Donor sheet, color filter, organic EL element and method for producing them

Abstract

A donor sheet for transferring an image pattern to an image receiving element by a thermal imaging process using laser beam, comprising a base having formed in order on the base a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layer and transferred to the image receiving element in a patterned form, in which the image component of the transfer layer contains an ink-repellent or solvent-repellent compound in an optimized amount. Using the donor sheet, it becomes possible to produce an separation member such as partition pattern and black matrix of a color filter by a shortened manufacturing step with ease and accuracy at high contrast, and can impart excellent ink repellency to the separation member.

1 . A donor sheet for transferring an image pattern to an image receiving element by a thermal imaging process using laser beam, comprising a base, a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layer and transferred to the image receiving element in a patterned form, said layers being formed in order on the base, characterized in that: 
 the image component of the transfer layer contains an ink-repellent or solvent-repellent compound in an optimized amount.    
     
     
         2 . The donor sheet according to  claim 1 , which further comprises an intermediate layer disposed between the light-to-heat conversion layer and the transfer layer.  
     
     
         3 . The donor sheet according to  claim 1 , wherein the transfer layer contains an fluorine-containing compound and/or a silicone compound.  
     
     
         4 . A color filter comprising a transparent substrate, a plurality of picture elements disposed on a predetermined position of the substrate, and a partition pattern for separating adjacent picture elements, characterized in that: 
 the partition pattern on the substrate is formed by making the transfer layer of the donor sheet of  claim 1  and the surface of the substrate come closely into contact with each other and transferring the image component of the transfer layer of the donor sheet in a pattern corresponding to the partition pattern by a thermal imaging process using laser beam.    
     
     
         5 . The color filter according to  claim 4 , wherein the picture elements are formed by forming the partition pattern and applying ink to a picture element forming area using an ink-jet system.  
     
     
         6 . The color filter according to  claim 4 , wherein the partition pattern is a black matrix of a liquid crystal display device.  
     
     
         7 . A method of producing a color filter comprising a transparent substrate, a plurality of picture elements disposed on a predetermined position of the substrate, and a partition pattern for separating adjacent picture elements, which comprises the steps of: 
 forming a thin film-like black matrix in a predetermined pattern on the surface of the substrate;    making the surface of the black matrix side of the substrate and a transfer layer of a donor sheet comprising a base, a light-to-heat conversion layer, and the transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layer and transferred to the substrate in a patterned form, said layers being formed in order on the base, come closely into contact with each other;    irradiating laser beam from the base side of the donor sheet corresponding to the pattern of the black matrix by a thermal image process using laser beam, thereby to melt the image component of the transfer layer of the donor sheet with heating and to pile up the molten image component on the black matrix; and    filling an opening portion surrounded by the formed partition pattern with ink having a predetermined color using an ink-jet method.    
     
     
         8 . The method according to  claim 7 , wherein the donor sheet  3  transfers an imaging pattern to an image receiving element by a thermal imaging process using laser beam, comprising a base, a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layers and transferred to the image receiving element in a patterned form, said layers being formed in order on the base, characterized in that: 
 the image component of the transfer layer contains an ink-repellent or solvent-repellent compound in an optimized amount.    
     
     
         9 . A method of producing a color filter comprising a transparent substrate, a plurality of picture elements disposed on a predetermined position of the substrate, and a partition pattern for separating adjacent picture elements, which comprises the steps of: 
 coating the surface of the substrate to form a thin film of a black matrix forming material;    laying the substrate and a donor sheet comprising a base, a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layer and transferred to the substrate in a patterned form, said layers being formed in order on the base, one upon another so that the thin film-like black matrix forming material and the transfer layer of the donor sheet come closely into contact with each other;    irradiating laser beam from the base side of the donor sheet corresponding to a desired pattern of the black matrix by a thermal image process using laser beam, thereby to melt the image component of the transfer layer of the donor sheet with heating and to transfer the melted image component on the thin film-like black matrix forming material;    removing the exposed black matrix forming material by etching using, as a mask, the image component transferred to the surface of the thin film-like black matrix forming material of the substrate in a patterned form; and    filling an opening portion surrounded by the partition pattern formed from the image component and black matrix as a ground thereof with ink having a predetermined color using an ink-jet method, thereby to form picture elements.    
     
     
         10 . The method according to  claim 9 , wherein the donor sheet transfers an imaging pattern to an image receiving element by a thermal imaging process using laser beam, comprising a base a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layers and transferred to the image receiving element in a patterned form, said layers being formed in order on the base, characterized in that: 
 the image component of the transfer layer contains an ink-repellent or solvent-repellent compound in an optimized amount.    
     
     
         11 . A method of producing a color filter comprising a transparent substrate, a plurality of picture elements disposed on a predetermined position of the substrate, and a light shielding partition pattern for separating adjacent picture elements, which comprises the steps of: 
 laying the substrate and a donor sheet comprising a base, a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layer and transferred to the substrate in a patterned form, said layers being formed in order on the base, one upon another so that the thin surface of the substrate and the transfer layer of the donor sheet come closely into contact with each other;    irradiating laser beam from the base side of the donor sheet corresponding to a desired pattern of the black matrix by a thermal image process using laser beam, thereby to melt the image component of the transfer layer of the donor sheet with heating and to transfer the molten image component on the substrate; and    filling an opening portion surrounded by the light shielding partition pattern formed from the image component with ink having a predetermined color using an ink-jet method, thereby to form picture elements.    
     
     
         12 . The method according to  claim 11 , wherein the donor sheet transfers an imaging pattern to an image receiving element by a thermal imaging process using laser beam, comprising a base, a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layers and transferred to the image receiving element in a patterned form, said layers being formed in order on the base, characterized in that: 
 the image component of the transfer layer contains an ink-repellent or solvent-repellent compound in an optimized amount.    
     
     
         13 . An organic EL element comprising a transparent substrate, a plurality of pixel electrodes disposed on a predetermined position of the substrate, a partition pattern for separating adjacent pixel electrode, at least one luminescent layer formed on the pixel electrodes, and a counter electrode formed on the luminescent layer, characterized in that: 
 the partition pattern on the substrate is formed by making the transfer layer of the donor sheet of  claim 1 , and the surface of the substrate come closely into contact with each other and transferring the image component of the transfer layer of the donor sheet in a pattern corresponding to the partition pattern by a thermal imaging process using laser beam.    
     
     
         14 . The organic EL element according to  claim 13 , wherein the luminescent layer is formed by forming the partition pattern and applying an organic material using an ink-jet system.  
     
     
         15 . A method of producing an organic EL element comprising a transparent substrate, a plurality of pixel electrodes disposed on a predetermined position of the substrate, a partition pattern for separating adjacent pixel electrodes, at least one luminescent layer formed on the pixel electrodes, and a counter electrode formed on the luminescent layer, which comprises the steps of: 
 forming pixel electrodes in a predetermined pattern on the surface of the substrate;    making the surface of the pixel electrodes side of the substrate and a transfer layer of a donor sheet comprising a base, a light-to-heat conversion layer, and the transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layer and transferred to the substrate in a patterned form, said layers being formed in order on the base, come closely into contact with each other;    irradiating laser beam from the base side of the donor sheet corresponding to the partition pattern by a thermal image process using laser beam, thereby to melt the image component of the transfer layer of the donor sheet with heating and to pile up the molten image component on the substrate; and    filling an opening portion surrounded by the formed partition pattern with an organic material having a predetermined color using an ink-jet method to form the luminescent layer.    
     
     
         16 . The method according to  claim 15 , wherein the donor sheet transfers an imaging pattern to an image receiving element by a thermal imaging process using laser beam, comprising a base, a light-to-heat conversion layer, and a transfer layer containing an image component which is melted by heating due to an action of the light-to-heat conversion layers and transferred to the image receiving element in a patterned form said layers being formed in order on the base, characterized in that: 
 the image component of the transfer layer contains an ink-repellent or solvent-repellent compound in an optimized amount.