Nanopastes for use as patterning compositions
View Patent ↗The present invention provides a patterned substrate and methods of forming patterns on a substrate, in which a thermally sensitive composition composed of an inorganic nanopaste is applied onto a surface of a substrate to form a layer. The layer may be imaged and developed to form a pattern area that adheres to the surface of the substrate. The patterned substrate may be used in the production of printing plates and masks.
1. A mask or printing plate precursor comprising:
a substrate; and
a thermally sensitive composition comprising metal nanoparticles applied as a layer on at least a portion of the substrate, wherein upon imagewise exposure to thermal radiation, exposed portions of the thermally sensitive composition have a different solubility in a developer than unexposed portions of the composition.
2. The mask or printing plate precursor of claim 1 wherein the substrate comprises a metal, polymeric material, ceramic, stiff paper, or a laminate.
3. The mask or printing plate precursor of claim 1 wherein the substrate comprises aluminum.
4. The mask or printing plate precursor of 1 wherein the substrate comprises a transparent material.
5. The mask or printing plate precursor of claim 1 wherein the substrate comprises polyester.
6. The mask or printing plate precursor of claim 1 wherein the substrate comprises a flexographic printing element.
7. The mask or printing plate precursor of claim 1 wherein the substrate comprises a photopolymerisable layer.
8. The mask or printing plate precursor of claim 1 wherein the substrate is oleophilic.
9. The mask or printing plate precursor of claim 1 wherein the substrate is hydrophilic.
10. The mask or printing plate precursor of claim 1 wherein the metal nanoparticles comprise silver, palladium or a mixture of silver and palladium.
11. The mask or printing plate precursor of claim 1 wherein the metal nanoparticles comprise copper, gold, platinum, nickel or combinations thereof.
12. The mask or printing plate precursor of claim 1 wherein the metal nanoparticles have an average diameter of less than about 50 nm.
13. The mask or printing plate precursor of claim 1 wherein the metal nanoparticles have an average diameter of less than about 25 nm.
14. The mask or printing plate precursor of claim 1 wherein the metal nanoparticles have an average diameter of less than about 15 nm.
15. The mask or printing plate precursor of claim 1 wherein the metal nanoparticles have an average diameter of less than about 10 nm.
16. The mask or printing plate precursor of claim 1 wherein the thermally sensitive composition further comprises a dispersing agent.
17. The mask or printing plate precursor of claim 16 wherein the dispersing agent comprises a surfactant.
18. The mask or printing plate precursor of claim 17 wherein the surfactant is a cationic, anionic or amphoteric surfactant.
19. The mask or printing plate precursor of claim 17 wherein the surfactant is a non-ionic surfactant.
20. The mask or printing plate precursor of claim 17 wherein the surfactant comprises a perfluoroalkyl, alkylphenyl, or polysiloxane surfactant.
21. The mask or printing plate precursor of claim 17 wherein the surfactant comprises a polysiloxane polyether, polysiloxane copolymer, alkyl-aryl modified methyl-polysiloxane or acylated polysiloxane.
22. The mask or printing late precursor of claim 17 wherein the surfactant comprises sorbitan tristearate, sorbitan monopalmitate, sorbitan triolate, monoglyceride stearate or polyoxyethylene nonylphenyl ether.
23. The mask or printing plate precursor of claim 17 wherein the surfactant comprises alkyl di (aminoethyl) glycine, alkyl polyaminoethylglycine hydrochloride, 2-alkyl-n-carboxyethyl-N-hydroxyethyl imidazo inium betaine, or N-tetradecyl-N, N-substituted betaine.
24. The mask or printing plate precursor of claim 16 wherein the thermally sensitive composition comprises between about 0.05 to about 15.0 w/w % dispersing agent.
25. The mask or printing plate precursor of claim 16 wherein the thermally sensitive composition comprises between about 0.1 to about 5.0 w/w % dispersing agent.
26. The mask or printing plate precursor of claim 1 wherein the thermally sensitive composition comprises a radiation absorber.
27. The mask or printing plate precursor of claim 26 wherein the thermally sensitive composition comprises between about 0.25% to about 25 w/w % radiation absorber.
28. The mask or printing plate precursor of claim 26 wherein the radiation absorber is a dye.
29. The mask or printing plate precursor of claim 28 wherein the thermally sensitive comprises between about 0.25% to about 15 w/w % dye.
30. The mask or printing plate precursor of claim 26 wherein the radiation absorber is a pigment.
31. The mask or printing plate precursor of claim 30 wherein the thermally sensitive composition comprises between about 5% to about 25 w/w % pigment.
32. The mask or printing plate precursor of claim 26 wherein the radiation absorber comprises the structure:
33. The mask or printing plate precursor of claim 1 wherein the thermally sensitive composition further comprises a binder.
34. The mask or printing plate precursor of claim 33 wherein the binder is soluble or dispersible in substantially organic carriers.
35. The mask or printing plate precursor of claim 33 wherein the binder is soluble or dispersible in substantially aqueous carriers.
36. The mask or printing plate precursor of claim 33 wherein the binder comprises epoxy resin, modified epoxy resin, polyester resin, novolak resin, cellulose resin, copolymers of vinylidene chloride and acrylonitrile, acrylic resin, polyvinyl resin, silicone resin, polyamide resin, vinyl alcohol resin, resol resin, acetal resin, polyacrylonitrile resin, formaldehyde resin, polycarbonate resin, polyimide resin, or copolymers or derivatives thereof.
37. The mask or printing plate precursor of claim 33 wherein the binder comprises polyvinylpyrrolidone, polyvinyl alcohol, polyvinylimidazole, acrylic acid polymers, polyethyleneimine, poly(ethyloxazoline), gelatin, starches, dextrin, amylogen, gum arabic, agar, algin, carrageenan, fucoidan, laminaran, corn hull gum, gum ghatti, karaya gum, locust bean gum, pectin, guar gum, hydroxypropylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose or carboxymethylcellulose.
38. The mask or printing plate precursor of claim 1 wherein the thermally sensitive composition is free of binders.
39. The mask or printing plate precursor of claim 1 wherein the thermally sensitive composition further comprises a humectant, biocide, viscosity builder, colorant, pH adjuster, drying agent, defoamer or a combination thereof.
40. A mask or printing plate comprising:
a substrate; and
an image area comprising metal nanoparticles adhered to a surface of the substrate.
41. The mask or printing plate of claim 40 wherein portions of the image area are hydrophilic.
42. The mask or printing plate of claim 40 wherein portions of the image area are oleophilic.
43. The mask or printing plate of claim 40 wherein portions of the image area are radiation opaque.
44. The mask or printing plate of claim 43 wherein the portions of the image area that are radiation opaque have an optical density of at least about 2.0.
45. The mask or printing plate of claim 43 wherein the portions of the image area that are radiation opaque have an optical density of greater than about 2.5.
46. The mask or printing plate of claim 43 wherein the portions of the image area that are radiation opaque have an optical density between about 2.5 and about 3.0.
47. A method for forming an image on a substrate comprising:
providing a substrate;
applying onto a surface of the substrate a thermally sensitive composition comprising a nanopaste, which comprises metal nanoparticles and a carrier;
treating the thermally sensitive composition to form a layer that adheres to the surface of the substrate;
imagewise exposing the layer to radiation to affect the solubility of exposed portions of the layer relative to unexposed portions of the layer; and
developing the layer to remove the exposed or unexposed portions of the layer to form an image area.
48. The method of claim 47 wherein the carrier is a substantially aqueous carrier.
49. The method of claim 47 wherein the carrier is a substantially organic carrier.
50. The method of claim 47 wherein the carrier consists essentially of water.
51. The method of claim 47 wherein the substantially aqueous carrier consists essentially of a mixture of water and a water-miscible organic liquid.
52. The method of claim 51 wherein the water-miscible liquid consists essentially of an alcohol.
53. The method of claim 47 wherein the nanopaste comprises metal nanoparticles and a substantially aqueous solution.
54. The method of claim 47 wherein the nanopaste comprises between about 0.5 and about 75 w/w % metal nanoparticles.
55. The method of claim 47 wherein the nanopaste comprises between about 0.5 and about 25 w/w % metal nanoparticles.
56. The method of claim 47 wherein the nanopaste comprises between about 0.5 and about 10 w/w % metal nanoparticles.
57. The method of claim 47 wherein the nanopaste comprises a dispersing agent.
58. The method of claim 47 wherein the thermally sensitive composition is free of binders.
59. The method of claim 47 wherein the treating step comprises air drying the layer.
60. The method of claim 47 wherein the treating step comprises oven drying the layer.
61. The method of claim 47 wherein the treating step comprises air drying and oven drying the layer.
62. The method of claim 47 further comprising heating the layer.
63. The method of claim 62 wherein heating the layer comprises heating the layer to between about 50 and 300° C.
64. The method of claim 62 wherein heating the layer comprises heating the layer to between about 50 and 150° C.
65. The method of claim 62 wherein heating the layer comprises heating the layer to about 80° C.
66. The method of claim 47 comprising enhancing the ink-receptiveness of the image area.
67. The method of claim 47 comprising applying a conditioner to the image area to enhance the ink-receptiveness of the image area.
68. The method of claim 47 wherein the conditioner comprises water, Ethoquad C25, phenylmercaptotetrazole, cetyltrimethyl ammonium bromide, sodium ferric EDTA, potassium iodide, potassium thiocyanate, acetic acid, and sodium acetate.
69. The method of claim 47 wherein exposing the layer to radiation comprises exposing the layer to IR radiation.
70. The method of claim 47 wherein developing the layer comprises developing the layer in an alkaline solution.
71. A method of forming an image on a substrate comprising:
providing a substrate;
applying onto a surface of the substrate a thermally sensitive composition comprising an inorganic nanopaste, which consists essentially of metal nanoparticles and a substantially aqueous caner;
treating the thermally sensitive composition to form a layer that adheres to the surface of the substrate;
imagewise exposing the layer to radiation to affect the solubility of exposed portions of the layer relative to unexposed portions of the layer; and
developing the layer to remove the exposed or unexposed portions of the layer to form an image area.
72. A method of making a printing plate precursor comprising:
providing a substrate;
applying onto a surface of the substrate a thermally sensitive composition comprising a nanopaste, comprising metal nanoparticles and a carrier;
treating the thermally sensitive composition to form a layer that adheres to the surface of die substrate.
73. The method of claim 72 wherein the carrier comprises a substantially aqueous carrier.
74. The method of claim 72 wherein the thermally sensitive composition is free of binders.
75. The method of claim 72 further comprising imagewise exposing the layer to radiation to affect the solubility of exposed portions of the layer relative to unexposed portions of the layer; and
developing the layer to remove the exposed or unexposed portions of the layer to form an image area.
76. The method of claim 72 wherein treating the thermally sensitive composition comprises air drying the thermally sensitive composition.
77. The method of claim 72 wherein treating the thermally sensitive composition comprises oven drying the thermally sensitive composition.
78. The method of claim 72 wherein thermally sensitive composition further comprises a radiation absorber.
79. The method of claim 72 further comprising applying a conditioner to the image area to enhance the ink-receptiveness of a portion of the image area.
80. The method of claim 72 wherein the condition comprises water, Ethoquad C25, phenylmercaptotetrazole, cetyltrimethyl ammonium bromide, sodium ferric EDTA, potassium iodide, potassium thiocyanate, acetic acid, and sodium acetate.
81. A method of making a mask precursor comprising:
providing a substrate;
applying onto a surface of the substrate a thermally sensitive composition comprising a nanopaste, which comprises metal nanoparticles and a carrier; and
treating the thermally sensitive composition to form a layer on at least a portion of the surface.
82. The method of claim 81 wherein the carrier comprises a substantially aqueous carrier.
83. The method of claim 81 wherein the thermally sensitive composition is free of binders.
84. The method of claim 81 further comprising imagewise exposing the layer to radiation to affect the solubility of exposed portions of the layer relative to unexposed portions of the layer; and
developing the layer to remove the exposed or unexposed portions of the layer to form a radiation opaque image area.
85. The method of claim 84 wherein the radiation opaque image area has an optical density of at least about 2.0.
86. The method of claim 84 wherein the radiation opaque image area has an optical density of greater than about 2.5.
87. The method of claim 84 wherein the radiation opaque image area has an optical density between about 2.5 and about 3.0.