Field of the invention
[0001] The present invention relates to a photothermographic recording material comprising
photosensitive silver halide spectrally sensitized with specific dyes and a recording
process therefor.
Background of the invention
[0002] Thermal imaging or thermography is a recording process wherein images are generated
by the use of imagewise modulated thermal energy.
[0003] In thermography three approaches are known:
1. Direct thermal formation of a visible image pattern by imagewise heating of a recording
material containing matter that by chemical or physical process changes colour or
optical density.
2. Imagewise transfer of an ingredient necessary for the chemical or physical process
bringing about changes in colour or optical density to a receptor element.
3. Thermal dye transfer printing wherein a visible image pattern is formed by transfer
of a coloured species from an imagewise heated donor element onto a receptor element.
[0004] Thermographic materials of type 1 become photothermographic when a photosensitive
agent is present which after exposure to UV, visible or IR light is capable of catalyzing
or participating in a thermographic process bringing about changes in colour or optical
density.
[0005] Examples of photothermographic materials are the so called "Dry Silver" photographic
materials of the 3M Company, which are reviewed by D.A. Morgan in "Handbook of Imaging
Science", edited by A.R. Diamond, page 43, published by Marcel Dekker in 1991.
[0006] The most widely used radiation-sensitive salt in such materials is silver halide,
which must be present in catalytic association with the organic silver salt so that
the species formed on exposure can catalyze the thermal image forming process. Silver
halide requires spectral sensitization with dyes to extend its sensitivity range into
the infrared region of actinic radiation.
[0007] Different classes of benzoxazole, benzothiazole and benzoselenazole cyanine spectral
sensitizers have been disclosed for use in infrared-sensitive photothermographic materials
on the basis of organic silver salts/silver halide/reducing agent-systems: US-P 4,835,096
discloses a photothermographic element characterised in that it contains as a sensitizer
a dye of the general formula:

wherein R
1 represents a lower alkyl group of from 1 to 5 carbon atoms and X
- represents an anion; JN03-163440A discloses a heat developing photosensitive element
comprising at least one sensitizing dye of formula (I):

wherein Z
1 and Z
2 are each S, O or Se; R
1 = H, alkyl, alkoxy; R
2 = carboxyalkyl or - (CH
2)
nCOOH; n= 1 to 4; and X = Cl, Br or I; US-P 5,441,866 discloses a heat-developable
photothermographic element comprising a preferably hydrophobic binder, supersensitizer
and a spectrally sensitizing amount of an infrared absorbing dye having the central
nucleus:

wherein R
1 represents a (CH
2)
n-COO
- group of from 1-20 carbon atoms, or an alkyl group of from 1 to 20 carbon atoms;
and n is an integer from 1 to 20; and EP-A 616 014 discloses a heptamethine cyanine
dye characterised in that both nitrogen atoms of the cyanine chromophore bear a 5
carboxyalkyl substituent comprising an alkyl chain of at least five carbon atoms,
which may be used in conjunction with supersensitizers such as 2-mercaptobenzimidazoles,
metal chelating agents and pyridine, pyrimidine and triazine derivatives. The detailed
descriptions and invention examples of all this patents are confined to photo-addressable
thermally developable elements coated from non-aqueous media.
[0008] There are no indications in these patents regarding the applicability of the particular
inventions described therein to photothermographic recording materials comprising
a photo-addressable thermally developable elements coated from an aqueous medium.
[0009] This reflects the standard teaching over such photothermographic materials based
on a substantially light-insensitive organic silver salt, photosensitive silver halide
in intimate catalytic association with the organic silver salt and a reducing agent
for the organic silver salt, which is that such materials are coated from non-aqueous
media. It is however, for economic, safety and ecological reasons, desirable to coat
such materials from aqueous media.
[0010] The production methods in accordance with the standard teaching are very inefficient,
requiring investment in explosion-prevention production infrastructure and infrastructure
for solvent recovery and the expenditure of energy in several drying processes, and
are ecologically unsound. It is, therefore, desirable to develop an alternative material
technology in which coating from solvent media is replaced by coating from aqueous
media.
[0011] However, the inventors' investigations into the spectral sensitization of photothermographic
materials based on organic silver salts/silver halide/reducing agent-systems coated
from aqueous media have shown that materials technology developed for such materials
coated from non-aqueous media cannot be readily extrapolated to such materials coated
from aqueous media.
[0012] Furthermore, all the IR-spectral sensitizers disclosed for the spectral sensitization
of such photothermographic materials require the presence of a supersensitizer in
concentrations of between 3 and 50 moles/mole spectral sensitizer to exhibit acceptable
spectral sensitization. The presence of an extra ingredient in such large quantities
is disadvantageous both from an economic standpoint and from the danger of interference
with functional ingredients.
Objects of the invention.
[0013] It is a first object of the invention to provide a photothermographic recording material
comprising a photo-addressable thermally developable element with a high infra-red
sensitivity and excellent image-forming properties, which can be coated from aqueous
media.
[0014] It is a second object of the invention to provide an infra-red spectral sensitizer
which can efficiently sensitize a photo-addressable thermally developable element
in the absence of a supersensitizer.
[0015] Further objects and advantages of the invention will become apparent from the description
hereinafter.
Summary of the invention
[0016] According to the present invention, a photothermographic material is provided comprising
a photo-addressable thermally developable element containing a substantially light-insensitive
organic silver salt, a reducing agent therefor in thermal working relationship therewith,
photosensitive silver halide spectrally sensitized to wavelengths > 700nm with a dye
and in catalytic association with the substantially light-insensitive organic silver
salt and a water-soluble binder, a water-dispersible binder or a mixture of a water-soluble
and a water-dispersible binder, characterized in that the photothermographic recording
material has an infra-red sensitivity of less than 80J/m
2 and the dye satisfies the following test: an exposure required by a photothermographic
recording material A, consisting of a polyester 100µm thick support provided with
a photo-addressable thermally developable element produced as described in the description
and including the dye and a compound corresponding to the formula

is > 90% of an exposure required by a photothermographic recording material B produced
as described for the photothermographic recording material A except that the compound
is omitted, the exposure of the materials A and B being that required to obtain an
optical density in an exposed part thereof 0.5 higher than in an non-exposed part
thereof when exposed to infra-red light to which it is sensitive and heating with
a heat source at 105°C for 15s with the polyester support thereof in contact with
the heat source.
[0017] According to the present invention, a process is also provided for producing a photothermographic
recording material, as referred to above, comprising the steps of: (i) producing an
aqueous dispersion or aqueous dispersions containing the substantially light-insensitive
organic silver salt, the photosensitive silver halide spectrally sensitized to infra-red
light with the dye, the reducing agent and the water-soluble binder, water-dispersible
binder or mixture of a water-soluble and a water-dispersible binder; (ii) coating
the aqueous dispersion or aqueous dispersions onto a support.
[0018] The term infra-red light for the purposes of the present invention means light with
a wavelength in the range from 700nm to 1000µm.
[0019] Preferred embodiments of the invention are disclosed in the dependent claims.
Detailed description of the invention.
Aqueous
[0020] The term aqueous for the purposes of the present invention includes mixtures of water
with water-miscible organic solvents such as alcohols e.g. methanol, ethanol, 2-propanol,
butanol, iso-amyl alcohol, octanol, cetyl alcohol etc; glycols e.g. ethylene glycol;
glycerine; N-methyl pyrrolidone; methoxypropanol; and ketones e.g. 2-propanone and
2-butanone etc.
IR-spectrally sensitizing dyes
[0021] According to the present invention the photo-addressable thermally developable element
comprises a dye satisfying the following test: an exposure required by a photothermographic
recording material A, consisting of a polyester 100µm thick support provided with
a photo-addressable thermally developable element produced as described in the description
and comprising the dye and a compound corresponding to the formula

is > 90% of an exposure required by a photothermographic recording material B produced
as described for the photothermographic recording material A except that the compound
is omitted, the exposure of the materials A and B being that required to obtain an
optical density in an exposed part thereof 0.5 higher than in an non-exposed part
thereof when exposed to infra-red light to which it is sensitive and heating with
a heat source at 105°C for 15s with the polyester support thereof in contact with
the heat source.
[0022] The dilithium salt of 2,2'-disulfo-4,4'-bis[2-{4,6-bis(2-oxynaphtho)}-triazino]-aminostilbene
was chosen as the supersensitizer for the above-mentioned test because it had been
found to be an efficient supersensitizer for photothermographic recording materials
comprising a photo-addressable thermally developable element coated from aqueous media
as is disclosed by the inventors in a copending European Patent Application and can
be seen from the comparative examples.
[0023] The photo-addressable thermally developable element utilized in the above-described
test is produced as follows:
i) a coating dispersion is produced by adding with stirring the following ingredients
to a stabilized aqueous dispersion of finely divided silver behenate at a pH of 6.5:
* 3-(triphenyl-phosphonium)propionic acid bromide in a quantity corresponding to 8mol%
with respect to the silver behenate in the dispersion as an aqueous solution with
a pH of 4 followed by at least 10 minutes stirring:
* the dilithium salt of 2,2'-disulfo-4,4'-bis[2-{4,6-bis(2-oxy-naphtho)}-triazino]-aminostilbene
corresponding to the formula

if appropriate, as a solution in methanol;
* the dye as a solution or dispersion in water and/or methanol followed by at least
15 minutes stirring;
* a film-forming non-proteinaceous binder in a quantity equal in weight to the silver
behenate in the dispersion as an aqueous solution or dispersion with a pH of 4; and
* 3-(3',4'-dihydroxyphenyl)propionic acid in a quantity of 40mol% with respect to
the silver behenate in the dispersion as an aqueous solution;
ii) the dispersion is then coated onto a subbed 100µm thick polyethylene terephthalate
support and dried to yield a coating weight of silver behenate of appoximately 4.5g/m2.
[0024] In a preferred embodiment of the present invention the photothermographic recording
material has an infra-red sensitivity of less than 20J/m
2 and in a particularly preferred embodiment of the present invention the photothermographic
recording material has an infrared sensitivity of less than 8J/m
2.
[0025] In a preferred embodiment of the photothermographic recording material of the present
invention, the dye is a merocyanine dye and in a further preferred embodiment of the
photothermographic recording material of the present invention, the dye is a heptamethine
cyanine dye.
[0026] In a particularly preferred embodiment of the photothermographic recording material
of the present invention, the dye corresponds to the general formula (I):

with an anion if necessary for charge compensation, wherein Z
1 and Z
2 independently represent S, O or Se; R
1 and R
17 are independently each an alkyl which may be substituted with at least one fluorine,
chlorine, bromine, iodine or an aryloxy-, alkoxy-, -(C=O)-R, -(S=O)-R' or -(SO
2)-R' group, where R is an alkoxy, aryloxy, amino or substituted amino group and R'
is a hydroxy, mercapto, alkoxy, aryloxy, amino or substituted amino group; R
2, R
3, R
4, R
5, R
13, R
14, R
15 and R
16 are independently each hydrogen, chlorine, bromine, fluorine or a keto-, sulfo-,
carboxy-, ester-, sulfonamide-, amidedialkylamino-, nitro-, cyano-, alkyl-, alkenyl-,
hetero-aromatic, aryl-, alkoxy- or aryloxy-group, which groups may be substituted;
or each of R
2 together with R
3, R
3 together with R
4, R
4 together with R
5, R
13 together with R
14, R
14 together with R
15 and R
15 together with R
16 may independently constitute the atoms necessary to complete a benzene ring which
may be substituted; R
6, R
7, R
8, R
9, R
10, R
11 and R
12 independently represent hydrogen, an alkyl group, a substituted alkyl group, an alkoxy
group, an aryloxy group, a thioalkyl group, a thioaryl group, chlorine, fluorine,
bromine, iodine, a disubstituted amino group, wherein the substituents may constitute
the atoms necessary to complete a 5-ring atom or 6-ring atom heterocyclic ring, or
each of R
6 together with R
8, R
8 together with R
10, R
1° together with R
12, R
7 together with R
9 and R
9 together with R
11 may independently constitute the atoms necessary to complete a 5-atom or 6-atom carbocyclic
or heterocyclic ring which may be substituted; and each of R
1 together with R
6 and R
12 together with R
17 may independently constitute the atoms necessary to complete a 5-atom or 6-atom heterocyclic
ring which may be substituted. In the case that the R group in the -(C=O)-R group
or R' group in the -(S=O)-R' and -(SO
2)-R' groups represents a substituted amino group, this includes all possible substitutions
of the amino group, including thereby, -NH-(C=O)-R'', -NH-(SO
2)-R''. -NH-(S=O)-R'', -N
--CN, -N
--(C=O)-R'', -N
--(SO
2)-R'', -N
--(S=O)-R'' and -N
--CN groups where R'' is an alkyl or aryl group which may be substituted.
[0027] In an especially preferred embodiment of the present invention the dye corresponds
to the formula

[0028] In a further especially preferred embodiment of the present invention the dye corresponds
to the formula

[0029] In a yet further especially preferred embodiment of the present invention the dye
corresponds to the formula

[0030] In a yet further especially preferred embodiment of the present invention the dye
corresponds to the formula

[0032] SENSI 01 was synthesized as described in INVENTION EXAMPLE 1. Similar synthetic techniques
to those described in INVENTION EXAMPLE 1 and those described in F.M. Hamer, "The
Cyanine Dyes and Related Compounds", Interscience Publishers, New York (1964) can
be used to synthesize other IR-sensitizing dyes used according to the present invention.
[0033] The sensitivity of the photothermographic recording materials comprising IR-sensitizing
dyes used according to the present invention will depend upon the choice of IR-sensitizing
dye, the concentration thereof, the way in which the IR-sensitizing dye is incorporated
and the exact composition of the photothermographic recording material.
Photo-addressable thermally developable element
[0034] The photo-addressable thermally developable element, used according to the present
invention, comprises a substantially light-insensitive organic silver salt, photosensitive
silver halide in catalytic association therewith and an organic reducing agent in
thermal working relationship with the substantially light-insensitive organic silver
salt and a water soluble or water-dispersible binder. The element may comprise a layer
system with the silver halide in catalytic association with the substantially light-insensitive
organic silver salt, spectral sensitizer optionally together with a supersensitizer
in sensitizing association with the silver halide particles and the other ingredients
active in the thermal development process or pre- or post-development stabilization
of the element being in the same layer or in other layers with the proviso that the
organic reducing agent and the toning agent, if present, are in thermal working relationship
with the substantially light-insensitive organic silver salt i.e. during the thermal
development process the reducing agent and the toning agent, if present, are able
to diffuse to the substantially light-insensitive organic silver salt.
Substantially light-insensitive organic silver salts
[0035] Preferred substantially light-insensitive organic silver salts used according to
the present invention are silver salts of organic carboxylic acids in particular aliphatic
carboxylic acids known as fatty acids, wherein the aliphatic carbon chain has preferably
at least 12 C-atoms, e.g. silver laurate, silver palmitate, silver stearate, silver
hydroxystearate, silver oleate and silver behenate, which silver salts are also called
"silver soaps"; silver dodecyl sulphonate described in US-P 4,504,575; and silver
di-(2-ethylhexyl)-sulfosuccinate described in EP-A 227 141. Modified aliphatic carboxylic
acids with thioether group as described e.g. in GB-P 1,111,492 and other organic silver
salts as described in GB-P 1,439,478, e.g. silver benzoate and silver phthalazinone,
may be used likewise to produce a thermally developable silver image. Further are
mentioned silver imidazolates and the substantially light-insensitive inorganic or
organic silver salt complexes described in US-P 4,260,677.
Photosensitive silver halide
[0036] The photosensitive silver halide used in the present invention may be employed in
a range of from 0.1 to 35 mol percent of substantially light-insensitive organic silver
salt, with the range of 0.5 to 20 mol percent being preferred and the range of 1 to
12 mol percent being particularly preferred.
[0037] The silver halide may be any photosensitive silver halide such as silver bromide,
silver iodide, silver chloride, silver bromoiodide, silver chlorobromoiodide, silver
chlorobromide etc. The silver halide may be in any form which is photosensitive including,
but not limited to, cubic, orthorhombic, tabular, tetrahedral, octagonal etc. and
may have epitaxial growth of crystals thereon.
[0038] The silver halide used in the present invention may be employed without modification.
However, it may be chemically sensitized with a chemical sensitizing agent such as
a compound containing sulphur, selenium, tellurium etc., or a compound containing
gold, platinum, palladium, iron, ruthenium, rhodium or iridium etc., a reducing agent
such as a tin halide etc., or a combination thereof. The details of these procedures
are described in T.H. James. "The Theory of the Photographic Process". Fourth Edition,
Macmillan Publishing Co. Inc., New York (1977), Chapter 5, pages 149 to 169.
[0039] According to a preferred embodiment used according to the present invention, particles
of the photosensitive silver halide are non-aggregating in the photo-addressable thermally
developable element and are uniformly distributed over and between particles of the
substantially light-insensitive organic silver salt, at least 80% by number of the
particles having a diameter, determined by transmission electron microscopy, of ≤40nm.
Emulsion of organic silver salt and photosensitive silver halide
[0040] According to a process, used according to the present invention, the suspension of
particles of a substantially light-insensitive organic silver salt may be produced
by simultaneous metered addition of an aqueous solution or suspension of an organic
carboxylic acid, or its salt, and an aqueous solution of a silver salt to an aqueous
liquid and the metered addition of the aqueous solution or suspension of the organic
carboxylic acid or its salt; and/or the aqueous solution of the silver salt is regulated
by the concentration of silver ions or the concentration of anions of the silver salt
in the aqueous liquid.
[0041] The silver halide may be added to the photo-addressable thermally developable element
in any fashion which places it in catalytic proximity to the substantially light-insensitive
organic silver salt. Silver halide and the substantially light-insensitive organic
silver salt which are separately formed, i.e. ex-situ or "preformed", in a binder
can be mixed prior to use to prepare a coating solution, but it is also effective
to blend both of them for a long period of time. Furthermore, it is effective to use
a process which comprises adding a halogen-containing compound to the organic silver
salt to partially convert the substantially light-insensitive organic silver salt
to silver halide as disclosed in US-P 3,457,075.
[0042] According to another preferred embodiment used according to the present invention,
a production process for the photothermographic recording material is provided further
comprising the step of forming particles of the photosensitive silver halide by reacting
an aqueous emulsion of particles of the substantially light-insensitive organic silver
salt with at least one onium salt with halide or polyhalide anion(s).
[0043] The aqueous emulsion of the organic silver salt optionally including photosensitive
silver halide can, according to the present invention, also be produced from particles
of the organic silver salt optionally containing photosensitive silver halide by dispersing
the particles in water in the presence of non-ionic or anionic surfactants or a mixture
of non-ionic and anionic surfactants using any dispersion technique known to one skilled
in the art such as ball milling, dispersion in a impingement mill (rotor-stator mixer),
dispersion in a microfluidizer etc. A combination of dispersion techniques may also
be used, for example using a first technique to produce a predispersion and a second
technique to produce a fine dispersion.
Onium halides and polyhalides
[0044] According to the present invention photosensitive silver halide particles produced
by reacting an aqueous dispersion of particles of the substantially light-insensitive
organic silver salt with at least one onium salt with halide or polyhalide anions
may be present. Onium cations, used according to the present invention, may be polymeric
or non-polymeric. Preferred non-polymeric onium salts for partial conversion of particles
of substantially light-insensitive organic silver salt into photosensitive silver
halides used according to the present invention are:
- PC01 =
- 3-(triphenyl-phosphonium)propionic acid bromide perbromide
- PC02 =
- 3-(triphenyl-phosphonium)propionic acid bromide
- PC03 =
- 3-(triphenyl-phosphonium)propionic acid iodide
[0045] The onium salts are present in quantities of between 0.1 and 35mol % with respect
to the quantity of substantially light-insensitive organic silver salt of organic,
with quantities between 0.5 and 20mol% being preferred and with quantities between
1 and 12mol % being particularly preferred.
Organic reducing agent for photo-addressable thermally developable elements coated
from aqueous media
[0046] Suitable organic reducing agents for the reduction of the substantially light-insensitive
organic heavy metal salts in photo-addressable thermally developable coated from aqueous
media are organic compounds containing at least one active hydrogen atom linked to
O, N or C. Particularly suitable organic reducing agents for the reduction of the
substantially light-insensitive organic silver salt in such photo-addressable thermally
developable elements are non-sulfo-substituted 6-membered aromatic or heteroaromatic
ring compounds with at least three substituents one of which is a hydroxy group at
a first carbon atom and a second of which is a hydroxy or amino-group substituted
on a second carbon atom one, three or five ring atoms removed in a system of conjugated
double bonds from the first carbon atom in the compound, in which (i) the third substituent
may be part of an annelated carbocyclic or heterocyclic ring system; (ii) the third
substituent or a further substituent is not an aryl- or oxo-aryl-group whose aryl
group is substituted with hydroxy-, thiol- or amino-groups; and (iii) the third substituent
or a further substituent is a non-sulfo-electron withdrawing group if the second substiuent
is an amino-group.
[0047] Particularly preferred reducing agents are substituted catechols or substitued hydroquinones
with 3-(3',4'-dihydroxyphenyl)-propionic acid, 3',4'-dihydroxy-butyrophenone, methyl
gallate, ethyl gallate and 1,5-dihydroxy-naphthalene being especially preferred.
Reducing agent incorporation
[0048] During the thermal development process the reducing agent must be present in such
a way that it is able to diffuse to the substantially light-insensitive organic silver
salt particles so that reduction of the organic silver salt can take place.
Auxiliary reducing agents
[0049] The above mentioned reducing agents, regarded as primary or main reducing agents,
may be used in conjunction with so-called auxiliary reducing agents. Auxiliary reducing
agents that may be used in conjunction with the above mentioned primary reducing agents
are sulfonyl hydrazide reducing agents such as disclosed in US-P 5,464,738, trityl
hydrazides and formyl-phenyl-hydrazides such as disclosed in US-P 5,496,695 and organic
reducing metal salts, e.g. stannous stearate described in US-P 3,460,946 and 3,547,648.
Water-dispersible and water-soluble binders
[0050] According to the present invention the photo-addressable thermally developable element
comprises a binder comprising a water-soluble binder, a water-dispersible binder or
a mixture of a water soluble binder and a water-dispersible binder. An important prerequisite
in the choice of binders and binder-mixtures is their ability to form a continuous
layer with the other ingredients present.
[0051] The water-dispersible binder can be any water-insoluble polymer e.g. water-insoluble
cellulose derivatives, polymers derived from α,β-ethylenically unsaturated compounds
such as polyvinyl chloride, after-chlorinated polyvinyl chloride, copolymers of vinyl
chloride and vinylidene chloride, copolymers of vinyl chloride and vinyl acetate,
polyvinyl acetate and partially hydrolyzed polyvinyl acetate, polyvinyl alcohol, polyvinyl
acetals that are made from polyvinyl alcohol as starting material in which only a
part of the repeating vinyl alcohol units may have reacted with an aldehyde, preferably
polyvinyl butyral, copolymers of acrylonitrile and acrylamide, polyacrylic acid esters,
polymethacrylic acid esters, polystyrene and polyethylene or mixtures thereof. A particularly
suitable polyvinyl butyral containing a minor amount of vinyl alcohol units is marketed
under the trade name BUTVAR B79 of Monsanto USA and provides a good adhesion to paper
and properly subbed polyester supports. It should be noted that there is no clear
cut transition between a polymer dispersion and a polymer solution in the case of
very small polymer particles resulting in the smallest particles of the polymer being
dissolved and those slightly larger being in dispersion.
[0052] Suitable water-soluble polymers used according to the present invention, are: polyvinyl
alcohol, polyacrylamide, polyacrylic acid, polymethacrylic acid, polyethyleneglycol
proteins, such as gelatin and modified gelatins such as phthaloyl gelatin, polysaccharides,
such as starch, gum arabic and dextran and water-soluble cellulose derivatives.
[0053] To improve the layer-forming properties of water-soluble and water-dispersible polymers,
plasticizers can be incorporated into the polymers, water-miscible solvents can be
added to the dispersion medium and mixtures of water-soluble polymers, mixtures of
water-dispersible polymers, or mixtures of water-soluble and water-dispersible polymers
may be used.
Weight ratio of binder to organic silver salt
[0054] The binder to organic silver salt weight ratio is preferably in the range of 0.2
to 6, and the thickness of the photo-addressable thermally developable element is
preferably in the range of 1 to 50 µm.
Thermal solvents
[0055] The above mentioned binders or mixtures thereof may be used in conjunction with waxes
or "heat solvents" also called "thermal solvents" or "thermosolvents" improving the
reaction speed of the redox-reaction at elevated temperature.
[0056] By the term "heat solvent" in this invention is meant a non-hydrolyzable organic
material which is in solid state in the recording layer at temperatures below 50°C
but becomes a plasticizer for the recording layer in the heated region and/or liquid
solvent for at least one of the redox-reactants, e.g. the reducing agent for the organic
silver salt, at a temperature above 60°C.
Toning agent
[0057] In order to obtain a neutral black image tone in the higher densities and neutral
grey in the lower densities the photo-addressable thermally developable element contains
preferably in admixture with the organic silver salts and reducing agents a so-called
toning agent known from thermography or photothermography.
[0058] Suitable toning agents are succinimide and the phthalimides and phthalazinones within
the scope of the general formulae described in US-P 4,082,901. Further reference is
made to the toning agents described in US-P 3,074,809, 3,446,648 and 3,844,797. Other
particularly useful toning agents are the heterocyclic toner compounds of the benzoxazine
dione or naphthoxazine dione as described in GB-P 1,439,478 and US-P 3,951,660.
[0059] A toner compound particularly suited for use in combination with polyhydroxy benzene
reducing agents is 3,4-dihydro-2,4-dioxo-1,3,2H-benzoxazine described in US-P 3,951,660.
Stabilizers and antifoggants
[0060] In order to obtain improved shelf-life and reduced fogging, stabilizers and antifoggants
may be incorporated into the photothermographic materials of the present invention.
Examples of suitable stabilizers and antifoggants and their precursors, which can
be used alone or in combination, include the thiazolium salts described in US-P 2,131,038
and 2,694,716; the azaindenes described in US-P 2,886,437 and 2,444,605; the urazoles
described in US-P 3,287,135; the sulfocatechols described in US-P 3,235,652; the oximes
described in GB-P 623,448; the thiuronium salts described in US-P 3,220,839; the palladium,
platinum and gold salts described in US-P 2,566,263 and 2,597,915; the tetrazolyl-thio-compounds
described in US-P 3,700,457; the mesoionic 1,2,4-triazolium-3-thiolate stablizer precursors
described in US-P 4,404,390 and 4,351,896; the tribromomethyl ketone compounds described
in EP-A 600 587; the combination of isocyanate and halogenated compounds described
in EP-A 600 586; the vinyl sulfone and β-halo sulfone compounds described in EP-A
600 589; and those compounds mentioned in this context in Chapter 9 of "Imaging Processes
and Materials, Neblette's 8th edition", by D. Kloosterboer, edited by J. Sturge, V.
Walworth and A. Shepp, page 279, Van Nostrand (1989); in Research Disclosure 17029
published in June 1978; and in the references cited in all these documents.
Surfactants
[0061] Non-ionic, cationic or anionic surfactants may be used, according to the present
invention, to produce dispersions of particles of the substantially light-insensitive
organic silver salt in aqueous media and to disperse water-dispersible binders, such
as polymer latexes, in aqueous media. In a preferred embodiment of the present invention
the surfactant is a sulfonate e.g. alkyl, aryl, alkaryl or aralkyl sulfonate, with
alkyl and alkaryl sulfonates being particularly preferred e.g.:
MERSOLAT™ H, a sodium salt of an alkyl sulfonate from BAYER
ULTRAVON™ W, a sodium salt of an aryl sulfonate from CIBA-GEIGY
Other additives
[0062] In addition to the ingredients the photo-addressable thermally developable element
may contain other additives such as free fatty acids, surface-active agents, antistatic
agents, e.g. non-ionic antistatic agents including a fluorocarbon group as e.g. in
F
3C(CF
2)
6CONH(CH
2CH
2O)-H, silicone oil, e.g. BAYSILONE Öl A (tradename of BAYER AG - GERMANY), ultraviolet
light absorbing compounds, white light reflecting and/or ultraviolet radiation reflecting
pigments. silica, colloidal silica, fine polymeric particles [e.g. of poly(methylmethacrylate)]
and/or optical brightening agents.
Antihalation dyes
[0063] According to a preferred embodiment of the present invention, the photothermographic
recording material further comprises an antihalation or acutance dye which absorbs
light which has passed through the photosensitive layer, thereby preventing its reflection.
Such dyes may be incorporated into the photo-addressable thermally developable element
or in any other layer comprising the photothermographic recording material of the
present invention. The antihalation dye may also be bleached either thermally during
the thermal development process or photo-bleached after removable after the thermal
development process and it may be contained in a layer which can be removed subsequent
to the exposure process. Suitable antihalation dyes for use with infra-red light are
described in the EP-A's 377 961 and 652 473, the EP-B's 101 646 and 102 781 and the
US-P's 4,581,325 and 5,380,635.
Support
[0064] The support for the photothermographic recording material used according to the present
invention may be transparent, translucent or opaque, e.g. having a white light reflecting
aspect and is preferably a thin flexible carrier made e.g. from paper, polyethylene
coated paper or transparent resin film, e.g. made of a cellulose ester, e.g. cellulose
triacetate, corona and flame treated polypropylene, polystyrene, polymethacrylic acid
ester, polycarbonate or polyester, e.g. polyethylene terephthalate or polyethylene
naphthalate as disclosed in GB 1,293,676, GB 1,441,304 and GB 1,454,956. For example,
a paper base substrate is present which may contain white reflecting pigments, optionally
also applied in an interlayer between the recording material and the paper base substrate.
[0065] The support may be in sheet, ribbon or web form and subbed if need be to improve
the adherence to the thereon coated thermosensitive recording layer. The support may
be made of an opacified resin composition, e.g. polyethylene terephthalate opacified
by means of pigments and/or micro-voids and/or coated with an opaque pigment-binder
layer, and may be called synthetic paper, or paperlike film; information about such
supports can be found in EP's 194 106 and 234 563 and US-P's 3,944,699, 4,187,113,
4,780,402 and 5,059,579. Should a transparent base be used, the base may be colourless
or coloured, e.g. having a blue colour.
[0066] One or more backing layers may be provided to control physical properties such as
curl or static.
Protective layer
[0067] According to a preferred embodiment of the photothermographic recording material
of the present invention, the photo-addressable thermally developable element is provided
with a protective layer to avoid local deformation of the photo-addressable thermally
developable element, to improve its resistance against abrasion and to prevent its
direct contact with components of the apparatus used for thermal development.
[0068] The protective layer preferably comprises a binder, which may be solvent soluble
(hydrophobic), solvent dispersible, water soluble (hydrophilic) or water dispersible.
Among the hydrophobic binders cellulose acetate butyrate, polymethylmethacrylate and
polycarbonates, for example as described in EP-A 614 769, are particularly preferred.
Suitable hydrophilic binders are, for example, gelatin, polyvinylalcohol, cellulose
derivatives or other polysaccharides, hydroxyethylcellulose, hydroxypropylcellulose
etc., with hardenable binders being preferred and polyvinylalcohol being particularly
preferred.
[0069] A protective layer of the photothermographic recording material, used according to
the present invention, may be crosslinked. Crosslinking can be achieved by using crosslinking
agents such as described in WO 95/12495 for protective layers, e.g. tetraalkoxysilanes,
polyisocyanates, zirconates, titanates, melamine resins etc., with tetraalkoxysilanes
such as tetramethylorthosilicate and tetraethylorthosilicate being preferred.
[0070] A protective layer used according to the present invention may comprise in addition
at least one solid lubricant having a melting point below 150°C and at least one liquid
lubricant in a binder, wherein at least one of the lubricants is a phosphoric acid
derivative, further dissolved lubricating material and/or particulate material, e.g.
talc particles, optionally protruding from the outermost layer. Examples of suitable
lubricating materials are surface active agents, liquid lubricants, solid lubricants
which do not melt during thermal development of the recording material, solid lubricants
which melt (thermomeltable) during thermal development of the recording material or
mixtures thereof. The lubricant may be applied with or without a polymeric binder.
[0071] Such protective layers may also comprise particulate material, e.g. talc particles,
optionally protruding from the protective outermost layer as described in WO 94/11198.
Other additives can also be incorporated in the protective layer e.g. colloidal particles
such as colloidal silica.
Antistatic layer
[0072] In a preferred embodiment the recording material of the present invention an antistatic
layer is applied to the outermost layer on the side of the support not coated with
the photo-addressable thermally developable element. Suitable antistatic layers therefor
are described in EP-A's 444 326, 534 006 and 644 456, US-P's 5,364,752 and 5,472,832
and DOS 4125758.
Coating
[0073] The coating of any layer of the photothermographic recording material of the present
invention may proceed by any coating technique e.g. such as described in Modern Coating
and Drying Technology, edited by Edward D. Cohen and Edgar B. Gutoff, (1992) VCH Publishers
Inc. 220 East 23rd Street, Suite 909 New York, NY 10010, U.S.A.
Photothermographic recording process
[0074] Photothermographic materials, used according to the present invention, may be exposed
with infrared radiation of wavelength > 700 nm with the image either being obtained
by pixel-wise exposure with a finely focussed light source, such as an IR wavelength
laser or an IR-laser diode, e.g. emitting at 780nm, 830nm or 850nm; or by direct exposure
to the object itself or an image therefrom with appropriate illumination with IR light.
[0075] For the thermal development of image-wise exposed photothermographic recording materials,
used according to the present invention, any sort of heat source can be used that
enables the recording materials to be uniformly heated to the development temperature
in a time acceptable for the application concerned e.g. contact heating, radiative
heating, microwave heating etc.
[0076] According to the present invention a photothermographic recording process is also
provided comprising the steps of: (i) image-wise exposing a photothermographic recording
material, as referred to above, with actinic radiation to which the photothermographic
recording material is sensitive; and (ii) thermally developing the image-wise exposed
photothermographic recording material.
Applications
[0077] The photothermographic recording materials of the present invention can be used for
both the production of transparencies and reflection type prints. This means that
the support will be transparent or opaque, e.g. having a white light reflecting aspect.
For example, a paper base substrate is present which may contain white reflecting
pigments, optionally also applied in an interlayer between the recording material
and the paper base substrate. Should a transparent base be used, the base may be colourless
or coloured, e.g. has a blue colour.
[0078] In the hard copy field photothermographic recording materials on a white opaque base
are used, whereas in the medical diagnostic field black-imaged transparencies are
widely used in inspection techniques operating with a light box.
[0079] While the present invention will hereinafter be described in connection with a preferred
embodiment thereof, it will be understood that it is not intended to limit the invention
to that embodiment. On the contrary, it is intended to cover all alternatives, modifications
and equivalents as may be included in the spirit and scope of the invention as defined
by the appending claims.
[0080] The following ingredients in addition to those mentioned above were used in the photothermographic
recording materials of the invention examples and comparative examples:
a) photo-addressable thermally developable element ingredients for coating of element
from aqueous media:
- BINDER 01:
- copolymer consisting of 45% by weight of methylmethacrylate, 45% by weight of butadiene
and 10% by weight of itaconic acid.

[0081] The following examples and comparative examples illustrate the present invention.
The percentages and ratios used in the examples are by weight unless otherwise indicated.
INVENTION EXAMPLE 1
Synthesis of SENSI 01:
[0082] The synthesis of SENSI 01 involves the coupling of two intermediates, A and B, which
are themselves synthesized from a succession of intermediates in a synthesis ladder.
Synthesis of intermediate A:
[0083] The first step in the synthesis of intermediate A was the synthesis of D. D was prepared
according to the following reaction scheme:

10L of butylacetate, 2425g of F en 3038 g of E were added to a flask and the mixture
heated to the reflux temperature and then heated for a further 8 hours at the reflux
temperature. Upon subsequent cooling to room temperature, the product precipitated
out. It was then filtered off and washed with butyl acetate to produce a yield of
74% of intermediate D.
[0084] Intermediate A was then synthesized according to the following reaction scheme:

294g of intermediate D, 343g of intermediate C and 600mL of sulfolan was added to
a flask and heating with stirring on an oil bath for 24 hours at 125°C. The reaction
mixture was then cooled to 60°C and 1200mL of acetone added. The resulting suspension
was then stirred for 1 hour at room temperature after which it was filtered and thoroughly
washed with acetone to produce a 51% yield of intermediate A.
Synthesis of intermediate B:
[0085] The first step in the synthesis of intermediate B, was the preparation of intermediate
H according to the following synthesis scheme:

2L of ethanol, 5.5g of sodium ethoxide and 759mL diethyl malonate were added to a
flask and the mixture cooled to -30°C and the atmosphere above the mixture changed
to nitrogen. 758mL of acrolein dissolved in 750mL of ethanol were then added over
a period of 60 hours while maintaining the temperature of the reaction mixture between
0 and 5°C. Upon completion of the acrolein addition the temperature was allowed to
rise to room temperature and 8g of sodium ethoxide dissolved in 180mL of ethanol was
added. After allowing to stand overnight, 19mL of acetic acid was added and the reaction
mixture evaporated under reduced pressure. The liquid residue was then distilled under
reduced temperature to produce a 26% yield of intermediate H.
[0086] Intermediate H was then used to prepare intermediate G according to the following
synthesis scheme:

162 g of intermediate H, 162mL of ethanol and 0.16g of p-toluenesulfonic acid monohydrate
were added to a flask and thoroughly mixed at room temperature. 206mL of intermediate
I were then added with stirring and the stirred reaction mixture then heated to 30
to 40°C until the reaction was completed. 0.33mL of a 33% soltion of odium methoxide
was then addedand the mixture stirred at 30 to 40°C for a further 15 minutes. Finally
the reaction mixture was vacuum distilled to produce a 99% yield of intermediate G.
[0087] Intermediate G was then used to prepare intermediate B according to the following
reaction scheme:

73mL of dimethylformamide in a flask was cooled to 0°C. 59mL of phosphoryl chloride
were then added with stirring and the mixture stirred for a further hour at room temperature.
98g of intermediate G were then added with stirring and the mixture stirred for a
further 90 minutes at room temperature. 720mL of ethanol and 33mL of deionized water
were then added and the mixture stirred for a further 30 minutes at room temperature.
273mL of aniline were then added with stirring and the mixture stirred for a further
30 minutes at room temperature. Finally 3000mL of a 6N solution of hydrochloric acid
was added and the mixture stirred for a further 15 minutes at room temperature. The
resulting precipitate was filtered off and washed with a warm mixture of methanol
and ethyl acetate to produce an 86% yield of intermediate B.
Synthesis of SENSI 01:
[0088] SENSI 01 was prepared according to the following reaction scheme:

28g of intermediate B, 180mL of N,N-dimethylacetamide, 11mL of acetic acid anhydride
and 37mL of 1-8 diazabicyclo[5,4,0]undec-7ene were added to a flask and mixed at room
temperature to produce an orange solution. 39g of intermediate A were then added to
the reaction mixture and then stirred for 2.5 hours at room temperature. An extra
9mL of 1-8 diazabicyclo[5,4,0]undec-7ene were then added and the mixture stirred for
a further hour at room temperature. Finally 360mL of acetone were added to precipitate
the product and filtration, washing and drying produced a 62% yield of SENSI 01.
INVENTION EXAMPLES 2 to 35 and COMPARATIVE EXAMPLES 1 to 6
Silver behenate dispersion
[0089] Silver behenate was prepared by dissolving 34g (0.1 moles) of behenic acid in 340mL
of 2-propanol at 65°C, converting the behenic acid to sodium behenate by adding 400mL
of 0.25M aqueous sodium hydroxide to the stirred behenic acid solution and finally
adding 250mL of 0.4M aqueous silver nitrate the silver behenate precipitating out.
This was filtered off and then washed with a mixture of 10% by volume of 2-propanol
and 90% by volume of deionized water to remove residual sodium nitrate.
[0090] After drying at 45°C for 12h, the silver behenate was dispersed in deionized water
with the anionic dispersion agents Ultravon™ W and Mersolat™ H to produce, after rapid
mixing using a high speed impingement mill (rotor-stator mixer) to obtain a paste
and homogenization with a microfluidizer, a finely divided and stable dispersion containing
20% by weight of silver behenate, 2.1% by weight of Ultravon™ W and 0.203% by weight
of Mersolat™ H. The pH of the resulting dispersion was adjusted to about 6.5.
[0091] The following ingredients were then added with stirring to 3.0g of the silver behenate
dispersion: 2g of a 2.22% by weight aqueous solution of 3-(triphenyl-phosphonium)propionic
acid bromide (PC02), corresponding to a concentration of 8 mol% of PC02 with respect
to silver behenate, at a pH of 4 to accomplish in situ conversion of part of the silver
behenate to silver bromide. After 10 minutes further stirring, the supersensitizer
was added with stirring as a solution in water and/or methanol, as specified in table
1, immediately followed by the IR-spectral sensitizer as a solution or dispersion
in water and/or methanol as specified in table 1. After stirring for a further 15
minutes 2g of a 30% by weight concentration of BINDER 01 at a pH of 4 was added with
stirring followed by 2g of a 4.5% by weight aqueous solution of 3-(3',4'-dihydroxyphenyl)propionic
acid.

Coating and drying of the photothermographic material
[0092] A subbed polyethylene terephthalate support having a thickness of 100µm was doctor
blade-coated with the silver behenate/silver bromide dispersion at a blade setting
of 90µm. After drying for several minutes at 40°C on the coating bed, the emulsion
layer was dried for 1 hour in a hot air oven at 40°C.
Image-wise exposure and thermal processing
[0093] The photothermographic materials of INVENTION EXAMPLES 2 to 35 and COMPARATIVE EXAMPLES
1 to 6 were exposed to a beam of a 836nm diode laser type HL 8318G from HITACHI with
a nominal power of 12.8mW focussed to give a spot diameter (1/e
2) of 115µm , scanned at a speed of 5m/s with a pitch of 63µm and an overlap of 30%
through a wedge filter with optical density varying between 0 and 3.3 in optical density
steps of 0.15. The maximum exposure (filter optical density = 0) was about 50J/m
2.
[0094] Thermal processing was carried for 15s with the side of the support not provided
with a silver behenate/silver halide emulsion layer with a heated metal block at a
temperature of 105°C . The optical densities of the images were measured in transmission
with a MacBeth™ TR924 densitometer through a visual filter to produce a sensitometric
curve for the photographic recording materials from which the exposure required to
obtain an optical density of D
min + 0.5 was determined.
[0095] The exposure values for an optical density of D
min + 0.5 obtained upon image-wise exposure and thermal processing of the photothermographic
recording materials of INVENTION EXAMPLES 2 to 35 and COMPARATIVE EXAMPLES 1 to 6
together with the IR-sensitizer, supersensitizer, molar ratio of super-sensitizer
to IR-sensitizer and the thermal processing conditions used are summarized in table
2.

[0096] It is evident from the results in table 2, that spectral sensitization of photothermographic
recording materials with IR-sensitizing dyes, used according to the present invention,
results in efficient spectral sensitization in the infra-red region of the spectrum.
The presence of the supersensitizer dilithium salt of 2,2'-disulfo-4,4'-bis[2-{4,6-bis(2-oxy-naphtho)}-triazino]-aminostilbene,
which exhibits efficient supersensitiization of the photothermographic recording materials
of COMPARATIVE EXAMPLES 2, 4 and 6 with the IR-sensitizing dyes SENSI C01, SENSI C02
and SENSI C03, in the case of the IR-sensitizing dyes, used according to the present
invention, results in exposures to obtain optical densities of D
min + 0.5 of between 100% and 712% of the exposures required by photothermographic materials
only differing in the omission of the dilithium salt of 2,2'-disulfo-4,4'-bis[2-{4,6-bis(2-oxy-naphtho)}-triazino]-aminostilbene.
This demonstrates the unexpected IR-sensitization properties of the dyes used according
to the present invention in photothermographic recording materials comprising a photo-addressable
thermally developable element coated from aqueous media.
[0097] Having described in detail preferred embodiments of the current invention, it will
now be apparent to those skilled in the art that numerous modifications can be made
therein without departing from the scope of the invention as defined in the following
claims.