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. In preferred embodiments stereolithographic articles are formed with a reduced production of waste by forming an article from a cationic composition; removing excess composition from the formed article using an air knife or liquid C0 2 ; separating the removed excess composition; and recycling the removed excess composition

1 . A method of forming stereolithographic articles and reducing the production of waste therefrom comprising:
 forming an article from a cationic composition;   removing excess composition from the formed article using an air knife or liquid C0 2 ;   separating the removed excess composition; and   recycling the removed excess composition.   
   
   
       2 . The method of  claim 1  wherein said cationic composition is non-hazardous. 
   
   
       3 . The method of  claim 1  wherein the step of forming an article from a cationic composition comprises curing a portion of a cationic composition comprising: 
     
       
         
         
             
             
         
       
       a photoacid diffusion inhibitor; and/or 
       an oxetane; and 
       a boron-containing, cationic initiator; and/or 
       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. 
     
   
   
       4 . The method of  claim 1 , wherein said cationic composition is antimony-free. 
   
   
       5 . The method of  claim 1 , wherein the waste is hazardous. 
   
   
       6 . The method of  claim 1 , wherein said cationic composition comprises a photoacid diffusion inhibitor. 
   
   
       7 . The method of  claim 5 , wherein the photoacid diffusion inhibitor is present in an amount sufficient to improve the imaging of said composition. 
   
   
       8 . The method of  claim 6 , wherein improving the imaging of said composition includes limiting the diffusion of a photoacid out of a stereolithographic imaging region. 
   
   
       9 . The method of  claim 6 , wherein limiting diffusion of a photoacid includes.
 forming an association between an activated cationic initiator and said composition using said photoacid diffusion inhibitor.   
   
   
       10 . The method of  claim 6 , wherein improving the imaging includes improving the diffusional resolution of the composition. 
   
   
       11 . The method of  claim 6 , wherein improving the imaging includes improving the layer formation of the composition.