications Ltd., The Book Barn, Westbourne, Hampshire PO10 8RS, UK. It is also available from Emsworth Design Inc., 200 Park Avenue South, Room 1101, New York, N.Y. 10003.
Other aspects, advantages, and benefits of the present invention are apparent from the detailed description, examples, and claims provided in this application.
The Photocatalyst
The photothermographic materials include one or more photocatalysts in the photothermographic emulsion layer(s). Useful photocatalysts are typically photosensitive silver halides such as silver bromide, silver iodide, silver chloride, silver bromoiodide, silver chlorobromoiodide, silver chlorobromide, and others readily apparent to one skilled in the art. Mixtures of silver halides can also be used in any suitable proportion. Silver bromide and silver bromoiodide are more preferred silver halides, with the latter silver halide having up to nearly 100 mol % silver iodide (more preferably up to 40 mol %) silver iodide, based on total silver halide, and up to the saturation limit of iodide as described in U.S. Patent Application Publication 2004/0053173 (Maskasky et al.).
The shape (morphology) of the photosensitive silver halide grains used in the present need not be limited. The silver halide grains may have any crystalline habit including cubic, octahedral, tetrahedral, orthorhombic, rhombic, dodecahedral, other polyhedral, tabular, laminar, twinned, or platelet morphologies and may have epitaxial growth of crystals thereon. If desired, a mixture of these crystals can be employed. Silver halide grains having cubic and tabular morphology (or both) are preferred. More preferably, the silver halide grains are predominantly (at least 50% based on total silver halide) present as tabular grains.
The silver halide grains may have a uniform ratio of halide throughout. They may have a graded halide content, with a continuously varying ratio of, for example, silver bromide and silver iodide or they may be of the core-shell type, having a discrete core of one or more silver halides, and a discrete shell of one of more different silver halides. Core-shell silver halide grains useful in photothermographic materials and methods of preparing these materials are described for example in U.S. Pat. No. 5,382,504 (Shor et al.), incorporated herein by reference. Iridium and/or copper doped core-shell and non-core-shell grains are described in U.S. Pat. No. 5,434,043 (Zou et al.) and U.S. Pat. No. 5,939,249 (Zou), both incorporated herein by reference.
In some instances, it may be helpful to prepare the photosensitive silver halide grains in the presence of a hydroxytetraazaindene or an N-heterocyclic compound comprising at least one mercapto group as described in U.S. Pat. No. 6,413,710 (Shor et al.), that is incorporated herein by reference.
The photosensitive silver halide can be added to (or formed within) the emulsion layer(s) in any fashion as long as it is placed in catalytic proximity to the non-photosensitive source of reducible silver ions.
It is preferred that the silver halide grains be “preformed” and thus prepared by an ex-situ process, chemically and spectrally sensitized, and then be added to and physically mixed with the non-photosensitive source of reducible silver ions.
It is also possible, but less preferred, to form the source of reducible silver ions in the presence of ex-situ-prepared silver halide grains. In this process, the source of reducible silver ions is formed in the presence of the preformed silver halide grains. Precipitation of the reducible source of silver ions in the presence of silver halide provides a more intimate mixture of the two materials [see, for example U.S. Pat. No. 3,839,049 (Simons)] to provide a “preformed emulsion.” This method is useful when non-tabular silver halide grains are used.
It is also possible to form some in-situ silver halide, by a process in which an inorganic halide- or an organic halogen-containing compound is added to an organic silver salt to partially convert the silver of the organic silver salt to silver halide as described in U.S. Pat. No. 3,457,075 (Morgan et al.).
In general, the non-tabular silver halide grains used in this invention can vary in average diameter of up to several micrometers (μM) and they usually have an average particle size of from about 0.01 to about 1.5 μm (preferably from about 0.03 to about 1.0 μM, and more preferably from about 0.05 to about 0.8 μm). The average size of the photosensitive silver halide grains is expressed by the average diameter if the grains are spherical, and by the average of the diameters of equivalent circles for the projected images if the grains are cubic, tabular, or other non-spherical shapes. Representative grain sizing methods are described by in Particle Size Analysis, ASTM Symposium on Light Microscopy, R. P. Loveland, 1955, pp. 94-122, and in C. E. K. Mees and T. H. James, The Theory of the Photographic Process, Third Edition, Macmillan, New York, 1966, Chapter 2.
In preferred embodiments of this invention, the silver halide grains are provided predominantly (based on at least 50 mol % silver) as tabular silver halide grains that are considered “ultrathin” and have an average thickness of at least 0.02 μm and up to and including 0.10 μm (preferably an average thickness of at least 0.03 μm and more preferably of at least 0.04 μM, and up to and including 0.08 μm and more preferably up to and including 0.07 μm).
In addition, these ultrathin tabular grains have an equivalent circular diameter (ECD) of at least 0.5 μm (preferably at least 0.75 μm, and more preferably at least 1 μm). The ECD can be up to and including 8 μm (preferably up to and including 6 μm, and more preferably up to and including 4 μm).
The aspect ratio of the useful tabular grains is at least 5:1 (preferably at least 10:1, and more preferably at least 15:1) and generally up to 50:1. The grain size of ultrathin tabular grains may be determined by any of the methods commonly employed in the art for particle size measurement, such as those described above. Ultrathin tabular grains and their method of preparation and use in photothermographic materials are described in U.S. Pat. No. 6,576,410 (Zou et al.) and U.S. Pat. No. 6,673,529 (Daubendiek et al.) that are incorporated herein by reference.
The ultrathin tabular silver halide grains can also be doped using one or more of the conventional metal dopants known for this purpose including those described in Research Disclosure, item 38957, September, 1996 and U.S. Pat. No. 5,503,970 (Olm et al.), incorporated herein by reference. Preferred dopants include iridium (III or IV) and ruthenium (II or III) salts. Particularly preferred silver halide grains are ultrathin tabular grains containing iridium-doped azole ligands. Such tabular grains and their method of preparation are described in copending and commonly assigned U.S. Ser. No. 10/826,708 (filed on Apr. 16, 2004 by Olm, McDugle, Hansen, Pawlik, Lewis, Mydlarz, Wilson, and Bell) that is incorporated herein by reference.
The one or more light-sensitive silver halides used in the photothermographic materials are preferably present in an amount of from about 0.005 to about 0.5 mole (more preferably from about 0.01 to about 0.25 mole, and most preferably from about 0.03 to about 0.15 mole) per mole of non-photosensitive source of reducible silver ions.
Chemical Sensitizers
If desired, the photosensitive silver halides used in the photothermographic materials can be chemically sensitized using any useful compound that contains sulfur, tellurium, or selenium, or may comprise a compound containing gold, platinum, palladium, ruthenium, rhodium, iridium, or combinations thereof, a reducing agent such as a tin halide or a combination of any of these. The details of these materials are provided for example, in T. H. James, The Theory of the Photographic Process, Fourth Edition, Eastman Kodak Company, Rochester, N.Y., 1977, Chapter 5, pp. 149-169. Suitable conventional chemical sensitization procedures and compounds are also described in U.S. Pat. No. 1,623,499 (Sheppard et al.), U.S. Pat. No. 2,399,083 (Waller et al.), U.S. Pat. No. 3,297,447 (McVeigh), U.S. Pat. No. 3,297,446 (Dunn), U.S. Pat. No. 5,049,485 (Deaton), U.S. Pat. No. 5,252,455 (Deaton), U.S. Pat. No. 5,391,727 (Deaton), U.S. Pat. No. 5,912,111 (Lok et al.), U.S. Pat. No. 5,759,761 (Lushington et al.), U.S. Pat. No. 6,296,998 (Eikenberry et al), and U.S. Pat. No. 5,691,127 (Daubendiek et al.), and EP 0 915 371 A1 (Lok et al.), all incorporated herein by reference.
Certain substituted and/or unsubstituted thioureas can be used as chemical sensitizers including those described in U.S. Pat. No. 6,296,998 (Eikenberry et al.), U.S. Pat. No. 6,322,961 (Lam et al.), U.S. Pat. No. 4,810,626 (Burgmaier et al.), and U.S. Pat. No. 6,368,779 (Lynch et al.), all of the which are incorporated herein by reference.
Still other useful chemical sensitizers include tellurium- and selenium-containing compounds that are described in U.S. Pat. No. 5,158,892 (Sasaki et al.), U.S. Pat. No. 5,238,807 (Sasaki et al.), U.S. Pat. No. 5,942,384 (Arai et al.), U.S. Pat. No. 6,620,577 (Lynch et al.), and U.S. Pat. No. 6,699,647 (Lynch et al.), all of which are incorporated herein by reference.
Noble metal sensitizers for use in the present invention include gold, platinum, palladium and iridium. Gold(I or III) sensitization is particularly preferred, and described in U.S. Pat. No. 5,858,637 (Eshelman et al.) and U.S. Pat. No. 5,759,761 (Lushington et al.). Combinations of gold(III) compounds and either sulfur- or tellurium-containing compounds are useful as chemical sensitizers and are described in U.S. Pat. No. 6,423,481 (Simpson et al.). All of the above references are incorporated herein by reference.
In addition, sulfur-containing compounds can be decomposed on silver halide grains in an oxidizing environment according to the teaching in U.S. Pat. No. 5,891,615 (Winslow et al.). Examples of sulfur-containing compounds that can be used in this fashion include sulfur-containing spectral sensitizing dyes. Other useful sulfur-containing chemical sensitizing compounds that can be decomposed in an oxidizing environment are the diphenylphosphine sulfide compounds described in copending and commonly assigned U.S. Ser. No. 10/731,251 (filed Dec. 9, 2003 by Simpson, Burleva, and Sakizadeh). Both the above patent and patent application are incorporated herein by reference.
The chemical sensitizers can be used in making the silver halide emulsions in conventional amounts that generally depend upon the average size of silver halide grains. Generally, the total amount is at least 10−10 mole per mole of total silver, and preferably from about 10−8 to about 10−2 mole per mole of total silver. The upper limit can vary depending upon the compound(s) used, the level of silver halide, and the average grain size and grain morphology.
Spectral Sensitizers
The photosensitive silver halides used in the photothermographic materials may be spectrally sensitized with one or more spectral sensitizing dyes that are known to enhance silver halide sensitivity to ultraviolet, visible, and/or infrared radiation of interest. Non-limiting examples of sensitizing dyes that can be employed include cyanine dyes, merocyanine dyes, complex cyanine dyes, complex merocyanine dyes, holopolar cyanine dyes, hemicyanine dyes, styryl dyes, and hemioxonol dyes. They may be added at any stage in chemical finishing of the photothermographic emulsion, but are generally added after chemical sensitization. It is particularly useful that the photosensitive silver halides be spectrally sensitized to a wavelength of from about 300 to about 850 nm, preferably from about 300 to about 600 nm, more preferably to a wavelength of from about 300 to about 450 nm, even more preferably from a wavelength of from about 360 to 420 nm, and most preferably from a wavelength of from about 380 to about 420 nm. In other embodiments, the photosensitive silver halides are spectrally sensitized to a wavelength of from about 650 to about 1150 nm. A worker skilled in the art would know which dyes would provide the desired spectral sensitivity.
Suitable sensitizing dyes such as those described in U.S. Pat. No. 3,719,495 (Lea), U.S. Pat. No. 4,396,712 (Kinoshita et al.), U.S. Pat. No. 4,439,520 (Kofron et al.), U.S. Pat. No. 4,690,883 (Kubodera et al.), U.S. Pat. No. 4,840,882 (Iwagaki et al.), U.S. Pat. No. 5,064,753 (Kohno et al.), U.S. Pat. No. 5,281,515 (Delprato et al.), U.S. Pat. No. 5,393,654 (Burrows et al), U.S. Pat. No. 5,441,866 (Miller et al.), U.S. Pat. No. 5,508,162 (Dankosh), U.S. Pat. No. 5,510,236 (Dankosh), and U.S. Pat. No. 5,541,054 (Miller et al.), and Japanese Kokai 2000-063690 (Tanaka et al.), 2000-112054 (Fukusaka et al.), 2000-273329 (Tanaka et al.), 2001-005145 (Arai), 2001-064527 (Oshiyama et al.), and 2001-154305 (Kita et al.), and Research Disclosure, item 308119, Section IV, December, 1989. All of these publications are incorporated herein by reference.
Teachings relating to specific combinations of spectral sensitizing dyes also provided in U.S. Pat. No. 4,581,329 (Sugimoto et al.), U.S. Pat. No. 4,582,786 (Ikeda et al.), U.S. Pat. No. 4,609,621 (Sugimoto et al.), U.S. Pat. No. 4,675,279 (Shuto et al.), U.S. Pat. No. 4,678,741 (Yamada et al.), U.S. Pat. No. 4,720,451 (Shuto et al.), U.S. Pat. No. 4,818,675 (Miyasaka et al.), U.S. Pat. No. 4,945,036 (Arai et al.), and U.S. Pat. No. 4,952,491 (Nishikawa et al.), all of which are incorporated herein by reference.
Also useful are spectral sensitizing dyes that decolorize by the action of light or heat as described in U.S. Pat. No. 4,524,128 (Edwards et al.) and Japanese Kokai 2001-109101 (Adachi), 2001-154305 (Kita et al.), and 2001-183770 (Hanyu et al.), all of which are incorporated herein by reference.
Dyes may be selected for the purpose of supersensitization to attain much higher sensitivity than the sum of sensitivities that can be achieved by using each dye alone.
An appropriate amount of spectral sensitizing dye added is generally about 10−10 to 10−1 mole, and preferably, from about 10−7 to 10−2 mole per mole of silver halide.
Non-Photosensitive Source of Reducible Silver Ions
The non-photosensitive source of reducible silver ions used in the photothermographic materials is a silver-organic compound that contains reducible silver(I) ions. Such compounds are generally silver salts of silver organic coordinating ligands that are comparatively stable to light and form a silver image when heated to 50° C. or higher in the presence of an exposed photocatalyst and a reducing agent composition.
Organic silver salts that are particularly useful in aqueous-based photothermographic materials include silver salts of compounds containing an imino group. Such salts include, but are not limited to, silver salts of benzotriazole and substituted derivatives thereof (for example, silver methyl-benzotriazole and silver 5-chlorobenzotriazole), silver salts of nitrogen acids selected from the group consisting of imidazole, pyrazole, urazole, 1,2,4-triazole and 1H-tetrazole, nitrogen acids or combinations thereof, as described in U.S. Pat. No. 4,220,709 (deMauriac). Also included are the silver salts of imidazole and imidazole derivatives as described in U.S. Pat. No. 4,260,677 (Winslow et al.). Both of these patents are incorporated herein by reference. A nitrogen acid as described herein is intended to include those compounds that have the moiety —NH— in the heterocyclic nucleus. Particularly useful silver salts are the silver salts of benzotriazole, substituted derivatives thereof, or mixtures of two or more of these salts. A silver salt of benzotriazole is most preferred.
Useful nitrogen-containing organic silver salts and methods of preparing them are also described in copending and commonly assigned U.S. Ser. No. 10/826,417 (filed Apr. 16, 2004 by Zou and Hasberg) that is incorporated herein by reference. Such silver salts (particularly the silver benzotriazoles) are rod-like in shape and have an average aspect ratio of at least 3:1 and a width index for particle diameter of 1.25 or less. Silver salt particle length is generally less than 1 μm. Also useful are the silver salt-toner co-precipitated nano-crystals comprising a silver salt of a nitrogen-containing heterocyclic compound containing an imino group, and a silver salt comprising a silver salt of a mercaptotriazole as described in copending and commonly assigned U.S. Ser. No. 10/935,384 (filed Sep. 7, 2004 by Hasberg, Lynch, Chen-Ho, and Zou). Both of these patent applications are incorporated herein by reference.
Other organic silver salts that are useful in both aqueous-based and non-aqueous-based photothermographic materials are silver carboxylates (both aliphatic and aromatic carboxylates). The aliphatic carboxylic acids generally have aliphatic chains that contain 10 to 30 carbon atoms. Silver salts of long-chain aliphatic carboxylic acids having 15 to 28 carbon atoms are particularly preferred. Examples of such preferred silver salts include silver behenate, silver arachidate, silver stearate, silver oleate, silver laurate, silver caprate, silver myristate, silver palmitate, silver maleate, silver fumarate, silver tartarate, silver furoate, silver linoleate, silver butyrate, silver camphorate, and mixtures thereof. Most preferably, silver bebenate is used alone or in mixtures with other silver carboxylates. Silver carboxylates are particularly useful in aqueous latex-based thermographic and photothermographic materials.
It is also convenient to use silver half soaps such as an equimolar blend of silver carboxylate and carboxylic acid that analyzes for about 14.5% by weight solids of silver in the blend and that is prepared by precipitation from an aqueous solution of an ammonium or an alkali metal salt of a commercially available fatty carboxylic acid, or by addition of the free fatty acid to the silver soap.
The methods used for making silver soap emulsions are well known in the art and are disclosed in Research Disclosure, April 1983, item 22812, Research Disclosure, October 1983, item 23419, U.S. Pat. No. 3,985,565 (Gabrielsen et al.), and the references cited above.
While the noted organic silver salts are the predominant silver salts in the materials, secondary organic silver salts can be used if present in “minor” amounts (less than 40 mol % based on the total moles of organic silver salts).
Such secondary organic silver salts include silver salts of heterocyclic compounds containing mercapto or thione groups and derivatives thereof such as silver triazoles, oxazoles, thiazoles, thiazolines, imidazoles, diazoles, pyridines, and triazines as described in U.S. Pat. No. 4,123,274 (Knight et al.) and U.S. Pat. No. 3,785,830 (Sullivan et al.). Also included are silver salts of aliphatic carboxylic acids containing a thioether group as described in U.S. Pat. No. 3,330,663 (Weyde et al.), soluble silver carboxylates comprising hydrocarbon chains incorporating ether or thioether linkages or sterically hindered substitution in the α- (on a hydrocarbon group) or ortho- (on an aromatic group) position as described in U.S. Pat. No. 5,491,059 (Whitcomb), silver salts of dicarboxylic acids, silver salts of sulfonates as described in U.S. Pat. No. 4,504,575 (Lee), silver salts of sulfosuccinates as described in EP 0 227 141 A1 (Leenders et al.), silver salts of aromatic carboxylic acids (such as silver benzoate), silver salts of acetylenes as described, for example in U.S. Pat. No. 4,761,361 (Ozaki et al.) and U.S. Pat. No. 4,775,613 (Hirai et al.). Examples of other useful silver salts of mercapto or thione substituted compounds that do not contain a heterocyclic nucleus include silver salts of thioglycolic acids, dithiocarboxylic acids, and thioamides.
Sources of non-photosensitive reducible silver ions can also be in the form of core-shell silver salts as described in U.S. Pat. No. 6,355,408 (Whitcomb et al.), or the silver dimer compounds that comprise two different silver salts as described in U.S. Pat. No. 6,472,131 (Whitcomb), both patents being incorporated herein by reference.
Still other useful sources of non-photosensitive reducible silver ions are the silver core-shell compounds comprising a primary core comprising one or more photosensitive silver halides, or one or more non-photosensitive inorganic metal salts or non-silver containing organic salts, and a shell at least partially covering the primary core, wherein the shell comprises one or more non-photosensitive silver salts, each of which silver salts comprises a organic silver coordinating ligand. Such compounds are described in U.S. Pat. No. 6,802,177 (Bokhonov et al.) that is incorporated herein by reference.
The one or more non-photosensitive sources of reducible silver ions (both primary and secondary organic silver salts) are preferably present in a total amount of about 5% by weight to about 70% by weight, and more preferably, about 10% to about 50% by weight, based on the total dry weight of the emulsion layers. Alternatively, the total amount of reducible silver ions is generally present in an amount of from about 0.001 to about 0.2 mol/m2 of the dry photothermographic material (preferably from about 0.01 to about 0.05 mol/m2).
The total amount of silver (from all silver sources) in the photothermographic materials is generally at least 0.002 mol/m2 and preferably from about 0.01 to about 0.05 mol/m2 for single-sided materials. For double-sided coated materials, total amount of silver from all sources would be doubled.
Reducing Agents
The reducing agent (or reducing agent composition comprising two or more components) for the source of reducible silver ions can be any material (preferably an organic material) that can reduce silver(I) ion to metallic silver. The “reducing agent” is sometimes called a “developer” or “developing agent.”
When a silver benzotriazole silver source is used, ascorbic acid and reductone reducing agents are preferred. An “ascorbic acid” reducing agent means ascorbic acid, complexes, and derivatives thereof. Ascorbic acid reducing agents are described in a considerable number of publications including U.S. Pat. No. 5,236,816 (Purol et al.) and references cited therein.
Useful ascorbic acid developing agents include ascorbic acid and the analogues, isomers and derivatives thereof. Such compounds include, but are not limited to, D- or L-ascorbic acid, sugar-type derivatives thereof (such as sorboascorbic acid, γ-lactoascorbic acid, 6-desoxy-L-ascorbic acid, L-rhamno-ascorbic acid, imino-6-desoxy-L-ascorbic acid, glucoascorbic acid, fucoascorbic acid, glucoheptoascorbic acid, maltoascorbic acid, and L-arabosascorbic acid), sodium ascorbate, potassium ascorbate, isoascorbic acid (or L-erythroascorbic acid), and salts thereof (such as alkali metal, ammonium or others known in the art), endiol type ascorbic acid, an enaminol type ascorbic acid, a thioenol type ascorbic acid, and an enamin-thiol type ascorbic acid, as described in 2,688,549 (James et al.), U.S. Pat. No. 5,089,819 (Knapp), U.S. Pat. No. 5,278,035 (Knapp), U.S. Pat. No. 5,376,510 (Parker et al.), U.S. Pat. No. 5,384,232 (Bishop et al.), and U.S. Pat. No. 5,498,511 (Yamashita et al.), EP 0 573 700A1 (Lingier et al.), EP 0 585 792A1 (Passarella et al.), EP 0 588 408A1 (Hieronymus et al.), Japanese Kokai 7-56286 (Toyoda), and Research Disclosure, item 37152, March 1995. Mixtures of these developing agents can be used if desired.
Particularly useful reducing agents are ascorbic acid mono- or di-fatty acid esters such as the monolaurate, monomyristate, monopalmitate, monostearate, monobehenate, diluarate, distearate, dipalmitate, dibehenate, and dimyristate derivatives of ascorbic acid as described in U.S. Pat. No. 3,832,186 (Masuda et al.) and U.S. Pat. No. 6,309,814 (Ito). Preferred ascorbic acid reducing agents and their methods of preparation are those described in copending and commonly assigned U.S. Ser. No. 10/764,704 (filed on Jan. 26, 2004 by Ramsden, Lynch, Skoug, and Philip) and U.S. Ser. No. 10/935,645 (filed on Sep. 7, 2004 by Brick, Ramsden, and Lynch), both of which are incorporated herein by reference. A preferred reducing agent is L-ascorbic acid 6-O-palmitate.
A “reductone” reducing agent means a class of unsaturated, di- or poly-enolic organic compounds which, by virtue of the arrangement of the enolic hydroxy groups with respect to the unsaturated linkages, possess characteristic strong reducing power. The parent compound, “reductone” is 3-hydroxy-2-oxo-propionaldehyde (enol form) and has the structure HOCH═CH(OH)—CHO. Examples of reductone reducing agents can be found in U.S. Pat. No. 2,691,589 (Henn et al), U.S. Pat. No. 3,615,440 (Bloom), U.S. Pat. No. 3,664,835 (Youngquist et al.), U.S. Pat. No. 3,672,896 (Gabrielson et al.), U.S. Pat. No. 3,690,872 (Gabrielson et al.), U.S. Pat. No. 3,816,137 (Gabrielson et al.), U.S. Pat. No. 4,371,603 (Bartels-Keith et al.), U.S. Pat. No. 5,712,081 (Andriesen et al.), and U.S. Pat. No. 5,427,905 (Freedman et al.), all of which references are incorporated herein by reference.
When a silver carboxylate silver source is used in a photothermographic material, one or more hindered phenol reducing agents are preferred. In some instances, the reducing agent composition comprises two or more components such as a hindered phenol developer and a co-developer that can be chosen from the various classes of co-developers and reducing agents described below. Ternary developer mixtures involving the further addition of contrast enhancing agents are also useful. Such contrast enhancing agents can be chosen from the various classes of reducing agents described below.
“Hindered phenol reducing agents” are compounds that contain only one hydroxy group on a given phenyl ring and have at least one additional substituent located ortho to the hydroxy group.
One type of hindered phenol reducing agent includes hindered phenols and hindered naphthols.
Another type of hindered phenol reducing agent are hindered bis-phenols. These compounds contain more than one hydroxy group each of which is located on a different phenyl ring. This type of hindered phenol includes, for example, binaphthols (that is dihydroxybinaphthyls), biphenols (that is dihydroxybiphenyls), bis(hydroxynaphthyl)methanes, bis(hydroxyphenyl)-methanes bis(hydroxyphenyl)ethers, bis(hydroxyphenyl)sulfones, and bis(hydroxyphenyl)thioethers, each of which may have additional substituents.
Preferred hindered phenol reducing agents are bis(hydroxy-phenyl)methanes such as, bis(2-hydroxy-3-t-butyl-5-methylphenyl)methane (CAO-5), 1,1′-bis(2-hydroxy-3,5-dimethylphenyl)-3,5,5-trimethylhexane (NONOX® or PERMANAX WSO), and 1,1′-bis(2-hydroxy-3,5-dimethylphenyl)-isobutane (LOWINOX® 221B46). Mixtures of hindered phenol reducing agents can be used if desired.
An additional class of reducing agents that can be used includes substituted hydrazines including the sulfonyl hydrazides described in U.S. Pat. No. 5,464,738 (Lynch et al.). Still other useful reducing agents are described in U.S. Pat. No. 3,074,809 (Owen), U.S. Pat. No. 3,094,417 (Workman), U.S. Pat. No. 3,080,254 (Grant, Jr.), U.S. Pat. No. 3,887,417 (Klein et al.), and U.S. Pat. No. 5,981,151 (Leenders et al.). All of these patents are incorporated herein by reference.
Additional reducing agents that may be used include amidoximes, azines, a combination of aliphatic carboxylic acid aryl hydrazides and ascorbic acid, a reductone and/or a hydrazine, piperidinohexose reductone or formyl-4-methylphenylhydrazine, hydroxamic acids, a combination of azines and sulfonamidophenols, α-cyanophenylacetic acid derivatives, reductones, indane-1,3-diones, chromans, 1,4-dihydropyridines, and 3-pyrazolidones.
Useful co-developer reducing agents can also be used as described in U.S. Pat. No. 5,496,695 (Simpson et al.), U.S. Pat. No. 5,545,515 (Murray et al.), U.S. Pat. No. 5,635,339 (Murray), U.S. Pat. No. 5,654,130 (Murray), U.S. Pat. No. 5,705,324 (Murray), U.S. Pat. No. 6,100,022 (Inoue et al.), and U.S. Pat. No. 6,387,605 (Lynch et al.), all of which are incorporated herein by reference.
Various contrast enhancing agents can be used in some photothermographic materials with specific co-developers. Examples of useful contrast enhancing agents include, but are not limited to, hydroxylamines, hydroxyamine acid compounds, N-acylhydrazine compounds, hydrogen atom donor compounds, alkanolamines and ammonium phthalamate compounds as described in U.S. Pat. No. 5,545,505 (Simpson), U.S. Pat. No. 5,545,507 (Simpson et al.), U.S. Pat. No. 5,558,983 (Simpson et al.), and U.S. Pat. No. 5,637,449 (Harring et al.), all of which are incorporated herein by reference.
The reducing agent (or mixture thereof) described herein is generally present as 1 to 10% (dry weight) of the emulsion layer. In multilayer constructions, if the reducing agent is added to a layer other than an emulsion layer, slightly higher proportions, of from about 2 to 15 weight % may be more desirable. Co-developers may be present generally in an amount of from about 0.001% to about 1.5% (dry weight) of the emulsion layer coating.
Thermal Solvents
Advantageously, the photothermographic materials also include one or more thermal solvents (also called “heat solvents,” “thermosolvents,” “melt formers,” “melt modifiers,” “eutectic formers,” “development modifiers,” “waxes,” or “plasticizers”). By the term “thermal solvent” is meant an organic material that becomes a plasticizer or liquid solvent for at least one of the imaging layers upon beating at a temperature above 60° C. These compounds are incorporated in one or more thermally developable layers, or they can be incorporated into other layers (such as a protective layer) and allowed to diffuse into the thermally developable layers.
The useful thermal solvents can be defined by the following Structure I:
wherein R1, R2, R3, and R4 are independently hydrogen, a substituted or unsubstituted alkyl or cycloalkyl group having 1 to 10 carbon atoms (such as methyl, ethyl, iso-propyl, n-propyl, t-butyl, cyclohexyl, and benzyl), or a substituted or unsubstituted alkenyl group having 1 to 10 carbon atoms (such as allyl, and 2-butenyl). Alternatively, R1 and R2, or R3 and R4 can be joined together to form a substituted or unsubstituted 3- to 6-membered heterocyclic ring containing one or more additional nitrogen, sulfur, oxygen, and carbon atoms (such as morpholinyl, piperazinyl, and oxazinyl rings). Still again, either R1 or R2 can be joined with either R3 or R4 to form a substituted or unsubstituted 6- to 8-membered ring with the >NC(═O)C(═O)N< group. In Structure I, at least one of R1, R2, R3, and R4 is not a hydrogen atom.
Preferably, R1 and R4 are substituted or unsubstituted alkyl or alkenyl groups of 1 to 8 carbon atoms and R2 and R3 are hydrogen. More preferably, R1 and R4 are hydroxy substituted or unsubstituted alkyl groups of 1 to 6 carbon atoms or unsubstituted alkenyl groups of 1 to 6 carbon atoms, and R2 and R3 are hydrogen, and most preferably, R1 and R4 are methyl, ethyl, propyl, or butyl groups, optionally substituted with hydroxy groups, or allyl or 2-butenyl groups, and R2 and R3 are hydrogen.
Useful thermal solvents can also be represented by the following Structure II:
wherein R5 is hydrogen or a substituted or unsubstituted alkyl or alkenyl group having 1 to 4 carbon atoms (as defined above for R1 to R4). R6 and R7 are independently hydrogen or a substituted or unsubstituted alkyl or alkenyl group having 1 to 10 carbon atoms (as defined above for R1 to R4). Alternatively, R6 and R7 can be joined together to form a substituted or unsubstituted 3- to 6-membered ring, or again either R6 or R7 can be joined with R5 to form a substituted or unsubstituted 6- to 12-membered ring with the >NC(═O)(L1)- group.
L1 is an alkylene group of 2 to 8 carbon atoms, substituted with 2 to 8 hydroxy groups.
Preferably, R6 and R7 are independently hydrogen or substituted or unsubstituted alkyl or alkenyl groups of 1 to 8 carbon atoms, L1 is an alkylene group having 2 to 5 carbon atoms that is substituted with 2 to 5 hydroxy groups, and R5 is hydrogen, methyl, or ethyl. More preferably, R6 and R7 are independently hydrogen or substituted or unsubstituted alkyl or alkenyl groups of 1 to 4 carbon atoms, L1 is an alkylene group having 2 to 5 carbon atoms that is substituted with 2 to 5 hydroxy groups, and R5 is hydrogen and most preferably, R6 and R7 are independently hydrogen, allyl, benzyl, methyl, ethyl, or propyl, L1 is n-pentylene bearing 5 hydroxy groups or n-butylene bearing 4 hydroxy groups, and R5 is hydrogen.
Useful thermal solvents can also be represented by the following Structure III:
wherein R8, R9, R10, and R11, are independently hydrogen, a substituted or unsubstituted alkyl or alkenyl group having 1 to 10 carbon atoms, or a substituted or unsubstituted alkylene group having 1 to 10 carbon atoms (as defined above for R1 to R4). Alternatively, R8 and R9, or R10 and R11 can be joined together to form a substituted or unsubstituted 3- to 6-membered ring. L2 is a substituted or unsubstituted alkylene group having 1 to 8 carbon atoms. When L2 is an alkylene group that is substituted with 1 or less hydroxyl groups, then at least one of R8, R9, R10, R11, is an alkyl group that is substituted with at least one hydroxy group or an alkenyl group.
Preferably, R8, R9, R10, and R11 are independently hydrogen or substituted or unsubstituted alkyl or alkenyl groups of 1 to 8 carbon atoms, and L2 is an alkylene group having 1 to 5 carbon atoms, substituted with 1 to 5 hydroxy groups. More preferably, R8, R9, R10, and R11 are independently hydrogen or substituted or unsubstituted alkyl or alkenyl groups of 1 to 4 carbon atoms, and L2 is an alkylene group having 1 to 4 carbon atoms, preferably substituted with 1 to 4 hydroxy groups, and most preferably, R8, R9, R10, and R11 are independently hydrogen, allyl, benzyl, methyl, ethyl, hydroxyethyl, hydroxypropyl, or propyl, L2 is methylene, ethylene, ethylene bearing 1 or 2 hydroxy groups, or n-butylene bearing 4 hydroxy groups.
Useful thermal solvents can further be represented by the following Structure IV:
wherein R12, R13, and R14 are independently substituted or unsubstituted hydroxyalkyl groups having 1 to 8 carbon atoms. More preferably, R12, R13, and R14 are independently substituted or unsubstituted hydroxyalkyl groups of 1 to 4 carbon atoms, and most preferably, R12, R13, and R14 are independently hydroxyethyl or hydroxypropyl.
Thermal solvents represented by Structures 1, III, and IV are preferred in the practice of this invention.
Representative thermal solvents comprise one or more of the following compounds TS-1 through TS-32:
Compounds TS-1 to TS-18, TS-20 to TS-22, TS-25, TS-26, and TS-29 to TS-31 are preferred and Compounds TS-1 to TS-11, TS-16, and TS-17 are most preferred.
The one or more thermal solvents are present in an amount of at least 0.0001 mol/m2, and preferably from about 0.0005 to about 0.05 mol/m2, and more preferably from about 0.001 to about 0.02 mol/m2.
The thermal solvents can be obtained from a number of commercial sources such as Aldrich Chemical Company, or prepared using known starting materials and synthetic methods. Representative synthetic methods for preparing Compounds TS-1 and TS-31 are provided below prior to the Examples.
Other Addenda
The thermally developable materials can also contain other additives where appropriate, such as shelf-life stabilizers and speed enhancing agents, antifoggants, contrast enhancing agents, toners, development accelerators, acutance dyes, post-processing stabilizers or stabilizer precursors, additional thermal solvents, humectants, and other image-modifying agents as would be readily apparent to one skilled in the art.
Toners are compounds that when added to the imaging layer shift the color of the developed silver image from yellowish-orange to brown-black or blue-black, and/or act as development accelerators to speed up thermal development. “Toners” or derivatives thereof that improve the black-and-white image are highly desirable components of the photothermographic materials.
Thus, compounds that either act as toners or react with a reducing agent to provide toners can be present in an amount of about 0.01% by weight to about 10% (preferably from about 0.1% to about 10% by weight) based on the total dry weight of the layer in which they are included. The amount can also be defined as being within the range of from about 1×10−5 to about 1.0 mol per mole of non-photosensitive source of reducible silver in the photothermographic material. The toner compounds may be incorporated in one or more of the emulsion layers as well as in adjacent layers such as the outermost protective layer or underlying “carrier” layer. Toners can be located on both sides of the support if thermally developable layers are present on both sides of the support.
Compounds useful as toners are described in U.S. Pat. No. 3,074,809 (Owen), U.S. Pat. No. 3,080,254 (Grant, Jr.), U.S. Pat. No. 3,446,648 (Workman), U.S. Pat. No. 3,844,797 (Willems et al.), U.S. Pat. No. 3,847,612 (Winslow), U.S. Pat. No. 3,951,660 (Hagemann et al.), U.S. Pat. No. 4,082,901 (Laridon et al.), U.S. Pat. No. 4,123,282 (Winslow), U.S. Pat. No. 5,599,647 (Defieuw et al.), and U.S. Pat. No. 3,832,186 (Masuda et al.), and GB 1,439,478 (AGFA).
Particularly useful toners are mercaptotriazoles as described in U.S. Pat. No. 6,713,240 (Lynch et al.), the heterocyclic disulfide compounds described in U.S. Pat. No. 6,737,227 (Lynch et al.), the triazine-thione compounds described in U.S. Pat. No. 6,703,191 (Lynch et al.), and the silver salt-toner co-precipitated nano-crystals described in copending and commonly assigned U.S. Ser. No. 10/935,384 (noted above). All of the above are incorporated herein by reference.
Also useful as toners are phthalazine and phthalazine derivatives [such as those described in U.S. Pat. No. 6,146,822 (Asanuma et al.) incorporated herein by reference], phthalazinone, and phthalazinone derivatives as well as phthalazinium compounds [such as those described in U.S. Pat. No. 6,605,418 (Ramsden et al.), incorporated herein by reference].
To further control the properties of photothermographic materials, (for example, supersensitization, contrast, Dmin, speed, or fog), it may be preferable to add one or more heteroaromatic mercapto compounds or heteroaromatic disulfide compounds of the formulae Ar—S-M1 and Ar—S—S—Ar, wherein M1 represents a hydrogen atom or an alkali metal atom and Ar represents a heteroaromatic ring or fused heteroaromatic ring containing one or more of nitrogen, sulfur, oxygen, selenium, or tellurium atoms. Useful heteroaromatic mercapto compounds are described as supersensitizers in EP 0 559 228 B1 (Philip Jr. et al.).
The photothermographic materials can be further protected against the production of fog and can be stabilized against loss of sensitivity during storage. Suitable antifoggants and stabilizers that can be used alone or in combination include thiazolium salts as described in U.S. Pat. No. 2,131,038 (Brooker et al.) and U.S. Pat. No. 2,694,716 (Allen), azaindenes as described in U.S. Pat. No. 2,886,437 (Piper), triazaindolizines as described in U.S. Pat. No. 2,444,605 (Heimbach), urazoles as described in U.S. Pat. No. 3,287,135 (Anderson), sulfocatechols as described in U.S. Pat. No. 3,235,652 (Kennard), oximes as described in GB 623,448 (Carrol et al.), polyvalent metal salts as described in U.S. Pat. No. 2,839,405 (Jones), and thiuronium salts as described in U.S. Pat. No. 3,220,839 (Herz).
The photothermographic materials may also include one or more polyhalo antifoggants that include one or more polyhalo substituents including but not limited to, dichloro, dibromo, trichloro, and tribromo groups. The antifoggants can be aliphatic, alicyclic or aromatic compounds, including aromatic heterocyclic and carbocyclic compounds. Particularly useful antifoggants of this type are polyhalo antifoggants, such as those having a —SO2C(X′)3 group wherein X′ represents the same or different halogen atoms. Compounds having —SO2CBr3 groups are particularly preferred. Such compounds are described, for example, in U.S. Pat. No. 5,369,000 (Sakizadeh et al.), U.S. Pat. No. 5,460,938 (Kirk et al.), U.S. Pat. No. 5,464,737 (Sakizadeh et al.), U.S. Pat. No. 5,594,143 (Kirk et al.), and U.S. Pat. No. 5,374,514 (Kirk et al.).
Another class of useful antifoggants includes those compounds described in U.S. Pat. No. 6,514,678 (Burgmaier et al.), incorporated herein by reference.
The photothermographic materials can also include one or more additional compounds that are considered thermal solvents but are not within the definition of Structures I, II, III, and IV described above.
Representative examples of such compounds include polyethylene glycols having a mean molecular weight in the range of 1,500 to 20,000, ethylene carbonate, niacinamide, hydantoin, 5,5-dimethylhydantoin, salicylanilide, succinimide, N-hydroxy-succinimide, phthalimide, N-potassium-phthalimide, N-hydroxyphthalimide, N-hydroxy-1,8-naphthalimide, phthalazine, 1-(2H)-phthalazinone, 2-acetylphthalazinone, benzanilide, urea, 1,3-dimethylurea, 1,3-diethylurea, 1,3-diallylurea, xylitol, meso-erythritol, D-sorbitol, neopentyl glycol, 1,1,1-tris(hydroxymethyl)ethane, pentaerythritol, trimethylolpropane, tetrahydro-2-pyrimidone, glycouril, 2-imidazolidone, 2-imidazolidone-4-carboxylic acid, methyl sulfonamide, and benzenesulfonamide. Combinations of these compounds can also be used. Known thermal solvents are disclosed, for example, in U.S. Pat. No. 3,347,675 (Henn et al.), U.S. Pat. No. 3,438,776 (Yudelson), U.S. Pat. No. 5,250,386 (Aono et al.), U.S. Pat. No. 5,368,979 (Freedman et al.), U.S. Pat. No. 5,716,772 (Taguchi et al.), and U.S. Pat. No. 6,013,420 (Windender), and in Research Disclosure, October 1976, item 15027. All of these are incorporated herein by reference.
One preferred group of additional thermal solvents includes one or more of ethylene carbonate, neopenyl glycol, D-sorbitol, pentaerythritol, N-hydroxysucciminide, 1,1,1-trishydroxymethyl)ethane, trimethylolpropane, and xylitol.
Still other preferred additional thermal solvents are polyhydroxy alkanes containing 4-, 5-, and 6- carbon atoms. Many of these are reduced sugars or “sugar-like” molecules. Xylitol, D-sorbitol, pentaerythritol, trimethylolpropane, and 1,1,1-tris(hydroxymethyl)ethane, are particularly preferred additional thermal solvents of this type.
When used, such additional thermal solvents are present in an amount of at least 0.2 g/m2, and more preferably in an amount of from about 0.3 to about 0.9 g/m2.
It may be advantageous to include a base-release agent or base precursor in the photothermographic materials. Representative base-release agents or base precursors include guanidinium compounds, such as guanidinium trichloroacetate, and other compounds that are known to release a base but do not adversely affect photographic silver halide materials, such as phenylsulfonyl acetates as described in U.S. Pat. No. 4,123,274 (Knight et al.).
Phosphors
In some embodiments, it is also effective to incorporate X-radiation-sensitive phosphors in the photothermographic materials as described in U.S. Pat. No. 6,440,649 (Simpson et al.) and U.S. Pat. No. 6,573,033 (Simpson et al.), both of which are incorporated herein by reference. Other useful phosphors are primarily “activated” phosphors known as phosphate phosphors and borate phosphors. Examples of these phosphors are rare earth phosphates, yttrium phosphates, strontium phosphates, or strontium fluoroborates (including cerium activated rare earth or yttrium phosphates, or europium activated strontium fluoroborates) as described in copending and commonly assigned U.S. Ser. No. 10/826,500 (filed Apr. 16, 2004 by Simpson, Sieber, and Hansen).
The one or more phosphors used in the practice of this invention are present in the photothermographic materials in an amount of at least 0.1 mole per mole per mole of total silver in the photothermographic material.
Binders
The photosensitive silver halide (if present), the non-photosensitive source of reducible silver ions, the reducing agent composition, and any other imaging layer additives are generally combined with one or more binders that are generally hydrophobic or hydrophilic in nature. Mixtures of different types of hydrophilic and/or hydrophobic binders can also be used. Preferably, hydrophilic polymer binders and water-dispersible polymeric latexes are used to provide aqueous-based formulations for the thermographic and photothermographic materials. Either aqueous or organic solvent-based formulations can be used to prepare and coat the thermally developable materials of this invention. Preferably, aqueous-based formulations are used.
Examples of useful hydrophilic polymer binders include, but are not limited to, proteins and protein derivatives, gelatin and gelatin derivatives (hardened or unhardened), cellulosic materials, acrylamide/methacrylamide polymers, acrylic/methacrylic polymers, polyvinyl pyrrolidones, polyvinyl alcohols, poly(vinyl lactams), polymers of sulfoalkyl acrylate or methacrylates, hydrolyzed polyvinyl acetates, polyamides, polysaccharides, and other naturally occurring or synthetic vehicles commonly known for use in aqueous-based photographic emulsions (see for example Research Disclosure, item 38957, noted above). Particularly useful hydrophilic polymer binders are gelatin, gelatin derivatives, polyvinyl alcohols, and cellulosic materials. Gelatin and its derivatives are most preferred, and comprise at least 75 weight % of total binders when a mixture of binders is used.
Aqueous dispersions of water-dispersible polymeric latexes may also be used, alone or with hydrophilic or hydrophobic binders described herein. Such dispersions are described in, for example, U.S. Pat. No. 4,504,575 (Lee), U.S. Pat. No. 6,083,680 (Ito et al), U.S. Pat. No. 6,100,022 (Inoue et al.), U.S. Pat. No. 6,132,949 (Fujita et al.), U.S. Pat. No. 6,132,950 (Ishigaki et al.), U.S. Pat. No. 6,140,038 (Ishizuka et al.), U.S. Pat. No. 6,150,084 (Ito et al.), U.S. Pat. No. 6,312,885 (Fujita et al.), and U.S. Pat. No. 6,423,487 (Naoi), all of which are incorporated herein by reference.
Minor amounts (less than 50 weight % based on total binder weight) of hydrophobic binders (not in latex form) may also be used in combination with hydrophilic binders. Examples of typical hydrophobic binders include polyvinyl acetals, polyvinyl chloride, polyvinyl acetate, cellulose acetate, cellulose acetate butyrate, polyolefins, polyesters, polystyrenes, polyacrylonitrile, polycarbonates, methacrylate copolymers, maleic anhydride ester copolymers, butadiene-styrene copolymers, and other materials readily apparent to one skilled in the art. Copolymers (including terpolymers) are also included in the definition of polymers. The polyvinyl acetals (such as polyvinyl butyral and polyvinyl formal), cellulose ester polymers, and vinyl copolymers (such as polyvinyl acetate and polyvinyl chloride) are preferred. Particularly suitable binders are polyvinyl butyral resins that are available under the name BUTVAR® from Solutia, Inc. (St. Louis, Mo.) and PIOLOFORM® from Wacker Chemical Company (Adrian, Mich.) and cellulose ester polymers.
Hardeners for various binders may be present if desired. Useful hardeners are well known and include diisocyanates as described for example, in EP 0 600 586B1 (Philip, Jr. et al.) and vinyl sulfone compounds as described in U.S. Pat. No. 6,143,487 (Philip, Jr. et al.), and EP 0 640 589A1 (Gathmann et al.), aldehydes and various other hardeners as described in U.S. Pat. No. 6,190,822 (Dickerson et al.).
Where the proportions and activities of the photothermographic materials require a particular developing time and temperature, the binder(s) should be able to withstand those conditions. Generally, it is preferred that the binder does not decompose or lose its structural integrity at 120° C. for 60 seconds. It is more preferred that it does not decompose or lose its structural integrity at 177° C. for 60 seconds.
The binder(s) is used in an amount sufficient to carry the components dispersed therein. Preferably, a binder is used at a level of about 10% by weight to about 90% by weight, and more preferably at a level of about 20% by weight to about 70% by weight, based on the total dry weight of the layer in which it is included. The amount of binders on opposing sides of the support in double-sided materials may be the same or different.
Support Materials
The photothermographic materials comprise a polymeric support that is preferably a flexible, transparent film that has any desired thickness and is composed of one or more polymeric materials. They are required to exhibit dimensional stability during thermal development and to have suitable adhesive properties with overlying layers. Useful polymeric materials for making such supports include, but are not limited to, polyesters, cellulose acetate and other cellulose esters, polyvinyl acetal, polyolefins, polycarbonates, and polystyrenes. Preferred supports are composed of polymers having good heat stability, such as polyesters and polycarbonates. Polyethylene terephthalate film is a particularly preferred support. Support materials may also be treated or annealed to reduce shrinkage and promote dimensional stability.
Also useful are transparent, multilayer, polymeric supports comprising numerous alternating layers of at least two different polymeric materials as described in U.S. Pat. No. 6,630,283 (Simpson et al.) that is incorporated herein by reference. Also useful are the supports comprising dichroic mirror layers as described in U.S. Pat. No. 5,795,708 (Boutet), incorporated herein by reference.
Support materials can contain various colorants, pigments, antihalation or acutance dyes if desired. For example, blue-tinted supports are particularly useful for providing images useful for medical diagnosis. Support materials may be treated using conventional procedures (such as corona discharge) to improve adhesion of overlying layers, or subbing or other adhesion-promoting layers can be used.
Thermally Developable Formulations and Constructions
The imaging components are preferably prepared in a formulation containing a hydrophilic polymer binder (such as gelatin, a gelatin-derivative, or a cellulosic material) or a water-dispersible polymer in latex form in an solvent such as water or water-organic solvent mixtures to provide coating formulations. Preferably the imaging layers on one or both sides of the support are prepared and coated out of aqueous-based formulations.
The photothemmographic materials can contain plasticizers and lubricants such as poly(alcohols) and diols as described in U.S. Pat. No. 2,960,404 (Milton et al.), fatty acids or esters as described in U.S. Pat. No. 2,588,765 (Robijns) and U.S. Pat. No. 3,121,060 (Duane), and silicone resins as described in GB 955,061 (DuPont). The materials can also contain inorganic or organic matting agents as described in U.S. Pat. No. 2,992,101 (Jelley et al.) and U.S. Pat. No. 2,701,245 (Lynn). Polymeric fluorinated surfactants may also be useful in one or more layers as described in U.S. Pat. No. 5,468,603 (Kub).
U.S. Pat. No. 6,436,616 (Geisler et al.), incorporated herein by reference, describes various means of modifying photothermographic materials to reduce what is known as the “woodgrain” effect, or uneven optical density.
The photothermographic materials can include one or more antistatic agents in any of the layers on either or both sides of the support. Preferably the conductive layers are “buried,” that is they are located in a non-imaging underlayer between the support and the photothermographic emulsion layer. More preferably the conductive layer is a carrier layer. Conductive components include soluble salts, evaporated metal layers, or ionic polymers as described in U.S. Pat. No. 2,861,056 (Minsk) and U.S. Pat. No. 3,206,312 (Sterman et al.), insoluble inorganic salts as described in U.S. Pat. No. 3,428,451 (Trevoy), polythiophenes as described in U.S. Pat. No. 5,747,412 (Leenders et al.), electro-conductive underlayers as described in U.S. Pat. No. 5,310,640 (Markin et al.), electronically-conductive metal antimonate particles as described in U.S. Pat. No. 5,368,995 (Christian et al.), and electrically-conductive metal-containing particles dispersed in a polymeric binder as described in EP 0 678 776 A1 (Melpolder et al.). Particularly useful conductive particles are the non-acicular metal antimonate particles described in U.S. Pat. No. 6,689,546 (LaBelle et al.), and in copending and commonly assigned U.S. Ser. No. 10/930,428 (filed Aug. 31, 2004 by Ludemann, LaBelle, Koestner, Hefley, Bhave, Geisler, and Philip), Ser. No. 10/930,438 (filed Aug. 31, 2004 by Ludemann, LaBelle, Philip, Koestener, and Bhave), and Ser. No. 10/978,205 (filed Oct. 29, 2004 by Ludemann, LaBelle, Koestner, and Chen). A particularly preferred buried conductive composition comprises a non-imaging conductive underlayer comprising one or more hydrophilic polymers, a conductive metal oxide, and a smectite clay as described in copending and commonly assigned U.S. Ser. No. 11/______ (filed on Apr. 18, 2005 by Sharon M. Simpson, Jon A. Hammerschmidt, and Kumars Sakizadeh, entitled Conductive Underlayers for Aqueous-Based Thermally Developable Materials, and having Attorney Docket No. 89412/JLT). All of the above patents and patent applications are incorporated herein by reference.
In addition, fluorochemicals such as FLORAD® FC-135 (3M Corporation), ZONYL® FSN (E. I. DuPont de Nemours & Co.), as well as those described in U.S. Pat. No. 5,674,671 (Brandon et al.), U.S. Pat. No. 6,287,754 (Melpolder et al.), U.S. Pat. No. 4,975,363 (Cavallo et al.), U.S. Pat. No. 6,171,707 (Gomez et al.), U.S. Pat. No. 6,699,648 (Sakizadeh et al.), and U.S. Pat. No. 6,762,013 (Sakizadeh et al.) can be used. All of the above are incorporated herein by reference.
The photothermographic materials can have a protective overcoat layer (or outermost topcoat layer) disposed over the one or more imaging layers on one or both sides of the support. The binders for such overcoat layers can be any of the binders described in the Binders Section, but preferably, they are predominantly (over 50 weight %) hydrophilic binders or water-dispersible polymer latex binders. More preferably, the protective layers include gelatin or a gelatin derivative as the predominant binder(s) especially when the one or more imaging layers also include gelatin or a gelatin derivative as the predominant binder(s).
For duplitized photothermographic materials, each side of the support can include one or more of the same or different imaging layers, interlayers, and protective overcoat layers. In such materials preferably an overcoat is present as the outermost layer on both sides of the support. The layers on opposite sides can have the same or different construction and can be overcoated with the same or different protective layers.
Layers to promote adhesion of one layer to another are also known, as described in U.S. Pat. No. 5,891,610 (Bauer et al.), U.S. Pat. No. 5,804,365 (Bauer et al.), and U.S. Pat. No. 4,741,992 (Przezdziecki). Adhesion can also be promoted using specific polymeric adhesive materials as described for example in U.S. Pat. No. 5,928,857 (Geisler et al.).
The formulations described herein (including the thermographic and photothermographic formulations) can be coated by various coating procedures including wire wound rod coating, dip coating, air knife coating, curtain coating, slide coating, or extrusion coating using hoppers of the type described in U.S. Pat. No. 2,681,294 (Beguin). Layers can be coated one at a time, or two or more layers can be coated simultaneously by the procedures described in U.S. Pat. No. 2,761,791 (Russell), U.S. Pat. No. 4,001,024 (Dittman et al.), U.S. Pat. No. 4,569,863 (Keopke et al.), U.S. Pat. No. 5,340,613 (Hanzalik et al.), U.S. Pat. No. 5,405,740 (LaBelle), U.S. Pat. No. 5,415,993 (Hanzalik et al.), U.S. Pat. No. 5,525,376 (Leonard), U.S. Pat. No. 5,733,608 (Kessel et al.), U.S. Pat. No. 5,849,363 (Yapel et al.), U.S. Pat. No. 5,843,530 (Jerry et al.), and U.S. Pat. No. 5,861,195 (Bhave et al.), and GB 837,095 (Ilford). A typical coating gap for the emulsion layer can be from about 10 to about 750 μm, and the layer can be dried in forced air at a temperature of from about 20° C. to about 100° C. It is preferred that the thickness of the layer be selected to provide maximum image densities greater than about 0.2, and more preferably, from about 0.5 to 5.0 or more, as measured by a MacBeth Color Densitometer Model TD 504.
Simultaneously with or subsequently to application of an emulsion formulation to the support, a protective overcoat formulation can be applied over the emulsion formulation.
Preferably, two or more layer formulations are applied simultaneously to a film support using slide coating techniques, an overcoat layer being coated on top of a photothermographic layer while the photothermographic layer is still wet.
Mottle and other surface anomalies can be reduced in the materials by incorporation of a fluorinated polymer as described in U.S. Pat. No. 5,532,121 (Yonkoski et al.) or by using particular drying techniques as described in U.S. Pat. No. 5,621,983 (Ludemann et al.).
While the overcoat and thermally developable layers can be coated on one side of the film support, manufacturing methods can also include forming on the opposing or backside of the polymeric support, one or more additional layers, including a conductive layer, an antihalation layer, or a layer containing a matting agent (such as silica), or a combination of such layers. Alternatively, one backside layer can perform all of the desired functions.
The photothermographic and thermographic materials may also usefully include a magnetic recording material as described in Research Disclosure, Item 34390, November 1992, or a transparent magnetic recording layer such as a layer containing magnetic particles on the underside of a transparent support as described in U.S. Pat. No. 4,302,523 (Audran et al.).
To promote image sharpness, photothermographic materials can contain one or more layers containing acutance and/or antihalation dyes that are chosen to have absorption close to the exposure wavelength and are designed to absorb scattered light. One or more antihalation compositions may be incorporated into one or more antihalation backing layers, antihalation underlayers, or as antihalation overcoats.
Dyes useful as antihalation and acutance dyes include squaraine dyes described in U.S. Pat. No. 5,380,635 (Gomez et al.) and U.S. Pat. No. 6,063,560 (Suzuki et al.), and EP 1 083 459A1 (Kimura), indolenine dyes described in EP 0 342 81 OAI (Leichter), and cyanine dyes described in U.S. Pat. No. 6,689,547 (Hunt et al.), all incorporated herein by reference.
It may also be useful to employ compositions including acutance or antihalation dyes that will decolorize or bleach with heat during processing, as described in U.S. Pat. No. 5,135,842 (Kitchin et al.), U.S. Pat. No. 5,266,452 (Kitchin et al.), U.S. Pat. No. 5,314,795 (Helland et al.), and U.S. Pat. No. 6,306,566, (Sakurada et al.), and Japanese Kokai 2001-142175 (Hanyu et al.) and 2001-183770 (Hanye et al.). Useful bleaching compositions are also described in Japanese Kokai 11-302550 (Fujiwara), 2001-109101 (Adachi), 2001-51371 (Yabuki et al.), and 2000-029168 (Noro). All of the noted publications are incorporated herein by reference.
Other useful heat-bleachable backside antihalation compositions can include an infrared radiation absorbing compound such as an oxonol dye or other compounds used in combination with a hexaarylbiimidazole (also known as a “HABI”), or mixtures thereof. HABI compounds are described in U.S. Pat. No. 4,196,002 (Levinson et al.), U.S. Pat. No. 5,652,091 (Perry et al.), and U.S. Pat. No. 5,672,562 (Perry et al.), all incorporated herein by reference. Examples of such heat-bleachable compositions are described for example in U.S. Pat. No. 6,455,210 (Irving et al.), U.S. Pat. No. 6,514,677 (Ramsden et al.), and U.S. Pat. No. 6,558,880 (Goswami et al.), all incorporated herein by reference.
Under practical conditions of use, these compositions are heated to provide bleaching at a temperature of at least 90° C. for at least 0.5 seconds (preferably, at a temperature of from about 100° C. to about 200° C. for from about 5 to about 20 seconds).
Imaging/Development
The photothermographic materials can be imaged in any suitable manner consistent with the type of material, using any suitable imaging source (typically some type of radiation or electronic signal). In some embodiments, the materials are sensitive to radiation in the range of from about at least 100 nm to about 1400 nm, and normally from about 300 nm to about 850 nm (preferably from about 300 to about 600 nm, more preferably from about 300 to about 450 nm, even more preferably from a wavelength of from about 360 to 420 nm, and most preferably from about 380 to about 420 nm), using appropriate spectral sensitizing dyes.
Imaging can be achieved by exposing the photothermographic materials to a suitable source of radiation to which they are sensitive, including X-radiation, ultraviolet radiation, visible light, near infrared radiation, and infrared radiation to provide a latent image. Suitable exposure means are well known and include incandescent or fluorescent lamps, xenon flash lamps, lasers, laser diodes, light emitting diodes, infrared lasers, infrared laser diodes, infrared light-emitting diodes, infrared lamps, or any other ultraviolet, visible, or infrared radiation source readily apparent to one skilled in the art such as described in Research Disclosure, item 38957 (noted above). Particularly useful infrared exposure means include laser diodes, including laser diodes that are modulated to increase imaging efficiency using what is known as multi-longitudinal exposure techniques as described in U.S. Pat. No. 5,780,207 (Mohapatra et al.). Other exposure techniques are described in U.S. Pat. No. 5,493,327 (McCallum et al.).
The photothermographic materials also can be indirectly imaged using an X-radiation imaging source and one or more prompt-emitting or storage X-radiation sensitive phosphor screens adjacent to the photothermographic material. The phosphors emit suitable radiation to expose the photothermographic material. Preferred X-ray screens are those having phosphors emitting in the near ultraviolet region of the spectrum (from 300 to 400 nm), in the blue region of the spectrum (from 400 to 500 nm), and in the green region of the spectrum (from 500 to 600 nm).
In other embodiments, the photothermographic materials can be imaged directly using an X-radiation imaging source to provide a latent image.
Thermal development conditions will vary, depending on the construction used but will typically involve heating the photothermographic material at a suitably elevated temperature, for example, at from about 50° C. to about 250° C. (preferably from about 80° C. to about 200° C. and more preferably from about 100° C. to about 200° C.) for a sufficient period of time, generally from about 1 to about 120 seconds. Heating can be accomplished using any suitable heating means. A preferred heat development procedure for photothermographic materials includes heating at from 130° C. to about 165° C. for from about 3 to about 25 seconds.
When imaging thermographic materials, the image may be “written” simultaneously with development at a suitable temperature using a thermal stylus, a thermal print-head or a laser, or by heating while in contact with a heat-absorbing material. The thermographic materials may include a dye (such as an IR-absorbing dye) to facilitate direct development by exposure to laser radiation.
Thermal development of either thermographic or photothermographic materials is carried out with the material being in a substantially water-free environment and without application of any solvent to the material.
Use as a Photomask
In some embodiments, the photothermographic materials are sufficiently transmissive in the range of from about 350 to about 450 nm in non-imaged areas to allow their use in a method where there is a subsequent exposure of an ultraviolet or short wavelength visible radiation sensitive imageable medium. The heat-developed materials absorb ultraviolet or short wavelength visible radiation in the areas where there is a visible image and transmit ultraviolet or short wavelength visible radiation where there is no visible image. The materials may then be used as a mask and positioned between a source of imaging radiation (such as an ultraviolet or short wavelength visible radiation energy source) and an imageable material that is sensitive to such imaging radiation, such as a photopolymer, diazo material, photoresist, or photosensitive printing plate.
These embodiments of the imaging method of this invention are carried out using the following Steps (A′) or (A) and (B) noted above and the following Steps (C) and (D):
(C) positioning the exposed and photothermographic material with the visible image therein between a source of imaging radiation and an imageable material that is sensitive to the imaging radiation, and
(D) exposing the imageable material to the imaging radiation through the visible image in the exposed and photothermographic material to provide an image in the imageable material.
Imaging Assemblies
In some embodiments, the photothermographic materials are used or arranged in association with one or more phosphor intensifying screens and/or metal screens in what is known as “imaging assemblies.” Duplitized visible light sensitive photothermographic materials are preferably used in combination with two adjacent intensifying screens, one screen in the “front” and one screen in the “back” of the material. The front and back screens can be appropriately chosen depending upon the type of emissions desired, the desired photicity, and emulsion speeds. The imaging assemblies can be prepared by arranging the photothermographic material and one or more phosphor intensifying screens in a suitable holder (often known as a cassette), and appropriately packaging them for transport and imaging uses.
There are a wide variety of phosphors known in the art that can be formulated into phosphor intensifying screens as described in hundreds of publications. U.S. Pat. No. 6,573,033 (noted above) describes phosphors that can be used in this manner. Particularly useful phosphors are those that emit radiation having a wavelength of from about 300 to about 450 nm and preferably radiation having a wavelength of from about 360 to about 420 nm.
Preferred phosphors useful in the phosphor intensifying screens include one or more alkaline earth fluorohalide phosphors and especially the rare earth activated (doped) alkaline earth fluorohalide phosphors. Particularly useful phosphor intensifying screens include a europium-doped barium fluorobromide (BaFBr2:Eu) phosphor. Other useful phosphors are described in U.S. Pat. No. 6,682,868 (Dickerson et al.) and references cited therein, all incorporated herein by reference.
The following examples are provided to illustrate the practice of the present invention and the invention is not meant to be limited thereby.
All materials used in the following examples can be prepared using known synthetic procedures or are available from standard commercial sources, such as Aldrich Chemical Co. (Milwaukee, Wis.), unless otherwise specified. All percentages are by weight unless otherwise indicated. The following additional materials were prepared or obtained and used.
BYK-022 is a defoamer and is available from Byk-Chemie Corp. (Wallingford, Conn.).
BZT is benzotriazole. AgBZT is silver benzotriazole. NaBZT is the sodium salt of benzotriazole.
CELVOL® 203S is a poly(vinyl alcohol) (PVA) and is available from Celanese Corp. (Dallas, Tex.).
Monopalmitin is the mono-ester of palmitic acid and glycerol and is available from TCI Tokyo Kasei Kogyo Co., LTD., (Tokyo, Japan).
SPP 3000 is an 88% hydrolyzed poly(vinyl alcohol) having a molecular weight of 3000. It is available from Scientific Polymer Products. (Ontario, N.Y.).
TRITON®X-114 is a nonionic surfactant that is available from Dow Chemical Corp. (Midland Mich.).
TRITON® X-200 is an anionic surfactant that is available from Dow Chemical Corp. (Midland Mich.).
ZONYL® FS-300 is a nonionic fluorosurfactant that is available from E. I. DuPont de Nemours & Co. (Wilmington, Del.).
Compound D-1 is L-Ascorbic acid 6-O-palmitate and is available from Aceto Corp., (Lake Success, N.Y.). It is believed to have the following structure.
Compound A-1 is the reaction product of butyl chloride and phthalazine as described in U.S. Pat. No. 6,605,418 (noted above) and is believed to have the following structure.
Compound PS-1 is S-octadecyl phenylcarbamothioate. It has the structure shown below and was prepared as described in copending and commonly assigned U.S. Ser. No. 11/025,633 (filed on Dec. 29, 2004 by Ramsden, Philip, Lynch, Chen-Ho, Ulrich, Sakizadeh, Leon, and Burgmaier) that is incorporated herein by reference.
Compound TAI-1 is the sodium salt of 5-bromo-4-hydroxy-6-methyl-1,3,3a,7-tetraazaindene. It has the structure shown below and can be prepared as described in copending and commonly assigned U.S. Ser. No. 11/______ (filed on Apr. 18, 2005 by Zou, Sakizadeh, Burgmaier, and Klaus, entitled Halogen Substituted Tetraazaindene Compounds in Photothermographic Materials and having Attorney Docket Number 89148/JLT) that is incorporated herein by reference.
Compound SS-1a is described in U.S. Pat. No. 6,296,998 (Eikenberry et al.) and is believed to have the following structure:
Compound VS-1 is 1,1′(methylenebis(sulfonyl))bis-ethene and is described in EP 0 640 589 A1 (Gathmann et al.). It is believed to have the following structure:
Compound S-1 is a 10:1 mixture of the compounds shown below.
Compound T-1 is 2,4-dihydro-4-(phenylmethyl)-3H-1,2,4-triazole-3-thione. It is believed to have the structure shown below. It may also exist as the thione tautomer. The silver salt of this compound is referred to as AgT-1.
Blue sensitizing dye SSD-1 is believed to have the following structure.
Gold sensitizer Compound GS-1 is believed to have the following structure.
Preparation of Thermal Solvent Compounds:
The thermal solvent compounds can be obtained from a number of commercial sources such as the Aldrich Chemical Company, or they can be prepared using known starting materials and synthetic methods, some of which can be found in the scientific literature. The procedures used to prepare two of the thermal solvents examples are provided below and are representative of the method that can be used by those skilled in the art to make other thermal solvent compounds of the present invention.
Preparation of Compound TS-1:
To a 500 ml round-bottom, three-necked flask equipped with a mechanical stirrer, an addition funnel with a nitrogen inlet, and a thermometer was added 62.7 g of L-diethyl tartrate and 120 ml of ethanol followed by the addition of 50 ml of allyl amine nearly all at once. The temperature rose to about 30° C. and then the mixture was heated with stirring for 20 hours using an oil bath heated to about 50° C. The contents were then cooled to room temperature and then to about 8° C. for 6 hr. The solid that had formed was collected and washed with about 100 ml of a cold mixture of 90 ml of diethyl ether and 10 ml of ethanol, to afford 52.91 g of a white solid, mp 180-1° C. Further purification was possible with a recrystallization from ethanol.
Preparation of Compound TS-31:
To a single-necked flask equipped with a distillation head was added 156 g of L-diethyl tartrate and 145.5 g of morpholine. The contents were heated at an internal temperature of about 105° C. for 24 hours. About 25 ml of ethanol was recovered from the distillation apparatus.
The warm reaction mixture was poured into an Erlenmeyer flask and about 225 ml of ethanol were added. The mixture was stirred overnight at room temperature and then allowed to stand without stirring at about 8° C. for 5 hours. The solid that had formed was collected and then suspended with stirring in a mixture of 500 ml of diethyl ether and 50 ml of ethanol for 30 minutes at room temperature and then collected to yield 27.48 g of a white solid, mp 216-219° C. Further purification is possible by recrystallization from a of 70/30 (by volume) alcohol/water mixture.
In the Examples below, Samples having the suffix “-I” are inventive and samples having the suffix “-C” are comparative. Thus, for example, Sample 1-1-C is a comparative example and Sample 1-2-I is an inventive example
An aqueous-based photothermographic material of this invention was prepared in the following manner.
Preparation of Dispersions of Compound D-1:
Aqueous slurries were prepared containing Compound D-1, CELVOL® 203S poly(vinyl alcohol), TRITON® X-114 surfactant, and BYK-022. The poly(vinyl alcohol), TRITON®X-114 surfactant, and BYK-022 were added at a level of 10.0%, 3.0%, and 0.1% by weight to that of Compound D-1, respectively. The mixture was milled with 0.7 mm zirconium silicate ceramic beads for about 7 hours. Filtration to remove the beads, followed by examination of the final dispersion by transmitted light microscopy at 1000× magnification showed well-dispersed particles, all below 1 μm.
Preparation of Dispersions of Compound PS-1:
A solid particle dispersion of Compound PS-1 was prepared by combining 10.00% of Compound PS-1, 2.70% SPP 3000 poly(vinyl alcohol), 0.05% TRITON® X-200 surfactant, and 87.25% deionized water by weight, respectively. The mixture was milled using a micro media mill with 0.7 mm zirconium silicate ceramic beads for 90 minutes at 2000 rpm. This mill is described in U.S. Pat. No. 5,593,097 (Corbin), incorporated herein by reference. Filtration to remove the beads gave an aqueous dispersion containing 10% of Compound PS-1 with an average particle size less than 1 μm.
Preparation of AgBZT/AgT-1 Co-Precipitated Emulsion:
A co-precipitated AgBZT/AgT-1 emulsion was prepared as described in copending and commonly assigned U.S. Ser. No. 10/935,384 (noted above).
A stirred reaction vessel was charged with 900 g of lime-processed gelatin, and 6000 g of deionized water. The mixture in the reaction vessel was adjusted to a pH of 8.9 with 2.5N sodium hydroxide solution, and 0.8 g of Solution A (prepared below) was added to adjust the solution vAg to 80 mV. The temperature of the reaction vessel was maintained at approximately 50° C.
Solution A was prepared containing 216 g/kg of benzotriazole, 710 g/kg of deionized water, and 74 g/kg of sodium hydroxide.
Solution B was prepared containing 362 g/kg of silver nitrate and 638 g/kg of deionized water.
Solution C was prepared containing 336 g/kg of T-1, 70 g/kg of sodium hydroxide and 594 g/kg of deionized water.
Solutions A and B were then added to the reaction vessel by conventional controlled double-jet addition. Solution B was continuously added at the flow rates and for the times given below, while maintaining constant vAg and pH in the reaction vessel. After consumption of 97.4% total silver nitrate solution (Solution B), Solution A was replaced with Solution C and the precipitation was continued. Solution B and Solution C were added to the reaction vessel also by conventional controlled double-jet addition, while maintaining constant vAg and pH in the reaction vessel.
The AgBZT/AgT-1 co-precipitated emulsions were washed by conventional ultrafiltration process as described in Research Disclosure, Vol. 131, March 1975, Item 13122. The pH of AgBZT/AgT-1 emulsions was adjusted to 6.0 using 2.0N sulfuric acid. Upon cooling the emulsion solidified and was stored.
Preparation of Ultra-Thin Tabular Grain Silver Halide Emulsion:
A reaction vessel equipped with a stirrer was charged with 6 liters of water containing 2.1 g of deionized oxidized-methionine lime-processed bone gelatin, 3.49 g of sodium bromide, and an antifoamant (at pH=5.8). The solution was held at 39° C. for 5 minutes. Simultaneous additions were then made of 50.6 ml of 0.3 molar silver nitrate and 33.2 ml of 0.448 molar sodium bromide over 1 minute. Following nucleation, 3.0 ml of a 0.1 M solution of sulfuric acid was added. After 1 minute 15.62 g sodium chloride plus 375 mg of sodium thiocyanate were added and the temperature was increased to 54° C. over 9 minutes. After a 5-minute hold, 79.6 g of deionized oxidized-methionine lime-processed bone gelatin in 1.52 liters of water containing additional antifoamant at 54° C. were then added to the reactor. The reactor temperature was held for 7 minutes (pH=5.6).
During the next 36.8 minutes, the first growth stage took place (at 54° C.), in three segments, wherein solutions of 0.3 molar AgNO3, 0.448 molar sodium bromide, and a 0.16 molar suspension of silver iodide (Lippmann) were added to maintain a nominal uniform iodide level of 3.2 mole %. The flow rates during this growth stage were increased from 9 to 42 ml/min (silver nitrate) and from 0.73 to 3.3 ml/min (silver iodide). The flow rates of the sodium bromide were allowed to fluctuate as needed to affect a monotonic pBr shift of 2.45 to 2.12 over the first 12 minutes, of 2.12 to 1.90 over the second 12 minutes, and of 1.90 to 1.67 over the last 12.8 minutes. This was followed by a 1.5-minute hold.
During the next 59 minutes the second growth stage took place (at 54° C.) during which solutions of 2.8 molar silver nitrate, and 3.0 molar sodium bromide, and a 0.16 molar suspension of silver iodide (Lippmann) were added to maintain a nominal iodide level of 3.2 mole %. The flow rates during this segment were increased from 10 to 39.6 ml/min (silver nitrate) and from 5.3 to 22.6 ml/min (silver iodide). The flow rates of the sodium bromide were allowed to fluctuate as needed to affect a monotonic pBr shift of 1.67 to 1.50. This was followed by a 1.5-minute hold.
During the next 34.95 minutes, the third growth stage took place during which solutions of 2.8 molar silver nitrate, 3.0 molar sodium bromide, and a 0.16 molar suspension of silver iodide (Lippmann) were added to maintain a nominal iodide level of 3.2 mole %. The flow rates during this segment were 39.6 ml/min (silver nitrate) and 22.6 ml/min (silver iodide). The temperature was linearly decreased to 35° C. during this segment. At the 23rd minute of this segment a 50 ml aqueous solution containing 0.85 mg of iridium dopant (K2[Ir(5-Br-thiazole)Cl5]) was added. The flow rate of the sodium bromide was allowed to fluctuate to maintain a constant pBr of 1.50.
A total of 8.5 moles of silver iodobromide (3.2% bulk iodide) were formed. The resulting emulsion was washed using ultrafiltration. Deionized lime-processed bone gelatin (326.9 g) was added along with a biocide and pH and pBr were adjusted to 6 and 2.5 respectively.
The resulting emulsion was examined by Scanning Electron Microscopy. Tabular grains accounted for greater than −99% of the total projected area. The mean ECD of the grains was 2.522 μm. The mean tabular thickness was 0.049 μm.
This emulsion was spectrally sensitized with 3.31 mmol of blue sensitizing dye SSD-1 per mole of silver halide. This dye quantity was split 80%/20% with the majority being added before chemical sensitization and the remainder afterwards. Chemical sensitization was carried out using 0.0085 mmol of sulfur sensitizer (compound SS-1a) and 0.00079 mmol per mole of silver halide of gold sensitizer (compound GS-1) at 60° C. for 6.3 minutes.
Preparation of Photothermographic Materials:
Component A: The AgBZT/AgT-1 co-precipitated emulsion prepared above and hydrated gelatin (35% gelatin/65% water) were placed in a beaker and heated to 50° C. for 15 minutes. A 5% aqueous solution of 3-methyl-benzothiazolium iodide was added and the mixture was heated for 15 minutes at 50° C. A 0.73 molar aqueous solution of sodium salt of benzotriazole was added and the mixture was heated for 10 minutes at 50° C. The mixture was cooled to 40° C. and its pH was adjusted to 5.0 with 2.5N sulfuric acid. A 18% aqueous solution of A-1 was added and the mixture was heated for 10 minutes at 40° C. A 4% active aqueous solution of ZONYL® FS-300 surfactant was then added and the mixture was held at 40° C.
Component B: A portion of the ultra-thin tabular grain silver halide emulsion prepared above was placed in a beaker and melted at 40° C.
Component C: A mixture of indicated thermal solvent and xylitol (an additional thermal solvent as noted above) was dissolved in water by heating at 50° C. The dispersions of Compounds D-1 and PS-1 described above were added to the above solution at room temperature.
Component D: A mixture of boric acid and indicated thermal solvent was dissolved in water by heating at 50° C. The solution was cooled to room temperature. A portion of deionized lime-processed gelatin was added to the solution to be hydrated for 30 min. The mixture was heated to 40° C. for 10 minutes to melt. A portion of a dispersion of 6.5 μm polystyrene beads in gelatin was placed in another beaker and heated to 40° C. for 10 minutes to melt. Both melts were combined and the mixture was added a 4% active aqueous solution of ZONYL® FS-300 surfactant.
Component E: A 1.7% aqueous solution of compound VS-1 was prepared by dissolving VS-1 in water at 50° C.
Coating and Evaluation of Photothermographic Materials:
Components A, B, and C were mixed immediately before coating to form a photothermographic emulsion formulation, and components D and E were mixed immediately before coating to form an overcoat formulation. The photothermographic formulation and the overcoat formulation were simultaneously coated as a dual layer on a 7 mil (178 μm) transparent, blue-tinted poly(ethylene terephthalate) film support using a conventional dual-knife coating machine. The coating gaps for both layers were adjusted to achieve the dry coating weights shown in TABLE I. Samples were dried at 120° F. (48.9° C.) for 10 minutes. Inventive Samples 1-2-I and 1-3-I contained Compound TS-1 and Compound TS-16, with dry coating weight shown in TABLE II, respectively. Comparative Sample 1-1-C was also prepared. It contained 1,3-dimethylurea and succinimide as a thermal solvent combination with dry coating weights shown in TABLE II.
The resulting photothermographic films were imaged using a sensitometer equipped with filters to provide an exposure simulating a phosphor emitting at 390 to 395 nm. Exposure was for 1/10 second using a 3000° K. tungsten lamp. Following exposure, the films were developed on a heated flat bed for 18 seconds at 150° C. to generate continuous tone wedges. These samples provided initial Dmin, Dmax, and Relative Speed-2 and are shown in TABLE III.
Densitometry measurements were made on a custom built computer-scanned densitometer meeting ISO Standards 5-2 and 5-3 and are believed to be comparable to measurements from commercially available densitometers. Density of the wedges was measured with above computer densitometer using a filter appropriate to the sensitivity of the photothermographic material to obtain graphs of density versus log exposure (that is, D log E curves). Dmin is the density of the non-exposed areas after development and it is the average of the eight lowest density values. Relative Speed-2 is determined at a density value of 1.00 above Dmin and then normalized against Sample 1-1-C, which contained 1,3-dimethylurea and succinimide as thermal solvents and was assigned a relative speed value of 100.
Dark Stability Test: Imaged and processed samples of each film were illuminated with 100 foot-candles (1076 lux) at 70° F. (21.2° C.) and 50% relative humidity (RH) for 2 hours. The test samples were then packaged in an aluminum envelope at 70° F. (21.2° C.) and 50% Relative Humidity (RH) and heat-sealed. The envelope was placed in an oven at 120° F. (49° C.) and 50% RH for 24 hours. The change in Dmin (ΔDmin) was calculated by subtracting the Dmin of the initial sample from the Dmin of sample after testing. The Dmin of each sample was measured at visual and blue density both before and after testing using an X-Rite® Model 301 densitometer (X-Rite Inc. Grandville, Mich.) equipped with a visible filter having a transmittance peak at about 530 nm and a blue filter having a transmittance peak at about 440 nm. The change in visual density (Δvis) and blue density (Δblue) were calculated by subtracting the Dmin of the initial sample from the Dmin of sample after being subjected to the Dark Stability Test and are shown in TABLE III.
Accelerated Aging Test: Samples of unprocessed film were packaged in a black polyethylene bag and placed in an oven at 120° F. (49° C.) and 50% RH for 3 days. The film was cooled to room temperature and then imaged and processed as described above to obtain Dmin, Dmax, and Relative Speed-2. The change in Dmin (ΔDmin) was calculated by subtracting the initial Dmin from the Dmin of the sample after accelerated aging. The results are shown in TABLE IV.
Nature Age Keeping (NAK) Test: The unprocessed film was packaged in a black polyethylene bag and stored under ambient conditions for 10 weeks. The film was imaged and processed as described above to obtain Dmin, Dmax, and Relative Speed-2. The change in Dmin (ΔDmin) was calculated by subtracting the initial Dmin from the Dmin of the sample after Natural Age Keeping. The results are shown in TABLE IV.
The results, shown below in TABLES III and IV, demonstrate that replacing the thermal solvent combination of 1,3-dimethylurea and succinimide by thermal solvents of the present invention (compounds TS-1 and TS-16) afforded similar initial sensitometry. Additionally, both inventive compounds afforded substantial improvement on sensitometry after either accelerated aging or Natural Age Keeping. Both inventive samples retained more speed and Dmax after accelerated aging, and both inventive samples showed less increase in Dmin and better speed retention after Natural Age Keeping than Comparative Sample 1-1-C. Furthermore, Compound TS-1 showed significantly improved Dark Stability with less change in Δ(vis) and Δ(blue).
Preparation of Thermal Solvent Dispersions:
A solid particle dispersion of thermal solvent compound was prepared by combining 20 weight % of the indicated thermal solvent compound, 2 weight % of SPP 3000 poly(vinyl alcohol), and 78 weight % of deionized water. The mixture was milled using a micro media mill with 0.7 mm zirconium silicate ceramic beads for 90 minutes at 2000 rpm. This mill is described in U.S. Pat. No. 5,593,097 (Corbin) incorporated herein by reference. Filtration to remove the beads gave an aqueous dispersion containing 20% of the thermal solvent compound.
Preparation of Photothermographic Materials:
Components A, B, and E: Components A, B, and E were prepared as described in Example 1.
Component C: For thermal solvent compounds tested as a dispersion, Component C was prepared as following. Xylitol (an additional thermal solvent) was dissolved in water by heating at 50° C. Dispersions of Compounds D-1, PS-1, and thermal solvent compound were added to the above solution at room temperature. For other thermal solvent compounds, Component C was prepared as described in Example 1.
Component D: For dispersions of thermal solvent compound, Component D was prepared by dissolving boric acid in water by heating at 50° C. The solution was cooled to room temperature. A portion of deionized lime-processed gelatin was added to the solution to be hydrated for 30 min. The mixture was heated to 40° C. for 10 minutes to melt the gelatin. A portion of a dispersion of 6.5 μm polystyrene beads in gelatin was placed in another beaker and heated to 40° C. for 10 minutes to melt the gelatin. Both melts were combined and the mixture was added a 4% active aqueous solution of ZONYL® FS-300 surfactant and the thermal solvent dispersion described above. For soluble thermal solvent compounds, Component D was prepared as described in Example 1.
Coating and Evaluation of Photothermographic Materials:
The components were coated and dried as described in Example 1 to give an imaging layer with the dry composition shown in TABLES V and VI. The resulting photothermographic films were imaged, developed, and evaluated in a manner similar to that described in Example 1. Comparative Samples 2-1-C and 2-2-C were also prepared. Comparative Sample 2-1-C contained 1,3-dimethylurea and succinimide as a thermal solvent combination with dry coating weights shown in TABLE VI. Comparative Sample 2-2-C contained only xylitol and no other thermal solvents.
Dark Stability Test: Imaged and processed samples of each film were illuminated with 100 foot-candles (1076 lux) at 70° F. (21.2° C.) and 50% relative humidity (RH) for 2 hours, The test samples were then packaged in an aluminum envelope at 70° F. (21.2° C.) and 50% relative humidity (RH) and heat sealed. The envelope was placed in a 120° F. (49° C.) and 50% RH oven for 48 hours. The samples were then evaluated as described in Example 1.
The sensitometry and dark stability results, shown below in TABLES VII and VIII, demonstrate that samples containing thermal solvents of the present invention showed much improved sensitometric properties, such as higher Dmax and faster relative speed when compared with Sample 2-2-C which contained no thermal solvent. Samples containing inventive thermal solvent compounds TS-1, TS-12, TS-18, and TS-21 showed improved dark stability with less increase in Dmin than Sample 2-2-C after 48-hours of dark stability testing.
The advantage of the thermal solvent compounds of the present invention is further emphasized by comparing Sample 2-3-I containing Compound TS-1 with Comparative Sample 2-1-C which contained 1,3-dimethylurea and succinimide as a thermal solvent combination. Inventive compound TS-1 not only afforded similar initial sensitometry, but also showed less loss of Dmax and relative speed after accelerated aging, showed less increase in Dmin and better speed retention after Natural Age Keeping, and had much improved dark stability after 48 hours of dark stability testing.
Preparation of Monopalmitin-Stabilized Dispersions of Compound D-1:
Aqueous dispersions were prepared containing Compound D-1, CELVOL® 203S poly(vinyl alcohol), TRITON® X-114 surfactant, monopalmitin, and BYK-022. The poly(vinyl alcohol), TRITON® X-114 surfactant, monopalmitin, and BYK-022 were added at a level of 10.0%, 3.0%, 2.0%, and 0.1% by weight to that of Compound D-1, respectively. The mixture was milled with 0.7 mm zirconium silicate ceramic beads for about 7 hours. Filtration to remove the beads, followed by examination of the final dispersion by transmitted light microscopy at 1000× magnification, showed an average particle size of 0.36 μm with 30.46% of Compound D-1.
Preparation of Thermal Solvent Dispersions:
A solid particle dispersion of thermal solvent compound was prepared by combining 15.0% indicated thermal solvent compound, 1.5% SPP 3000 poly(vinyl alcohol), and 83.5% deionized water by weight, respectively. The mixture was milled using a micro media mill with 0.7 mm zirconium silicate ceramic beads for 90 minutes at 2000 rpm. This mill is described in U.S. Pat. No. 5,593,097 (Corbin) incorporated herein by reference. Filtration to remove the beads gave an aqueous dispersion containing 15% thermal solvent compound.
Preparation of Photothermographic Materials:
Components A and E: Components A and E were prepared as described in Example 1.
Component B: A portion of the ultra-thin tabular grain silver halide emulsion prepared in Example 1 was placed in a beaker and melted at 40° C. A 0.0199% solution of Compound S-1 was added to the melt and the mixture was kept at 40° C. for 2 hours.
Component C: For thermal solvent compound tested as dispersion, Component C was prepared by dissolving xylitol (an additional thermal solvent) in water by heating at 50° C. The monopalmitin-stabilized dispersion of Compound D-1 and the dispersions of Compound PS-1 and thermal solvent described above were added to the xylitol solution at room temperature. For soluble thermal solvent compounds, Component C was prepared by dissolving a mixture of indicated thermal solvent and xylitol in water by heating at 50° C. The monopalmitin-stabilized dispersion of Compound D-1 and the dispersion of Compound PS-1 described above were added to that solution at room temperature.
Component D: A mixture of 5-bromo-4-hydroxy-6-methyl-1,3,3a,7-tetraazaindene, water, and 2.5N NaOH was placed in a beaker and heated to 50° C. to dissolve the materials and form Compound TAI-1. A mixture of boric acid and the indicated thermal solvent was dissolved in water by heating at 50° C. The solution was cooled to room temperature and a portion of deionized lime-processed gelatin was added to the solution to be hydrated for 30 minutes. The mixture was heated to 40° C. for 10 minutes to melt the gelatin. A portion of a dispersion of 6.5 μm polystyrene beads in gelatin was placed in another beaker and heated to 40° C. for 10 minutes to melt the gelatin. The two gelatin containing subcomponents were combined and the mixture was added a 4% active aqueous solution of ZONYL® FS-300 surfactant and a portion of the Compound TAI-1 solution described above.
Coating and Evaluation of Photothermographic Materials:
The components were coated and dried as described in Example 1 to give the imaging layer with the dry compositions shown in TABLES IX and X. The resulting photothermographic films were imaged, developed, and evaluated in a manner similar to that described in Example 2. Comparative Sample 3-1-C was also prepared. It contained 1,3-dimethylurea and succinimide as a thermal solvent combination and had the dry composition shown in TABLES IX and X.
The results, shown below in TABLES XI and XII, demonstrate that even in the presence of Compound TAI-1, a compound known to improve the dark stability of photothermographic materials, inventive Compounds TS-1 to TS-14 provide further improvement in dark stability than Comparative Sample 3-1-C which contained a combination of known thermal solvents 1,3-dimethylurea and succinimide. Furthermore, inventive thermal solvent Compounds TS-1 to TS-10, TS-17, and TS-20 provided better retention of Dmax and relative speed after accelerated aging than the samples containing a combination of known thermal solvents 1,3-dimethylurea and succinimide.
Preparation of Photothermographic Materials:
Components A, B, and E were prepared as described in Example 1. Components C and D were prepared as described in Example 3. Comparative Sample 4-1-C, was also prepared. It contained succinimide as a thermal solvent. All thermal solvent compounds were added as a solution.
The components were coated and dried as described in Example 1 to give an imaging layer with the dry composition shown in TABLES XIII and XIV. The resulting photothermographic films were imaged, developed, and evaluated in a manner similar to that described in Example 2.
The results, shown below in TABLE XV demonstrate the thermal solvent compounds of the present invention afforded similar initial sensitometry as Comparative Sample 4-1-C containing succinimide as thermal solvent while providing less loss in Dmax after accelerated aging.
All samples were prepared, coated, and dried as described in Example 3 to give an imaging layer with the dry composition shown in TABLES XVI and XVII.
The resulting photothermographic films were imaged, developed, and evaluated in a manner similar to that described in Example 3.
The results, shown below in TABLES XVIII and XIX, demonstrate that inventive compounds TS-2 and TS-5 are capable of serving as the sole thermal solvent and provide excellent sensitometry and dark stability. Dark stability was progressively improved using the thermal solvent compounds of the present invention to replace not only 1,3-dimthylurea (compare Sample 5-1-C with Samples 5-2-C and 5-4-C), but also xylitol and succinimide (compare Sample 5-3-I with Sample 5-2-C and Sample 5-5-I with Sample 5-4-C). These replacements provided similar initial speed and excellent retention of sensitometric properties after accelerated aging.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
