This invention relates to light sensitive imaging elements in
general and in particular to annealable supports with an antistat layer with
electrically conductive particles.
In photographic film manufacture, an imaging layer which
typically consists of silver halide grains dispersed in gelatin is deposited onto a
polymeric film support which provides support and mechanical integrity to the
final product. Cellulosic or polyester supports, such as poly(ethylene
terephthalate) (PET) and poly(ethylene naphthalate)(PEN), are typically
employed. Polyester supports are considered to be advantageous to cellulose
triacetate supports for many imaging applications because they have excellent
mechanical strength, dimensional stability and resistance to attack by many
chemicals. Furthermore, polyester supports can be manufactured efficiently and
at a reduced cost compared to cellulose triacetate supports. However, the
chemical inertness of polyester supports also results in difficulty in obtaining
acceptable adhesion of polar materials, such as gelatin-based photographic
emulsions, to PET and PEN substrates.
To obtain acceptable adhesion of a silver-halide emulsion layer or
a backing layer to a polyester support a variety of methods have been used
including, surface treatment of the support or application of adhesion promoting
or subbing layers either prior to orientation and crystallization of the support or
post-orientation. Adhesion of the anchoring, or subbing layer is promoted by a
variety of methods, including the use of chlorine-containing copolymers, as
described in US Pat. Nos. 2,627,088; and 3,143,421. The application of the
adhesive layer prior to the orientation and heat setting or crystallization of the
polyester, and the addition of organic solvents which attack the polyester film
surface is described in US Patent No. 3,501,301. In addition, a subsequent
gelatin-containing layer is often required on the emulsion side of the support,
prior to photographic emulsion coating, for adequate adhesion.
Similarly, surface treatment or a subbing system is used on the
back side of a polyester support, to promote adhesion of electrically-conductive
antistatic layers, abrasion resistant layers, magnetic layers, anti-halation layers,
curl-control layers, lubricant layers, or other auxiliary layers. A particularly
effective subbing system for use on both the emulsion side and back side of
polyester supports is a vinylidene chloride containing polymer.
Despite the above-described advantages of polyester films, there is
a drawback that when used in a roll format, a persistently remaining core set curl
can occur which may result in poor handling properties. An increasing trend for
smaller cameras requires a reduction in the thickness of photographic imaging
elements to maintain a similar number of exposures in a smaller film cartridge.
Reducing the thickness of the film support has the most impact on the thickness of
the photographic element. However, this results in increased demands on core
set, dimensional stability and mechanical strength which require the use of
polyester supports; particularly for small format films. In order to satisfy these
increasing demands a polyester support comprising a poly(alkylene aromatic
dicarboxylate) whose glass transition point is from 50 °C to 200 °C such as
polyethylene terephtalate or polyethylene naphthalate has increasingly been used
in photographic elements. Furthermore, it is well-known that heat-treatment of
the polyester support at a temperature of from 40 °C up to the glass transition
temperature for a period of from 0.1 hr to 1500 hrs significantly reduces the core
set curl.
In addition to a polymeric support, image forming layer and
adhesion promoting layers, it is well known to include in various imaging
elements various auxiliary layers including antistatic layers, lubricant or transport-controlling
layers, hydrophobic barrier layers, antihalation layers, abrasion and
scratch protection layers, transparent magnetic recording layers and other special
function layers. The inclusion and use of such transparent magnetic recording
layers in light-sensitive silver halide photographic elements has been described in
U.S. Pat. Nos. 3,782,947; 4,279,945; 4,302,523; 5,217,804; 5,229,259; 5,395,743;
5,413,900; 5,427,900; 5,498,512; and others. Such elements are advantageous
because images can be recorded by customary photographic processes while
information can be recorded simultaneously into or read from the magnetic
recording layer by techniques similar to those employed for traditional magnetic
recording art.
Problems associated with the generation and discharge of
electrostatic charge have been recognized for many years by the photographic
industry. The accumulation of charge leads to the attraction of dust, which can
produce physical defects. The discharge of accumulated charge can produce
irregular fog patterns or static marks in the sensitized emulsion. The presence of
dust not only can result in the introduction of physical defects and the degradation
of the image quality of the photographic element but also can result in the
introduction of noise and the degradation of magnetic recording performance
(e.g., S/N ratio, "drop-outs", etc.) for an imaging element containing a magnetic
recording layer. In order to prevent these problems arising from electrostatic
charging, there are various well known methods by which an electrically-conductive
or antistatic layer can be introduced into the photographic element to
dissipate electrostatic charge. Typically, in photographic elements comprising a
transparent magnetic recording layer, the antistatic layer is present as a backing
layer underlying the magnetic recording layer.
As indicated above, it is desirable to heat-treat or anneal the
polyester support to impart the required physical properties, particularly to reduce
core set to an acceptable level for recent applications such as small format films
for use in smaller cameras. In addition, annealing the support with subbing or
backing layers is advantageous for manufacturing efficiency. Annealing of
polyester supports having coated thereon an antistatic layer has been disclosed in
U.S. Pat. Nos. 5,629,141; 5,582,963; 5,585,229; 5,739,309 and 5,766,835. The
process taught in the above patents consists of surface treatment of the polyester
support followed by application of an antistatic layer having tin oxide dispersed in
gelatin. In the case of '309 and '963 the antistatic layer is applied directly to the
surface treated support. In the remaining patents a gelatin undercoat layer is
applied prior to the antistatic layer. The support having an antistatic layer is
subjected to heat treatment. After heat treatment, a gelatin subbing layer is
applied on the photographic emulsion side and additional backing layers may be
applied. As an additional backing layer, a protective overcoat layer consisting of
cellulose diacetate and a crosslinking agent is taught in the '141, '963, '229, and
'309 patents. A magnetic layer having Co-γ-Fe2O3 and abrasive particles
dispersed in cellulose diacetate which is further crosslinked is applied after heat-treatment
of the support as an additional backing layer in '835. The above
indicated patents also disclose that the specific heat-treatment conditions are
important to control so as to avoid self-adhesion or blocking of the support. U.S.
Patent No. 5,629,141 indicates self-adhesion may occur if the winding tension or
humidity are too high or the knurl height too low during heat treatment. It is
further disclosed that electrification of the support accelerates self-adhesion and it
is therefore desirable to include electrically-conductive particles to avoid
electrification. U.S. Pat. No. 5,585,229 discloses that in addition to winding
tension, temperature, and knurl height, the differences in roll diameter must be
kept small to reduce the tendency for sticking or blocking during heat-treatment.
It is also disclosed that heat-treatment is preferably conducted before providing a
subbing layer for the photographic emulsion side since such subbing layers
typically contain gelatin and therefore the layer easily adheres on heating.
Examples 1-26, 2-21, and 3-26 of '229 indicate a greatly increased tendency for
self-adhesion or blocking and larger regions of poor planeness for samples where
the antistatic layer is annealed against a gelatin subbing layer than for similar
samples prepared in which the subbing layer is applied after heat-treatment. U.S.
Pat. No. 5,739,309 claims heat-treatment of the support is carried out in vacuo or
in a current of an inactive gas and additionally discloses it is preferable to carry
out the heat-treatment prior to application of the subbing layer.
Heat-treatment of a backing layer against a gelatin containing
subbing layer is taught in U.S. Pat. Nos. 5,580,707; 5,597,682; and 5,719,015. A
polyester support is surface treated by corona discharge treatment on both sides,
followed by application of a gelatin containing subbing layer on the emulsion
side. The opposite side of the support has an antistatic layer consisting of tin
oxide particles dispersed in gelatin and coated out of a methanol and water
mixture. The antistatic layer is then overcoated with a protective layer containing
cellulose triacetate. The support having a subbing layer, antistatic layer, and
protective layer is then heat-treated before application of the photographic
emulsion layers.
A silver halide photographic material having a support, a silver
halide emulsion layer, a magnetic recording layer and a layer containing metal
oxide particles having a crystallite size, on the average, of 1 to 20 nm is claimed
in U.S. Pat. No. 5,459,021. A photographic imaging element is taught in which
both sides of a polyester support are surface treated by corona discharge, followed
by application of subbing layers using various latex polymers consisting of butyl
acrylate, styrene, and additional acrylates. The subbing layer on the emulsion side
is overcoated with a gelatin subbing layer, while the subbing layer on the opposite
side is coated with an antistatic layer consisting of conductive metal oxide
particles dispersed in a mixture of a copolymer latex and gelatin. A magnetic
layer consisting of Co-γ-Fe3O3 dispersed in cellulose nitrate is also taught. Heat-treatment
of polyethylene terephthalate or polyethylene naphthalate supports
having a subbing layer and a backing layer at a temperature of 60 °C or 80 °C,
respectively, for 24 hrs is also indicated. The curl or core set for a film sample
prepared in the above manner was evaluated by winding on a 10 mm diameter
core and left for 3 days at 55 °C and 20 % relative humidity. For a sample on
polyethylene naphthalate which was heat-treated at 80 °C a curl removal of 60 to
70 percent was determined, somewhat improved over a similar sample which was
not heat-treated and had a curl removal of 50-60 percent. The core set
improvements demonstrated in '021 are advantageous for 35 mm film
applications and simulate long term storage at room temperature. However, the
core set results demonstrated are not sufficient for photographic elements intended
for small format films in which a core diameter of less than 10 mm, typically 6-7
mm, is used in which core set requirements are more stringent. Furthermore,
cellulose nitrate is not preferred as a binder for the magnetic layer due to
flammability concerns which pose a significant safety risk during manufacturing.
An object of the present invention is to provide an imaging support
having as outermost layers, a gelatin-containing subbing layer on the imaging side
of the support, and an antistatic layer on the opposite side which is subsequently
annealed at temperatures in excess of 80 °C prior to emulsion coating without
causing blocking or self-adhesion of the support or requiring an additional
protective or intermediate layer prior to annealing. It is a further objective of the
present invention that excellent adhesion of a transparent magnetic recording layer
or other auxiliary layers to the annealed support be achieved.
The present invention is an imaging support which includes a
polyester base having a glass transition temperature (Tg) of from 90 to 200 °C, a
gelatin-containing subbing layer on one side of the support, and an antistatic layer
on the opposite side of the support comprising electrically-conductive metal-containing
fine particles dispersed in a gelatin containing layer, and wherein the
electrically-conductive fine particles are present at between 45 and 80 volume
percent. The imaging support is annealed at a temperature of from 80 °C to the Tg
of the polyester base, for 0.1 h to 1500 h. In a further embodiment, a transparent
magnetic recording layer is applied to the annealed imaging support.
The present invention discloses: an imaging support comprising:
a polyester base having a first and a second side; a gelatin subbing layer on the first side; and on the second side an antistatic layer comprising electrically-conductive
metal-containing fine particles dispersed in gelatin.
Annealable supports of the invention, having a gelatin subbing
layer on the emulsion side and an antistatic layer comprising electrically-conductive
metal-containing fine particles dispersed in gelatin on the backing
side, does not block during annealing. Furthermore, excellent adhesion of an
overlying magnetic layer is obtained for an antistatic layer continuing between 45
and 80 volume percent conductive particle.
The invention provides an annealable support which does not block
against a gelatin subbing layer and yet provides good adhesion of a magnetic
layer. In particular, excellent adhesion of the magnetic layer is maintained after
annealing and after photographic processing, which has so far been difficult to
achieve. The present annealable package does not require an additional protective
layer over the antistatic layer. Furthermore, it requires no further magnetic or
lubricant development.
The present invention is an imaging support which includes a
polyester base coated with a gelatin-containing subbing layer on the imaging side
of the support, and an antistatic layer on the opposite side of the support having
electrically-conductive metal-containing fine particles dispersed in a gelatin
containing layer, and wherein the electrically-conductive fine particles are present
at between 45 and 75 volume percent. The polyester base has a glass transition
temperature (Tg) of from 90 to 200 °C. The imaging support having a gelatin
subbing layer and a gelatin containing antistatic layer as outermost layers is heat-treated
at a temperature of from 80 °C to the Tg of the polyester base, for 0.1 h to
1500 h. In a preferred embodiment, the heat-treated imaging support is
subsequently coated with a transparent magnetic recording layer superposed on
the antistatic layer and an imaging layer is superposed on the gelatin containing
subbing layer. The specified volume percentage of electrically-conductive fine
particles in the antistatic layer was found to prevent self-adhesion or blocking
between the gelatin subbing layer and antistatic layer during heat-treatment
without the requirement of an intermediate protective layer. Furthermore,
excellent adhesion of a transparent magnetic recording layer to the imaging
support of the present invention is obtained for the specified volume percentages
of conductive particles.
The composite imaging support of this invention is suitable for use
in various imaging elements including, for example, photographic,
electrostatographic, photothermographic, migration, electrothermographic,
dielectric recording, and thermal-dye-transfer imaging elements. Details with
respect to the composition and function of this wide variety of imaging elements
are provided in U.S. Patent No. 5,719,016. Imaging elements that can be
provided with a composite support in accordance with this invention can differ
widely in structure and composition. For example, they can vary in regard to the
type of support, the number and composition of the image forming layers, and the
number and kinds of auxiliary layers included in the elements. The image
forming layer(s) of a typical photographic imaging element includes a radiation-sensitive
agent (e.g., silver halide) dispersed in a hydrophilic water-permeable
colloid. Suitable hydophilic colloids include both naturally-occurring substances
such as proteins, for example, gelatin, gelatin derivatives, cellulose derivatives,
polysaccharides such as dextran, gum arabic, and the like; as well as synthetic
polymers, for example, water-soluble polyvinyl compounds such as
poly(vinylpyrrolidone), acrylamide polymers, and the like. A common example
of an image-forming photographic layer is a gelatin-silver halide emulsion layer.
In particular, the photographic elements can be still films, motion picture films, x-ray
films, graphic arts films or microfiche. They can be black-and-white
elements, color elements adapted for use in negative-positive process or color
elements adapted for use in a reversal process.
Polymer film supports which are useful for the present invention
have a glass transition temperature of from 90 °C to 200 °C and include polyester
supports such as poly-1,4-cyclohexanedimethylene terephthalate, polyethylene
1,2-diphenoxyethane-4,4'-dicarboxylate, polybutylene terephthalate, and
polyethylene naphthalate and the like; and blends or laminates thereof.
Particularly preferred are polyethylene naphthalate and blends of polyethylene
naphthalate with polyethylene terephthalate. Additional suitable polyester
supports, polyester copolymers and polyester blends are disclosed in detail in U.S.
Pat. No. 5,580,707. A laminated support may be prepared by co-extrusion, in-line
lamination, or off-line lamination methods. A feedblock or a multi-manifold can
be used for coextrusion of polyester supports according to the present invention.
A biaxially stretched laminate support is obtained by laminating unstretched or
uniaxially stretched film, and then subjecting the laminate film to additional
stretching (orientation). In an off-line lamination method, biaxially stretched films
are laminated by heat or various adhesives, to give a biaxially stretched laminated
support. The supports can either be colorless or colored by the addition of a dye
or pigment. Addition of a dye or pigment is particularly desirable for high
refractive index polyester supports to reduce the tendency of light-piping or edge-fogging.
An ultraviolet absorbent may also be added for anti-fluorescence. The
thickness of the support is not particularly critical. Support thicknesses of 2 to 10
mils (50 µm to 254 µm) are suitable for photographic elements in accordance
with this invention.
Film supports can be surface-treated on either or both sides prior to
application of the gelatin subbing layer or gelatin-containing antistatic layer by
various processes including corona discharge, glow discharge, UV exposure,
flame treatment, electron-beam treatment or treatment with adhesion-promoting
agents including dichloroacetic acid and trichloroacetic acid, phenol derivatives
such as resorcinol and p-chloro-m-cresol, solvent washing prior to overcoating
with a subbing layer of the present invention. In addition to surface treatment or
treatment with adhesion promoting agents, additional adhesion promoting primer
or tie layers containing polymers such as vinylidene chloride-containing
copolymers, butadiene-based copolymers, glycidyl acrylate or methacrylate-containing
copolymers, maleic anhydride-containing copolymers, condensation
polymers such as polyesters, polyamides, polyurethanes, polycarbonates, mixtures
and blends thereof, and the like may be applied to the polyester support.
Particularly preferred primer or tie layers comprise a chlorine containing latex or
solvent coatable chlorine containing polymeric layer. Vinyl chloride and
vinylidene chloride containing polymers are preferred as primer or subbing layers
of the present invention. Typically the primer compositions of this invention are
composed of, by weight, from about 1 to 20 parts of latex polymer solids, and
from 0.1 to 5 parts by weight of an adhesion promoter such as resorcinol,
chlorophenol or chloromethylphenol in an aqueous system. A stable latex polymer
is prepared by emulsion polymerization as described in U.S. Pat. Nos. 2,627,088
and 3,501,301. Suitable chloride containing polymers are composed of from
about 70 to 100 percent by weight of vinyl chloride monomer or vinylidene
chloride monomer. Acid containing monomers are desirably included to promote
adhesion of overlying layers. Additional monomers may be incorporated in the
polymer to adjust the glass transition temperature. Suitable acid containing
monomers include acrylic acid, methacrylic acid, itaconic acid and maleic acid.
Suitable monomers for adjusting the glass transition temperature include
acrylonitrile, styrene, methacrylonitrile, glycidyl acrylates and alkyl acrylates.
Preferred chlorine containing polymers are composed of a mixture of (1) from
about 70 to 90 percent by weight of vinylidene chloride monomer (2) of from
about 0.5 to 15 weight percent of an acid containing monomer and (3) from about
5 to 30 weight percent of a Tg modifying monomer. Particularly preferred
polymers as a subbing layer are disclosed in U.S. Pat. Appl. No. 09/106,623.
The subbing or primer composition may be applied to the polyester
base using an in-line process during the base manufacture or by an off-line
process. When applied in an in-line process, the layer may be coated on the
polyester base prior to orientation, after orientation, or after uniaxial orientation
but before biaxial orientation. The primer composition described is typically
applied in accordance with U.S. Pat. Nos. 2,627,088 and 3,143,421. The coating
formulation is coated onto the amorphous support material, dried, and then the
resulting film is oriented by stretching and other steps applied to the film such as
heat setting, as described in detail in U.S. Pat. No. 2,779,684. Accordingly, the
particular support film used, the procedure and apparatus for the coating thereof
and the orientation of the film are not limitations of the present invention. Any of
the usual coating apparatus and processing steps employed in the art may be
employed in treating the film product of the present invention.
For the imaging side of the support, a hydrophilic subbing layer
containing gelatin, gelatin derivatives, a combination of gelatin and polymeric
film-forming binder, or a combination of gelatin and non-film-forming polymer
latex particles, and the like, is applied to the polyester film base prior to heat-treatment.
The subbing layer may be applied to a polyester support which has
been surface treated or be superposed on any suitable primer layer. A preferred
subbing layer for the imaging side of the support is described in USSN
09/067,306. The gelatin subbing layer is typically used in an amount of from
0.25 to 5 weight percent, preferably 0.5 to 1 weight percent. The subbing layer
may include addenda such as dispersants, surface active agents, plasticizers,
coalescing aids, solvents, co-binders, soluble dyes, solid particle dyes, haze
reducing agents, adhesion promoting agents, hardeners, antistatic agents, matting
agents, etc. For altering the coating and drying characteristics it is a common
practice in the art to use surface active agents (coating aids) or to include a water
miscible solvent in an aqueous dispersion. Suitable solvents include ketones such
as acetone or methyl ethyl ketone, and alcohols such as ethanol, methanol,
isopropanol, n-propanol, and butanol. Underlying subbing, primer or tie layers
may also be surface treated, for example by corona discharge treatment, to aid
wetting by the gelatin subbing formulation.
The electrically conductive antistatic layer of the present invention
is coated on the opposite side of the support from the gelatin-containing subbing
layer. The antistatic layer consists of electrically conductive metal-containing
particles dispersed in a polymeric film-forming binder which includes gelatin or a
gelatin-derivative. The electrically conductive particles are present at between 45
and 75 volume percent. Below 45 volume percent conductive particles, an
effective antistatic layer can be obtained, however, adhesion of a magnetic
recording layer is difficult to achieve, particularly without the presence of a
crosslinking agent. Furthermore, significantly below 45 volume percent
conductive particles blocking between the antistatic layer and the gelatin subbing
layer occurs during heat-treatment. Significantly above 75 volume percent
conductive particles, cohesive failure of the antistatic layer, dusting, and increased
optical density or haze occurs. Between 45 and 75 volume percent conductive
particles, the support can be heat-treated without causing adhesion or blocking,
and a subsequent transparent magnetic recording layer or other auxiliary layers
can be applied after heat-treatment and exhibit excellent adhesion without the
presence of a crosslinking agent. Additional materials in the antistatic layer may
include ionically conducting materials, electronically conductive polymers, non-conductive
particles, magnetic particles, abrasive particles, matte particles,
dispersants, surface active agents, dyes, lubricants, haze reducing agents, adhesion
promoting agents, hardeners, etc. The polymeric binder of the antistatic layer
contains gelatin or a gelatin derivative and could also include, latex polymers or
hydrophilic polymers.
Electrically conductive metal-containing particles which may be
used in the electrically conductive antistatic layer include, e.g., conductive
crystalline inorganic oxides, conductive metal antimonates, and conductive
inorganic non-oxides or combinations thereof. Crystalline inorganic oxides may
be chosen from ZnO, TiO2, SnO2, Al2O3, In2O3, SiO2, MgO, BaO, MoO3,
WO3, and V2O5 or composite oxides thereof, as described in, e.g., U.S. Pat. Nos.
4,275,103; 4,394,441; 4,416,963; 4,418,141; 4,431,764; 4,495,276; 4,571,361;
4,999,276 and 5,122,445. The use of antimony-doped tin oxide at an antimony
doping level of at least 8 atom percent and haying an X-ray crystallite size less
than 100 Å and an average equivalent spherical diameter less than 15 nm but no
less than the X-ray crystallite size as taught in U.S. Pat. No. 5,484,694 is the
preferred granular conductive oxide. Conductive metal antimonates suitable for
use in the antistatic layer include those as disclosed in, e.g., U.S. Pat. Nos.
5,368,995 and 5,457,013. Zinc antimonate is the preferred metal antimonate.
Conductive inorganic non-oxides suitable for use as conductive particles in the
antistatic layer include: TiN, TiB2, TiC, NbB2, WC, LaB6, ZrB2, MoB, and the
like, as described, e.g., in Japanese Kokai No. 4/55492, published February 24,
1992. The conductive particles present in the electrically conductive antistatic
layer are not specifically limited in particle size or shape. The particle shape may
range from roughly spherical or equiaxed particles to high aspect ratio particles
such as fibers, whiskers or ribbons. In addition conductive acicular metal-containing
particles as described in US Patent Nos. 5,719,016 and 5,831,119 are
also preferred as antistatic agents. Additionally, the conductive materials
described above may be coated on a variety of other particles, also not particularly
limited in shape or composition. For example the conductive inorganic material
may be coated on non-conductive SiO2, Al2O3 or TiO2 particles, whiskers or
fibers. For the preferred electrically-conductive particles of zinc antimonate and
antimony-doped tin oxide the volume percentage of 45 to 75 percent corresponds
to about a ratio of 85/15 to 95/5 conductive particles to gelatin.
Any gelatin, gelatin derivative, or combination of gelatin with a
polymeric co-binder may be used for the gelatin-containing subbing layer and as
the binder for the antistatic layer. Preferred gelatins include alkali-treated (i.e.,
lime treated), acid-treated, and enzyme-treated gelatins. The gelatin may be
hardened using any of a variety of means known to one skilled in the art. Useful
hardening agents include aldehyde compounds such as formaldehyde and
glutaraldehyde; ketone compounds such as diacetyl and cyclopentanedione;
compounds having reactive halogens such as bis(2-chloroethylurea), 2-hydroxy-4,6-dichloro-1,3,5-triazine,
and those described in U.S. Patent Nos. 3,288,775 and
2,732,303 and British Patent No. 994,869; N-methylol compounds such as N-hydroxymethylolphthalimide
and those described in U.S. Patent Nos. 2,732,316
and 2,586,168; isocyanates described in U.S. Patent No. 3,103,437; aziridine
compounds disclosed in U.S. Patent Nos. 3,017,280 and 2,983,611; acid
derivatives described in U.S. Patent Nos. 2,725,294 and 2,725,295; epoxy
compounds described in U.S. Patent No. 3,091,537; halogenated
carboxyaldehydes such as mucochloric acid; inorganic compounds such as
chrome alum, zirconium sulfate, and the carboxyl group activating compounds
described in Japanese Patent Publication Nos. 56-12853, 58-32699, 60-225148,
51-126125, 58-50699, 52-54427 and U.S. Patent No. 3,321,313; and the like.
The gelatin containing layers may additionally serve as an acid scavenger,
neutralizing HCl which may result from thermal degradation of a chlorine
containing primer layer.
Optional polymeric film-forming cobinders suitable for use in
conductive layers of this invention include: water-soluble, hydrophilic polymers
such as maleic acid anhydride copolymers such as sulfonated styrene/maleic acid
anhydride; cellulose derivatives such as carboxymethyl cellulose, hydroxyethyl
cellulose, cellulose acetate butyrate, diacetyl cellulose or triacetyl cellulose;
synthetic hydrophilic polymers such as polyvinyl alcohol, poly-N-vinylpyrrolidone,
acrylic acid copolymers, polyacrylamide, their derivatives and
partially hydrolyzed products, vinyl polymers and copolymers such as polyvinyl
acetate and polyacrylate acid ester; derivatives of the above polymers; and other
synthetic resins. Other suitable cobinders include aqueous emulsions of addition-type
polymers and interpolymers prepared from ethylenically unsaturated
monomers such as acrylates including acrylic acid, methacrylates including
methacrylic acid, acrylamides and methacrylamides, itaconic acid and its half-esters
and diesters, styrenes including substituted styrenes, acrylonitrile and
methacrylonitrile, vinyl acetates, vinyl ethers, vinyl and vinylidene halides, and
olefins and aqueous dispersions of polyurethanes or polyesterionomers.
Polyurethanes, polyesterionomers, and aqueous emulsions of vinylidene halide
interpolymers are the preferred cobinders.
Coated supports in accordance with the present invention having as
outermost layers a gelatin-containing subbing layer and an antistatic layer,
containing gelatin and electrically-conductive particles present at between 45 and
75 volume percent, are subjected to an extended heat treatment or annealing step
after conventional support film manufacturing heat treatment to reduce core-set
curling tendencies of the support. Such "post manufacture" heat tempering or
annealing includes heating the coated film support at a temperature in the range of
from about 80 °C (more preferably about 90 °C) up to about the glass transition
temperature (Tg) of the polymer support for about 0.1 to 1500 hours (more
preferably 0.25 to 500 hours) as described in US Patent Nos. 4,141,735 and
5,326,689. The heat tempering or annealing step for reducing core-set curling
tendencies is distinguishable from typical support manufacturing heat treatment in
that it is performed after the support is wound on a roll rather than as part of the
primary support manufacturing process. In a preferred embodiment of the present
invention, the imaging support consists of a polyethylene-2,6-naphthalate film
base which is coated on both sides with vinylidene chloride primer layers. A
gelatin subbing layer is applied on one side of the support and an aqueous
antistatic coating composition having tin oxide or zinc antimonate particles
dispersed in gelatin is coated on the opposite side of the support. The support is
annealed at a temperature from about from 90 °C to 4 °C below the Tg of the
polyester base for between 0.25 and 500 hours. With respect to polyethylene-2,6-naphthalate,
the Tg is about 140° C., and the heat treatment temperature is from
90° C. to 120° C., preferably from 100° C. to 115° C., and more preferably from
105° C. to 115° C.
As indicated in the prior art, the winding tension, winding speed,
knurl height, humidity, roll diameter, roll uniformity, core material, and core
diameter are also important considerations during the heat treatment process. A
preferred winding tension is from 3 to 75 kg/m, more preferably from 5 to 40
kg/m, and most preferably from 10 to 35 kg/m. When the winding tension is too
high, self-adhesion of the support may occur, particularly for a gelatin subbing on
the imaging side and a gelatin containing antistatic layer having between 45 and
about 55 volume percent conductive particles. On the other hand, when the
tension is less than 3 kg/m, slippage may occur which results in poor handling
characteristics. The winding may be conducted at a constant tension, or while
gradually increasing or decreasing the tension. A preferred method is to conduct
the winding while decreasing the tension. The winding procedure may be
conducted at any temperature ranging from room temperature to the Tg of the
support. It is preferred to wind the support at a temperature of greater than 80 °C
to reduce the time required at elevated temperature to achieve the appropriate core
set reduction while in the rolled format. It is generally preferred to control the
humidity during the heat-treatment. The preferred relative humidity is from 0%
to 85%, more preferably from 0% to 80%, and most preferably from 0% to 75%.
After heat-treatment of the support, the antistatic layer of the
present invention may optionally be overcoated with a wide variety of additional
functional or auxiliary layers such as a transparent magnetic recording layer,
abrasion resistant layers, protective layers, curl control layers, transport control
layers, lubricant layers, image recording layers, adhesion promoting layers, layers
to control water or solvent permeability. In preferred embodiments of the
invention, the imaging element further comprises a transparent magnetic
recording layer superposed on the antistatic layer, and an image forming layer
comprising a silver halide emulsion layer is superposed on the gelatin subbing
layer. The transparent magnetic recording layer and the image forming layer are
applied after heat-treatment of the support.
Transparent magnetic layers suitable for use in the composite
supports and imaging elements in accordance with the invention include those as
described, e.g., in Research Disclosure, November 1992, Item 34390. Research
Disclosure is published by Kenneth Mason Publications, Ltd., Dudley House, 12
North Street, Emsworth, Hampshire P010 7DQ, ENGLAND. The magnetic layer
may contain optional additional components for improved manufacturing or
performance such as crosslinking agents or hardeners, catalysts, coating aids,
dispersants, surfactants, including fluorinated surfactants, charge control agents,
lubricants, abrasive particles, filler particles and the like. The magnetic particles
of the present invention can comprise ferromagnetic or ferromagnetic oxides,
complex oxides including other metals, metallic alloy particles with protective
coatings, ferrites, hexaferrites, etc. and can exhibit a variety of particulate shapes,
sizes, and aspect ratios. Ferromagnetic oxides useful for transparent magnetic
coatings include γ-Fe2O3, Fe3O4, and CrO2. The magnetic particles optionally
can be in solid solution with other metals and/or contain a variety of dopants and
can be overcoated with a shell of particulate or polymeric materials. Preferred
additional metals as dopants, solid solution components or overcoats are Co and
Zn for iron oxides; and Li, Na, Sn, Pb, Fe, Co, Ni, and Zn for chromium dioxide.
Surface-treatments of the magnetic particle can be used to aid in chemical
stability or to improve dispersibility as is commonly practiced in conventional
magnetic recording. Additionally, magnetic oxide particles may contain a thicker
layer of a lower refractive index oxide or other material having a low optical
scattering cross-section as taught in U.S. Pat. Nos. 5,217,804 and 5,252,441.
Cobalt surface-treated γ-iron oxide is a preferred magnetic particle.
Ferromagnetic particles of this type are available commercially, for example,
from Toda Kogyo Corp. under the tradenames CSF 4085V2, CSF 4565V, CSF
4585V, and CND 865V, and also from ISK Magnetics, Inc. under the tradenames
RPX-4392, RPX-5003, RPX-5026, and RPX-5012.
Suitable polymeric binders for the transparent magnetic recording
layer, antistatic layer, or auxiliary layers coated over the subbing layer of the
present invention include: gelatin; cellulose compounds such as cellulose nitrate,
cellulose acetate, cellulose diacetate, cellulose triacetate, carboxymethyl cellulose,
hydroxyethyl cellulose, cellulose acetate butyrate, cellulose acetate propionate,
cellulose acetate phthalate and the like; vinyl chloride or vinylidene chloride-based
copolymers such as, vinyl chloride-vinyl acetate copolymers, vinyl
chloride-vinyl acetate-vinyl alcohol copolymers, vinyl chloride-vinyl acetate-maleic
acid copolymers, vinyl chloride-vinylidene chloride copolymers, vinyl
chloride-acrylonitrile copolymers, acrylic ester-vinylidene chloride copolymers,
methacrylic ester-vinylidene chloride copolymers, vinylidene chloride-acrylonitrile
copolymers, acrylic ester-acrylonitrile copolymers, methacrylic ester-styrene
copolymers, thermoplastic polyurethane resins, thermosetting
polyurethane resins, phenoxy resins, phenolic resins, epoxy resins, polycarbonate
or polyester resins, urea resins, melamine resins, alkyl resins, urea-formaldehyde
resins, and the like; polyvinyl fluoride, butadiene-acrylonitrile copolymers,
acrylonitrile-butadiene-acrylic acid copolymers, acrylonitrile-butadiene-methacrylic
acid copolymers, polyvinyl alcohol, polyvinyl butyral, polyvinyl
acetal, styrene-butadiene copolymers, acrylic acid copolymers, polyacrylamide,
their derivatives and partially hydrolyzed products; and other synthetic resins.
Other suitable binders include aqueous emulsions of addition-type polymers and
interpolymers prepared from ethylenically unsaturated monomers such as
acrylates including acrylic acid, methacrylates including methacrylic acid,
acrylamides and methacrylamides, itaconic acid and its half-esters and diesters,
styrenes including substituted styrenes, acrylonitrile and methacrylonitrile, vinyl
acetates, vinyl ethers, vinyl and vinylidene halides, and olefins and aqueous
dispersions of polyurethanes or polyesterionomers. Preferred binders for the
transparent magnetic recording layer include polyurethanes, polyesters, vinyl
chloride based copolymers, and cellulose esters, particularly cellulose diacetate
and cellulose triacetate. Cellulose diacetate is the most commonly used polymeric
binder for a transparent magnetic recording layer for application in a small format
photographic imaging element and is frequently crosslinked by any suitable
crosslinking or hardening agent, though crosslinking is not required according the
present invention. Common crosslinking agents which may be used include
isocyanates, aziridines, and melamine resins, such as melamine-formaldehyde
resins. However, one significant advantage of the present invention is that
acceptable adhesion can be obtained without crosslinking of an overlying
magnetic recording layer.
Photographic elements in accordance with the preferred
embodiment of the invention can be single color elements or multicolor elements.
Multicolor elements contain image dye-forming units sensitive to each of the
three primary regions of the spectrum. Each unit can comprise a single emulsion
layer or multiple emulsion layers sensitive to a given region of the spectrum. The
layers of the element, including the layers of the image-forming units, can be
arranged in various orders as known in the art. In an alternative format, the
emulsions sensitive to each of the three primary regions of the spectrum can be
disposed as a single segmented layer.
A typical multicolor photographic element comprises a support
bearing a cyan dye image-forming unit comprised of at least one red-sensitive
silver halide emulsion layer having associated therewith at least one cyan dye-forming
coupler, a magenta dye image-forming unit comprising at least one
green-sensitive silver halide emulsion layer having associated therewith at least
one magenta dye-forming coupler, and a yellow dye image-forming unit
comprising at least one blue-sensitive silver halide emulsion layer having
associated therewith at least one yellow dye-forming coupler. The element can
contain additional layers, such as filter layers, interlayers, antihalation layers,
overcoat layers, subbing layers, and the like.
Photographic elements in accordance with one embodiment of the
invention are preferably used in conjunction with an applied magnetic layer as
described in Research Disclosure, November 1992, Item 34390. It is also
specifically contemplated to use composite supports according to the invention in
combination with technology useful in small format film as described in Research
Disclosure, June 1994, Item 36230. Research Disclosure is published by Kenneth
Mason Publications, Ltd., Dudley House, 12 North Street, Emsworth, Hampshire
P010 7DQ, ENGLAND.
In the following discussion of suitable materials for use in the
photographic emulsions and elements that can be used in conjunction with the
composite supports of the invention, reference will be made to Research
Disclosure, September 1994, Item 36544, available as described above, which
will be identified hereafter by the term "Research Disclosure." The Sections
hereafter referred to are Sections of the Research Disclosure, Item 36544.
The silver halide emulsions employed in the image-forming layers
of photographic elements can be either negative-working or positive-working.
Suitable emulsions and their preparation as well as methods of chemical and
spectral sensitization are described in Sections I, and III-IV. Vehicles and vehicle
related addenda are described in Section II. Dye image formers and modifiers are
described in Section X. Various additives such as UV dyes, brighteners,
luminescent dyes, antifoggants, stabilizers, light absorbing and scattering
materials, coating aids, plasticizers, lubricants, antistats and matting agents are
described, for example, in Sections VI-IX. Layers and layer arrangements, color
negative and color positive features, scan facilitating features, supports, exposure
and processing can be found in Sections XI-XX.
In addition to silver halide emulsion image-forming layers, the
image-forming layer of imaging elements in accordance with the invention may
comprise, e.g., any of the other image forming layers described in. U.S. Pat.
5,457,013.
The method of the present invention is illustrated by the following
detailed examples of its practice. However, the scope of this invention is by no
means limited to these illustrative examples.
EXAMPLES
Support A
Subbed supports were prepared by first coating a solution of the
subbing materials onto both sides of a cast poly(ethylene naphthalate), PEN,
support. The solution contained 7% of a poly(acylonitrile-co-vinylidene chloride-co-acrylic
acid) latex, 1% resorcinol and 0.2% saponin in water. After drying, the
subbed PEN was stretched and tentered at elevated temperatures resulting in an
adhesion layer that is approximately 100 nm thick and a PEN layer which is about
95 um thick. To this support, a solution of 1% gelatin and 0.01% saponin in
water was applied onto the imaging side of the support to give a dried gel
thickness of about 100 nm. The support was then dried at 110 °C and heat
relaxed at about 140°C.
An aqueous antistatic coating formulation containing colloidal
conductive zinc antimonate particles dispersed in gelatin and containing various
other additives as described below was prepared at nominally 2.3 percent solids
by weight. The weight ratio of colloidal zinc antimonate to gelatin was nominally
90/10, and the zinc antimonate was present at nominally 58 volume percent of the
coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 2.077 |
| Gelatin0.231 |
| Hardener 0.005 |
| Wetting aid 0.030 |
| Water 97.657 |
The above coating formulation was applied to vinylidene chloride
subbed polyethylene naphthalate support using a coating hopper so as to provide a
nominal total dry coverage of 0.30 g/m2.
The support having coated thereon vinylidene chloride primer
layers on both sides, a gelatin containing subbing layer on the emulsion side, and
an antistatic layer on the opposite side from the gelatin subbing layer was
subsequently knurled to provide a nominal knurl height of between 10 and 20
micrometers between 5 and 15 mm width. The knurled support was wound on a
cylindrical core with the antistatic layer facing inwards. The cylidrical core
consisted of fiberglass and had an outer diameter of 6 inches (15 cm). The wound
support was heat-treated at conditions to give 100 °C for 48 hrs throughout the
roll.
Support B
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous
antistatic coating formulation containing colloidal conductive zinc antimonate
particles dispersed in gelatin and having various other additives as described
below was prepared at nominally 4.6 percent solids by weight. The weight ratio
of colloidal zinc antimonate to gelatin was nominally 90/10, and the zinc
antimonate was present at nominally 60 volume percent of the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 4.154 |
| Gelatin0.461 |
| Hardener 0.018 |
| Wetting aid 0.030 |
| Water 95.337 |
The above coating formulation was applied to a vinylidene
chloride subbed polyethylene naphthalate support using a coating hopper so as to
provide a nominal total dry coverage of 0.60 g/m2. The support having an
antistatic coating was dried and subsequently heat-treated according to the
conditions for Support A.
Support C
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous antistatic
coating formulation containing colloidal conductive zinc antimonate particles
dispersed in gelatin and having various other additives as described below was
prepared at nominally 4.3 percent solids by weight. The weight ratio of colloidal
zinc antimonate to gelatin was nominally 90/10, and the zinc antimonate was
present at nominally 60 volume percent of the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 3.807 |
| Gelatin0.423 |
| Hardener 0.011 |
| Wetting aid 0.033 |
| Water 95.726 |
The above coating formulation was applied to a vinylidene
chloride subbed polyethylene naphthalate support using a coating hopper so as to
provide a nominal total dry coverage of 0.55 g/m2. The support having an
antistatic coating was dried and subsequently heat-treated according to the
conditions for Support A.
Support D
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous
antistatic coating formulation containing colloidal conductive zinc antimonate
particles dispersed in gelatin and having various other additives as described
below was prepared at nominally 2.3 percent solids by weight. The weight ratio
of colloidal zinc antimonate to gelatin was nominally 93/7, corresponding to
about 65 volume percent zinc antimonate in the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 2.146 |
| Gelatin0.162 |
| Wetting aid 0.030 |
| Water 97.662 |
The above coating formulation was applied to a vinylidene
chloride subbed polyethylene naphthalate support using a coating hopper so as to
provide a nominal total dry coverage of 0.30 g/m2. The support having an
antistatic coating was dried and subsequently heat-treated according to the
conditions for Support A.
Support E
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous
antistatic coating formulation containing colloidal conductive zinc antimonate
particles dispersed in gelatin and having various other additives as described
below was prepared at nominally 4.5 percent solids by weight. The weight ratio
of colloidal zinc antimonate to gelatin was nominally 93/7, and the zinc
antimonate was present at nominally 68 volume percent of the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 4.292 |
| Gelatin0.323 |
| Hardener 0.006 |
| Wetting aid 0.030 |
| Water 95.349 |
The above coating formulation was applied to a vinylidene
chloride subbed polyethylene naphthalate support using a coating hopper so as to
provide a nominal total dry coverage of 0.60 g/m2. The support having an
antistatic coating was dried and subsequently heat-treated according to the
conditions for Support A.
Support F
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous
antistatic coating formulation containing colloidal conductive zinc antimonate
particles dispersed in gelatin and having various other additives as described
below was prepared at nominally 2.4 percent solids by weight. The weight ratio
of colloidal zinc antimonate to gelatin was nominally 80/20, and the zinc
antimonate was present at nominally 40 volume percent of the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 1.846 |
| Gelatin0.462 |
| Hardener 0.018 |
| Wetting aid 0.030 |
| Water 97.644 |
The above coating formulation was applied to a vinylidene
chloride subbed polyethylene naphthalate support using a coating hopper so as to
provide a nominal total dry coverage of 0.30 g/m2. The support having an
antistatic coating was dried and subsequently heat-treated according to the
conditions for Support A.
Support G
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous
antistatic coating formulation containing colloidal conductive zinc antimonate
particles dispersed in gelatin and having various other additives as described
below was prepared at nominally 7.0 percent solids by weight. The weight ratio
of colloidal zinc antimonate to gelatin was nominally 80/20, and the zinc
antimonate was present at nominally 42 volume percent of the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 5.538% |
| Gelatin 1.385 |
| Wetting aid 0.030 |
| Water 93.047 |
The above coating formulation was applied to vinylidene chloride
subbed polyethylene naphthalate support using a coating hopper so as to provide a
nominal total dry coverage of 0.90 g/m2. The support having an antistatic coating
was dried and subsequently heat-treated according to the conditions for Support
A.
Support H
A support was prepared according to Support A without the
application of an antistatic layer. Vinylidene chloride containing primer layers
were applied to the front and back surfaces of the support. A gelatin containing
subbing layer was applied to one surface. The support having coated thereon as
outermost layers, a gelatin-subbing layer and a vinylidene chloride primer layer
was heat-treated. The support exhibited severe blocking and could not be
unwound for subsequent coatings.
Support I
A heat-treated support having a subbing layer on the emulsion side
and an antistatic layer on the opposite side was prepared in a similar manner to
Support A, except for the composition of the antistatic layer. An aqueous
antistatic coating formulation containing colloidal conductive zinc antimonate
particles dispersed in a terpolymer latex consisting of vinylidene chloride,
acrylonitrile and acrylic acid and having various other additives as described
below was prepared at nominally 2.0 percent solids by weight. The weight ratio
of colloidal zinc antimonate to terpolymer was nominally 75/25, and the zinc
antimonate was present at nominally 34 volume percent of the coated layer.
| Component Weight % (wet) |
| Colloidal zinc antimonate | 1.441% |
| Terpolymer 0.481 |
| Wetting aid 0.033 |
| Dispersing aid | 0.036 |
| Water 98.009 |
The above coating formulation was applied to vinylidene chloride
subbed polyethylene naphthalate support using a coating hopper so as to provide a
nominal total dry coverage of 0.60 g/m2. The support having an antistatic coating
was dried and subsequently heat-treated according to the conditions for Support
A. The support exhibited severe blocking and could not be unwound for
subsequent coatings.
Support J
A support was prepared according to Support A without the
application of an antistatic layer. Vinylidene chloride containing primer layers
were applied to the front and back surfaces of the support. A gelatin containing
subbing layer was applied to one surface. The remaining surface had a gelatin
containing layer without the addition of an electrically-conductive metal-containing
material. The support was annealed against a similar support such that
the gelatin subbing layers contacted each other. The support exhibited moderate
blocking and was not used for subsequent coatings.
Examples 1-17
The resultant heat-treated supports, having a gelatin subbing layer
and an antistatic layer were subsequently overcoated with one of several
transparent magnetic recording layers MC-1 through MC-6. The transparent
magnetic recording layers contained cobalt surface-modified γ-Fe2O3 particles in a
polymeric binder which optionally may be cross-linked and contains suitable
abrasive particles. The formulations for the magnetic layers are given below.
Total dry coverage for all of the magnetic layers was nominally 1.5 g/m2. An
optional lubricant-containing topcoat layer containing carnauba wax and a
fluorinated surfactant as a wetting aid was applied over the transparent magnetic
recording layer to provide a nominal dry coverage of about 0.02 g/m2. The
resultant multilayer structure including a support having an electrically-conductive
antistatic layer and a gelatin subbing layer which has been heat-treated
and then subsequently overcoated with a transparent magnetic recording layer, an
optional lubricant layer, and other optional layers is referred to herein as a
"magnetic backing package."
Magnetic Coating 1 (MC-1) CTA
A magnetic coating formulation comprising Co-γ-Fe
2O
3 magnetic
particles, alumina abrasive particles, cellulose triacetate, cellulose diacetate and
various other additives was prepared according to the formulation indicated
below.
| Cellulose diacetate | 2.440 g |
| Cellulose triacetate | 0.180 g |
| Magnetic oxide Toda CSF-4085V2 | 0.113 |
| Surfactant Rhodafac PE510 | 0.006 g |
| Alumina Norton E-600 | 0.076 g |
| Dispersing aid, Zeneca Solsperse 24000 | 0.004 g |
| 3M FC431 | 0.015 |
| Dichloromethane | 67.919 |
| Acetone | 24.257 g |
| Methyl acetoacetate | 4.851 g |
Magnetic Coating MC-2
A magnetic coating formulation was prepared in a similar manner
to MC-1 except the binder was predominatly cellulose diacetate rather than
cellulose triacetate. The coating formulation is given below.
| Cellulose diacetate | 2.51 g |
| Cellulose triacetate | 0.115 g |
| Magnetic oxide Toda CSF-4085V2 | 0.113 g |
| Surfactant Rhodafac PE510 | 0.006 g |
| Alumina Norton E-600 | 0.076 g |
| Dispersing aid, Zeneca Solsperse 24000 | 0.004 g |
| 3M FC431 | 0.015 g |
| Dichloromethane | 67.919 g |
| Acetone | 24.257 g |
| Methyl acetoacetate | 4.851 g |
Magnetic Coating MC-3, MC-4, and MC-5
Magnetic coating formulations were prepared in a similar manner
to MC-2 however a crosslinking agent was included. MC-3 and MC-4,
respectively, had 5 and 10 weight percent based on the weight of cellulose
diacetate of Cymel 303 (Cytec Industries, Inc.) a melamine-formaldehyde resin as
a crosslinking agent. In addition, 3 % of paratoluene sulfonic acid based on the
weight of Cymel 303 was added as a catalyst for the crosslinking reaction.
An isocyanate crosslinking agent, Desmodur N3300 (Bayer Corporation ), was
added at 7.5 weight percent based on the weight of cellulose diacetate for
magnetic coating formulation MC-5.
Magnetic Coating Formulation MC-6 (MmE)
A magnetic coating formulation was prepared having Co-γ-Fe2O3
magnetic particles and alumina abrasive particles dispersed in a polymeric binder
consisting of a copolymer of methylmethacrylate-methacrylic acid. The coating
solvents used were methylene chloride, ethyl acetate and ethyl alcohol.
The magnetic backing packages prepared in accordance with this
invention and the comparative examples were evaluated for antistatic layer
performance, dry adhesion and wet adhesion. Antistatic performance was
evaluated by measuring the internal electrical resistivity using a salt bridge wet
electrode resistivity (WER) measurement technique (as described, for example, in
"Resistivity Measurements on Buried Conductive Layers" by R.A. Elder, pages
251-254, 1990 EOS/ESD Symposium Proceedings). Typically, antistatic layers
with WER values greater than about 1x1012 ohm/square are considered to be
ineffective at providing static protection for photographic imaging elements
Dry adhesion of the magnetic backing package was evaluated by
scribing a small region of the coating with a razor blade. A piece of high-tack
adhesive tape was placed over the scribed region and quickly removed multiple
times. The number of times the adhesive tape could be removed without any
coating removal is a qualitative measure of the dry adhesion. Dry adhesion was
evaluated both before and after photographic processing by the standard C-41
process. Wet adhesion was evaluated using a procedure which simulates wet
processing of silver halide photographic elements. A one millimeter wide line
was scribed into a sample of the magnetic backings package. The sample was
then immersed in KODAK Flexicolor developer solution at 38 °C and allowed to
soak for 3 minutes and 15 seconds. The test sample was removed from the heated
developer solution and then immersed in another bath containing Flexicolor
developer at about 25 °C and a rubber pad (approximately 3.5 cm dia.) loaded
with a 900 g weight was rubbed 100 times back and forth across the sample in the
direction perpendicular to the scribe line. The relative amount of additional
material removed is a qualitative measure of the wet adhesion of the various
layers. Blocking results, WER values and adhesion results are given in Table 1.

The above results indicate that an imaging support having a gelatin
subbing layer on one side of the support and an electrically-conductive layer
containing between 45 and 75 volume percent of electrically-conductive metal-containing
particles dispersed in gelatin on the opposite side of the support can be
annealed at a temperature greater than 80 °C without blocking and provide
acceptable adhesion when overcoated with a transparent magnetic recording layer.
Example 17 shows that a annealing of a gelatin subbing layer against another
gelatin containing layer results in blocking. Similarly, Examples 15 and 16
demonstrate severe blocking when a gelatin subbing layer is in contact with a
vinylidene chloride containing primer layer or antistatic layer during annealing of
the support. Examples 11-14 demonstrate unacceptable wet adhesion of a
transparent magnetic recording layer to an annealed support for an antistatic layer
containing less than 45 volume percent conductive particles, even when the
magnetic layer contains a crosslinking agent. In addition, the SER and WER
results indicate conductivity of the antistatic layer is essentially unaltered by
annealing the support and overcoating with a magnetic layer.