Method and composition for reducing waste in photo-imaging applications

Abstract

Waste reduction, including hazardous waste reduction in photoimaging processes can be accomplished by improving diffusional resolution of cationic curable compositions. The addition of fluorinated polymers including fluorinated surfactants provides improved diffusional resolution in cationic and/or radical based photoimaging formulations allowing for image accuracy improvements, and reduced product and process waste quantity and disposal cost. These fluorinated surfactants also allow for increased cure speed, and non-hazardous constituent formulations that result in less wasted material and time.

1 - 35 . (canceled) 
   
   
       36 . A cationic composition for reducing waste production comprising:
 (tolylcumyl) iodonium tetrakis(pentafluorphenyl)borate and a photosensitizer having the following chemical formula:   
     
       
         
         
             
             
         
       
       wherein R 1 -R 14  are independently H or C 1 -C 8  saturated or unsaturated, branched or unbranched, substituted or unsubstituted hydrocarbyl. 
     
   
   
       37 . The composition of  claim 36 , wherein said composition is antimony-free. 
   
   
       38 . The composition of  claim 36 , further comprising an epoxide. 
   
   
       39 . The composition of  claim 36 , wherein said photosensitizer has no significant absorbance above 400 nm. 
   
   
       40 . The composition of  claim 36 , wherein, said photosensitizer comprises 4-benzoyl-4-methyldiphenyl sulfide. 
   
   
       41 . The composition of  claim 36 , further comprising a free radical initiator. 
   
   
       42 . The composition of  claim 41 , wherein said free radical initiator comprises 2-hydroxy-2-2-methyl-1-phenyl propan-1-one. 
   
   
       43 . The composition of  claim 36 , wherein said composition is photocationic. 
   
   
       44 . The composition of  claim 36 , further comprising an oxetane. 
   
   
       45 . The composition of  claim 36 , further comprising a photoacid diffusion inhibitor. 
   
   
       46 . The composition of  claim 45 , wherein said photoacid diffusion inhibitor comprises a fluorinated polymer. 
   
   
       47 . The composition of  claim 45 , wherein said photoacid diffusion inhibitor comprises a fluorinated surfactant. 
   
   
       48 . A cationic high-solids composition for reducing waste production comprising:
 a photoacid diffusion inhibitor comprising a fluorinated polymer surfactant without a linking ester group.   
   
   
       49 . The composition of  claim 48 , wherein said photoacid diffusion inhibitor is 1.0 wt. % or less of said composition. 
   
   
       50 . The composition of  claim 48 , further comprising a cationic initiator. 
   
   
       51 . The composition of  claim 50 , wherein said cationic initiator comprises: phosphorus. 
   
   
       52 . The composition of  claim 50 , wherein said cationic initiator comprises boron. 
   
   
       53 . The composition of  claim 48 , wherein said composition is antimony-free. 
   
   
       54 . The composition of  claim 48 , wherein the composition has an improved diffusional resolution over an identical composition exclusive of the photoacid diffusion inhibitor. 
   
   
       55 . The composition of  claim 48 , further comprising an epoxide. 
   
   
       56 . The composition of  claim 48 , further comprising an acrylate. 
   
   
       57 . The composition of  claim 48 , further comprising an oxetane. 
   
   
       58 . The composition of  claim 48 , further comprising glycidyl epoxide monomers. 
   
   
       59 . The composition of  claim 48 , wherein said composition comprises only non-hazardous materials. 
   
   
       60 . The composition of  claim 48 , wherein said photoacid diffusion inhibitor contains fluorinated moieties having the following formula C k  F m  wherein m has a value of 3-5 and k has a value of 1 or 2. 
   
   
       61 . The composition of  claim 60 , wherein said moieties are part of a repeating group that is repeated at least 5 times. 
   
   
       62 . A mold or pattern formed from the composition of  claim 48 . 
   
   
       63 . A method of producing molded articles comprising:
 forming a mold from the composition of  claim 48 ; and   forming a thermoplastic film on the mold.   
   
   
       64 . The method of  claim 63 , wherein forming a thermoplastic film on the mold includes using a vacuum molding process.