Container for photographic film cartridge

Abstract: A container body for photographic film cartridge composed of a resin comprising more than 70 wt. % of polypropylene resin, 0.01 to 2 wt. % of a fatty acid amide lubricant, 0 to 1 wt. % of an antioxidant and 0.01 to 1 wt. % of an organic nucleating agent of which the surface has previously been treated with a stabilizer selected from the group consisting of aliphatic metal salts, metal salts of alkyl lactic acids and metal salts of lactic acid. The container body of the invention is excellent in dropping strength, transparency and odor. The injection moldability is also excellent, because of good resin fluidity and high crystallization temperature.

Description: This invention relates to a container body for photographic film cartridges. The body of a conventional container for a photographic film cartridge is made of high density polyethylene resin, homopolypropylene resin not containing an ethylene unit or block-type or random-type polypropylene resin containing about 2 wt. % of an ethylene unit the melt flow rate (MFR) of which is about 10 g/10 min in order to secure rigidity and to prevent burrs and stringiness at the injection molding. Since these resins are inferior in transparency, they are colored by blending with a pigment. The resins are also inferior in fluidity, and short shot and weld lines are liable to occur. The physical strength and thickness are insufficient. As a result, transparency becomes worse, the cooling time is elongated, the resin amount increases, and the container body is expensive. On the other hand, the present inventor has completed another container body for a photographic film cartridge improved in transparency and injection moldability as described in US-A-4,639,386. However, this container evolves a bad smell at the injection molding caused by inorganic or organic nucleating agents added thereto. JP-A-61-73947 discloses a container body for a film cartridge comprising polypropylene resin, 0.05 to 1 wt. % fatty acid amide lubricant and an organic nucleating agent. JP-A-62-138545 discloses a polypropylene resin composition suitable for the preparation of food packaging materials, containing 0.05 to 5 parts by weight of a dibenzylidene sorbitol or its alkyl derivatives being surface heated with a stabilizer having chlorine trapping abilities. It is the object of the invention to provide a container body for photographic film cartridges which does not evolve a bad smell at the injection molding and which is excellent in physical strength, transparency and moldability. Said object is achieved by a resin comprising more than 70 wt.% of a polypropylene resin, 0.01 to 2 wt.% of a fatty acid amide lubricant and a nucleating agent, characterized in that the nucleating agent is contained in an amount of 0.01 to 1 wt.%, more than 30% of the surface of the nucleating agent is coated with a stabilizer selected from the group consisting of aliphatic metal salts, metal salts of alkyl lactic acids and metal salts of lactic acid, the stabilizer being present in the resin in an amount of 0.003 to 5 wt.%, and the resin further comprises an antioxidant in an amount of 0,05 to 1 wt%. Figures 1 to 3 are sectional side views indicating several examples of the container to which the container body of the present invention is applied. Figures 4 to 6 are perspective views indicating several examples of the container body combined with the case of the container. The polypropylene resin may be homopolypropylene resin or a copolymer resin of propylene and α-olefin the α-olefin content of which is less than 10 wt. %. Preferred polypropylene resins include propylene-α-olefin copolymer resins having a propylene content of 90 to 99 wt. %,produced by using a chlorine-containing compound such as titanium trichloride or diethylaluminum monochloride as a catalyst, and propylene-ethylene random copolymer resins are particularly preferable. The MFR of the polypropylene resin is in the range of 12 to 80 g/10 min , preferably 16 to 60 g/10 min, more preferably 20 to 50 g/10 min, measured according to ASTM D-1238 at 230°C under 2160 g loading. The molecular weight distribution is preferably 2 to 5 (weight average molecular weight M w/number average molecular weight M n by the GPC method). Other thermoplastic resins may be blended with the polypropylene resin. A preferable thermoplastic resin among polyolefin resins is linear low density polyethylene resin. The fatty acid amide lubricant improves the injection moldability, particularly the fluidity of resin and mold releasability. It bleeds out to form a membrane of the fatty acid amide on the surface of the container body, and thereby prevents abrasion and the blocking of the container bodies. Moreover, it makes the inner surface slippery, and thereby improves mold releasability, prevents bucking, and facilitates removal of the photographic film cartridge The content of the lubricant is 0.01 to 2 wt. %. If the content is less than 0.01 wt. %, the above effects are insufficient causing problems particularly in the case of a resin composition the dropping strength of which is remarkably raised. While, if the content is beyond 2 wt. %, screw slip occurs and decreases the injection amount. The molded container body is sticky, and dust is liable to adhere to the surface, as well as the feeling becomes worse. The transparency is also degraded. Examples of commercial lubricants suitable for the present invention include: Oleic amide lubricants; "ARMOSLIP-CP" (Lion akzo Co., Ltd.), "NEWTRON" and "NEWTRON P" (Nippon Fine Chemical Co., Ltd.), "AMIDE-O" (Nitto Kagaku K.K.), "DIAMID O-200" and "DIAMID G-200" (Nippon Kasei Chemical Co., Ltd.), "ALFLOW E-10" (Nippon Oil and Fats Co., Ltd.). Erucic amide lubricants; "ALFLOW P-10" (Nippon Oil and Fats Co., Ltd.), "NEWTRON S" (Nippon Fine Chemical Co., Ltd.). Stearic amide lubricants; "ALFLOW S-10" (Nippon Oil and Fats Co., Ltd.), "NEWTRON 2" (Nippon Fine Chemical Co., Ltd.), "DIAMID 200" (Nippon Kasei Chemical Co., Ltd.). Stearylerucic amide lubricants; "SNT" (Nippon Fine Chemical Co., Ltd.). Bis fatty acid amide lubricants; "BISAMIDE" (Nitto Kagaku K.K.), "DIAMID-200 BIS" (Nippon Kasei Chemical Co., Ltd.), "ARMOWAX-EBS" (Lion Akzo Co., Ltd.). Behenic amide; "BNT" (Nippon Fine Chemical Co., Ltd.). Two or more fatty acid amide lubricants may be combined. The antioxidant prevents coloring troubles at the time of temperature elevation. It is incorporated in an amount of 0.05 to 1 wt. %. If the content is beyond 1 wt. %, it exerts a bad influence, such as fogging and increase or decrease of the sensitivity, upon the photographic film using oxidation-reduction reaction. A preferable content is 0.05 to 0.5 wt. %. There are, for example, phenol antioxidants, phosphite antioxidants, sulfur-containing antioxidants, and preferred antioxidants are phenol antioxidants and phosphite antioxidants. The phenol antioxidants include n-octadecyl-3-(3',5'-di-t-butyl-4'-hydroxyphenyl) propionate, 2,6-di-t-butyl-4-methylphenol, 2,6-di-t-butyl-p-cresol (BHT), 2,2'-methylenebis(4-methyl-6-t-butylphenol), 4,4-thiobis(3-methyl-6-t-butylphenol), 4,4'-butylidenebis(3-methyl-6-t-butylphenol), stearyl-β-(3,5-di-4-butyl-4-hydroxyphenyl) propionate, 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)butane, 1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxybenzyl) benzene, tetrakis[methylene-3-(3',5'-di-t-butyl-4'-hydroxyphenyl)propionate]methane. The phosphite antioxidants include trinonylphenylphosphite and triphenylphosphite. The sulfur-containing antioxidants include dilaurylthiodipropionate and distearylthiopropionate. Among these, particularly preferred antioxidants are BHT, dilaurylthiodipropionate and distearylthiopropionate. Dialkylphosphate is also particularly preferred, though it does not belong to the above three antioxidant groups. The particularly preferred antioxidants are preferably combined. The organic nucleating agent improves injection moldability, rigidity, transparency and physical strength. The organic nucleating agent includes carboxylic acids, dicarboxylic acids, their salts and anhydrides, salts and esters of aromatic sulfonic acids, aromatic phosphinic acids, aromatic phosphonic acids, aromatic carboxylic acids and their aluminum salts, metal salts of aromatic phosphoric acids, alkyl alcohols having 3 to 30 carbon atoms, condensation products of a polyhydric alcohol and an aldehyde, and alkylamines. Examples are aluminum p-t-butylbenzoate, aluminum hydroxy-di-p-t-butylbenzoate, 1,3,2,4-dibenzylidenesorbitol, di-substituted benzylidene-sorbitol represented by the following formula: wherein R₁ and R₂ represent an alkyl group or an alkoxy group having 1 to 8 carbon atoms or a halogen, and m and n are 0 to 3 and m+n≧1 , ( such as 1,3,2,4-di(methylbenzylidene)sorbitol, 1,3,2,4-di (ethylbenzylidene)sorbitol, 1,3,2,4-di(propylbenzylidene) sorbitol, 1,3,2,4-di(methoxybenzylidene)sorbitol, 1,3,2,4-di(ethoxybenzylidene)sorbitol, 1,3,2,4-di (p-methylbenzylidene)sorbitol, 1,3,2,4-di (p-chlorobenzylidene)sorbitol, 1,3,2,4-di(alkylbenzylidene) sorbitol and 1,3,2,4-bis(methylbenzylidene)sorbitol); N-(2-hydroxyethyl)-stearylamine represented by the following formula; wherein R₃ represents an alkyl group having 8 to 30 carbon atoms, and k and l are 0 to 10 and k+l≧1 . metal salts, such as a lithium salt, a sodium salt, a potassium salt, a calcium salt and a magnesium salt, of 1,2-dihydroxystearic acid, stearyl alcohol, lauryl alcohol, sodium benzoate, benzoic acid, and sebacic acid. Preferred nucleating agents are dibenzylidenesorbitol, the derivatives thereof and tribenzylidenesorbitol, and dibenzylidenesorbitol and its derivatives concretely enumerated are particularly preferable. The content of the organic nucleating agent is 0.01 to 1 wt. %. If the content is less than 0.01 wt. %, the effect of the nucleating agent is insufficient. While, if the nucleating agent is added beyond 1 wt. %, the effect of the excess amount of the nucleating agent is minor. The surface of the organic nucleating agent has previously been coated with the following stabilizer in order to improve the heat stability of the organic nucleating agent and to prevent the evolution of odor. The stabilizer is selected from the group consisting of aliphatic metal salts, metal salts of alkyl lactic acids and metal salts of lactic acid. The aliphatic metal salts are metal salts of fatty acids having of 7 to 32, preferably 11 to 26, carbon atoms. The metal salts are alkali metal salts, such as a sodium salt and a potassium salt, alkaline earth metal salts, such as a magnesium salt and a calcium salt, zinc family element salts, such as a zinc salt, and aluminum family element salts, such as an aluminum salt. Examples of the aliphatic metal salt are calcium stearate, aluminum stearate, zinc stearate, sodium stearate, magnesium stearate and calcium behenate. The alkyl lactic acids are the condensates of lactic acid and a fatty acid having 7 to 32 preferably 11 to 26, carbon atoms, formed by the dehydration between the hydroxyl group of lactic acid and the carboxyl group of the fatty acid. Examples of the alkyl lactic acid are stearyl lactic acid and lauryl lactic acid. During the above dehydration, the dehydration between lactic acid molecules usually occurs, and for example, stearyl lactic acid includes stearyl lactyl lactic acid and the like. The metal of the salt may be selected from the ones mentioned above. Examples of the metal salt of alkyl lactic acid are calcium stearyl lactate and calcium lauryl lactate. The metal of the metal salt of lactic acid may be selected from the ones mentioned above, and examples of the metal salt of lactic acid are calcium lactate and barium lactate. Among these, calcium stearate is the most preferred. The blending amount of the stabilizer is 30 to 500 % by weight, preferably 100 to 300 % by weight of the organic nucleating agent. However, the stabilizer may also be added for other purposes, such as improving mold-releasability. Therefore, the content of the stabilizer is usually 0.003 to 5 wt. %, preferably 0.01 to 3 wt. %. The treatment with the stabilizer may be carried out by any method capable of coating more than 30 % of the surface of the organic nucleating agent. As a preferred method, the stabilizer is mixed with the organic nucleating agent by a known method such as using a ball mill or a jet mill, and the mixture is heated at a temperature higher than the melting point of the stabilizer but lower than the melting point of the organic nucleating agent with stirring or another mixing method so as to coat the melted stabilizer on the organic nucleating agent. After cooling, the mixture is crushed or ground. The treatment may be carried out by melt blending, powder blending, crush blending or the like. The bending rigidity of the resin composing the container body of the invention is preferably higher than 784532 kPa (8,000 kg/cm²), particularly higher than 980665 kPa (10,000 kg/cm²) (ASTM D-790). In addition, the notched Izod impact strength is preferably higher than 2.0 kg · cm/cm, particularly higher than 3.5 kg · cm/cm (ASTM D-256, at 20°C). The container body of the invention may have any shape capable of placing a photographic film cartridge therein. For example, the containers illustrated in Figures 1 to 3 are preferable in view of sealing and easy detachment. Particularly, the containers of Figures 1 and 2 have the advantage that the cap can easily be detached by one hand. The container of Figure 1 consists of a container body 1 and a cap 2. The container body 1 is cylindrical, and a fitting groove 4 the cross section of which is a circular arc is formed around the vicinity of the opening on the inside of a peripheral wall 3 thickened in the inside direction. An indent 6 so as not to project a gate mark 7 is formed in the center of bottom 5. The depth of indent 6 is usually 0.5 to 5 mm, preferably 1 to 3 mm. The cap 2 is comprised of a top plate portion and a short tube-shaped peripheral wall portion fitted into container body 1. The indent so as not to project the gate mark is formed in the center of the upper face of the cap 2, and a rib 8 to fit to a fitting groove 4 is formed around the vicinity of the center of the peripheral wall portion. Container body 1 of Figure 2 is the same as that of Figure 1, except that the opening portion of the peripheral wall 3 is expanded to the outside. Cap 2 of Figure 2 is also the same as Figure 1, except that the gate portion is positioned on the reverse face, and the indent for the gate mark is not formed. Container body 1 of Figure 3 is also cylindrical, and a rib 9 the cross section of which is a circular arc is formed on the outside edge of the opening. Bottom 5 of the container body 1 is depressed in three steps, and a gate mark 7 is present in the center of indent 6. Cap 2 is comprised of a top plate portion, a short tube-shaped peripheral wall portion and a short tube-shaped skirt portion. The reverse channel portion 10 formed by the margin of the top plate portion, the skirt portion and the peripheral wall portion is fitted onto the opening edge of container body 1, and fixed by engaging the rib the cross section of which is a circular arc formed on the inside edge of the skirt portion with rib 9 of container body 1. On the other hand, the container body of the invention may be combined with the case of the container, as shown in Figures 4 to 6. In the embodiments, the transparency of the material composing the container body is effectively exhibited, and packaging costs may further be decreased. The combined container body of Figure 4 is cylindrical, that of Figure 5 is rectangular, and that of Figure 6 is a box-shaped having a circular receiving place of photographic film cartridge. The container body of the invention is formed by injection molding, such is injection blow molding, inter mold vacuum injection molding and stack molding using multicavity as well as common injection molding. Preferred materials of the cap are more elastic than the container body, and preferable resins include those composed of low density polyethylene resin, L-LDPE resin or a mixture thereof, containing 0.05 to 2 wt. % of a fatty acid amide lubricant. In the container body of the invention, the polypropylene resin imparts transparency, rigidity and injection moldability, and the fatty acid amide lubricant improves injection moldability, resin fluidity and slipping characteristics among the molded articles to prevent the generations of blocking, static electrification, abrasion and white powder without lowering photographic property and transparency. The antioxidant prevents yellowing, coloring and decomposition of the resin, and the organic nucleating agent improves transparency, rigidity, dropping strength and injection moldability without evolving a bad smell. The container body of the invention is excellent in dropping strength, transparency and odor. The injection moldability is also excellent because of good resin fluidity and high crystallization temperature. The following examples illustrate the invention. EXAMPLES Three examples of the container body of the invention, five comparative container bodies and one conventional container body were molded by using the molding machine "Nestal" (Sumitomo Heavy Industries Ltd.) at a mold clamping pressure of 150 000 kg (150 t). The type of runner is a hot runner, and the molding number per once was 24. The shape of the respective container bodies was the same as shown in Figure 1, and the wall thickness was 0.7 mm on average. The container body of Example I was composed of a resin consisting of 99.35 wt. % of propylene-ethylene random copolymer resin composed of 96.5 wt. % of propylene units and 3.5 wt. % of ethylene units having a MFR of 38 g/10 min and a molecular weight distribution ( M w/ M n) of 3.3 produced by a vapor phase method, 0.3 wt. % of oleic amide lubricant, 0.05 wt. % of 2,6-di-t-butyl-p-cresol, 0.1 wt. % of tetrakis [methylene-3-(3',5'-di-t-butyl-4'-hydroxyphenyl)propionate ] methane, 0.05 wt. % of dilaurylthiodipropionate, and 0.15 wt. % of 1,3,2,4-di(methylbenzylidene)sorbitol the surface of which had previously been treated with calcium stearate. The treatment with calcium stearate was carried out as follows. Calcium stearate was added to the equal weight of 1,3,2,4-di(methylbenzylidene)sorbitol, and mixed well using a ball mill. Then, the mixture was heated so that calcium stearate alone melted, and it was stirred well so as to entirely coat calcium stearate on the sorbitol compound. After cooling, the coated mixture was crushed. The container body of Example II was composed of a resin consisting of 89.35 wt. % of propylene-ethylene random copolymer resin composed of 98 wt. % of propylene units and 2 wt. % of ethylene units having a MFR of 40 g/10 min and a M w/ M n of 3.0 produced by a vapor phase method, 10.00 wt. % of L-LDPE resin being a copolymer of ethylene and 4-methylpentene-1 having a MFR of 8 g/10 min (ASTM D-1238, at 190°C), a density of 0.920 g/cm³ (ASTM D-1505) and a M w/ M n of 3.0, and the same contents of the same lubricant, antioxidants and organic nucleating agent as in Example I. The container body of Example III was composed of a resin consisting of 99.35 wt. % of propylene-ethylene random copolymer resin composed of 97 wt. % of propylene units and 3 wt. % of ethylene units having a MFR of 30 g/10 min and a M w/ M n of 3.5 produced by a solution method, and the same contents of the same lubricant, antioxidants organic nucleating agent as in Example I. Comparative container body I was composed of the same propylene-ethylene random copolymer resin as employed in Example II alone. Comparative container body II was composed of the same propylene-ethylene random copolymer resin as employed in Example III alone. Comparative container body III was composed of a resin consisting of 99.5 wt. % of the same propylene-ethylene random copolymer resin and the same contents of the same lubricant and antioxidants as in Example II. No organic nucleating agent was added. Comparative container body IV was composed of a resin consisting of 99.65 wt. % of the same propylene-ethylene random copolymer resin and the same contents of the same antioxidants and organic nucleating agent as in Example III. No lubricant was added. Comparative container body V was the same as in Example III, except that the 1,3,2,4-di(methylbenzylidene)sorbitol was not treated with a stabilizer. Conventional container body I was composed of a resin consisting of 99.5 wt. % of homopolypropylene resin having a MFR of 9 g/10 min and a M w/ M n of 3.5, 0.3 wt. % of calcium stearate as lubricant, and 0.2 wt. % of 2,6-di-t-butyl-p-cresol (BHT) as antioxidant. Each resin composition of the above containers is summarized in Table 1, and various properties of the containers are shown in Table 2. The evaluations in Table 1 were carried out as follows: A very excellent B excellent C practical D causing problems E impractical The testing methods were as follows: Molecular Weight Distribution ( M w/ M n): Each resin was dissolved in o-dichlorobenzene, and the molecular weight distribution was measured by gel permeation chromatography (GPC method) using a mixed polystyrene gel column. The value in the table is represented by Injection Moldability: Judged by the weight dispersion of products, the generation of short shot, the generation of bottom sink mark and stringiness, resin remains at gate, the generation of buckling and the like. Odor: Judged by human sense of smell around the mold during molding each container body. Crack Generation: A cartridge containing 36 exposures photographic film was placed in each container, and a cap was attached. The container was dropped on a concrete floor from 5 m height at 10°C, and the number of the cracked container bodies per 100 pieces was indicated in Table 2. Transparency: Each container body was gradually moved far from the transparency inspection chart of a white paper on which parallel lines each 0.5 mm in thickness were drawn at an interval of 2 mm. The transparency is expressed as the distance (cm) where the parallel lines are not seen.

Claims: A container body for photographic film cartridges composed of a resin comprising more than 70 wt.% of a polypropylene resin, 0.01 to 2 wt.% of a fatty acid amide lubricant and a nucleating agent, characterized in that the nucleating agent is contained in an amount of 0.01 to 1 wt.%, more than 30% of the surface of the nucleating agent is coated with a stabilizer selected from the group consisting of aliphatic metal salts, metal salts of alkyl lactic acids and metal salts of lactic acid, the stabilizer being present in the resin in an amount of 0.003 to 5 wt.%, and the resin further comprises an antioxidant in an amount of 0.05 to 1 wt%. The container body of claim 1 wherein said polypropylene resin is a propylene-α-olefin copolymer resin the propylene content of which is 90 to 99 wt. %. The container body of claim 1 wherein the melt flow rate of said polypropylene resin is 12 to 80 g/10 min measured according to ASTM D-1238 at 230°C under 2160 g loading. The container body of claim 1 wherein said organic nucleating agent is selected from the group consisting of carboxylic acids, dicarboxylic acids, their salts and anhydrides, salts and esters of aromatic sulfonic acids, aromatic phosphinic acids, aromatic phosphonic acids, aromatic carboxylic acids and their aluminum salts, metal salts of aromatic phosphoric acids, alkyl alcohols having 3 to 30 carbon atoms, condensation products of a polyhydric alcohol and an aldehyde and alkylamines. The container body of claim 1 wherein said organic nucleating agent is selected from the group consisting of aluminum p-t-butylbenzoate, aluminum hydroxy-di-p-t-butylbenzoate, 1,3,2,4-dibenzylidenesorbitol, disubstituted benzylidene-sorbitol represented by the following formula wherein R₁ and R₂ represent an alkyl group or an alkoxy group having 1 to 8 carbon atoms or a halogen, and m and n are 0 to 3 and m+n≧1 ; N-(2-hydroxyethyl)-stearylaminerepresented by the following formula: wherein R₃ represents an alkyl group having 8 to 30 carbon atoms and k and l are 0 to 10 and k+1≧1 ; metal salts of 1,2-dihydroxystearic acid, stearyl alcohol, lauryl alcohol, sodium benzoate, benzoic acid and sebacic acid. The container body of claim 1 wherein said organic nucleating agent is selected from the group consisting of dibenzylidenesorbitol, 1,3,2,4-di(methylbenzylidene) sorbitol, 1,3,2,4-di(ethylbenzylidene)sorbitol, 1,3,2,4-di(propylbenzylidene)sorbitol, 1,3,2,4-di(methoxybenzylidene)sorbitol, 1,3,2,4-di(ethoxybenzylidene)sorbitol, 1,3,2,4-di(p-methylbenzylidene)sorbitol, 1,3,2,4-di-(p-chlorobenzylidene)sorbitol, 1,3,2,4-di(p-methoxybenzylidene)sorbitol, 1,3,2,4-di-(alkylbenzylidene)sorbitol and 1,3,2,4-bis(methylbenzylidene)sorbitol and tribenzylidenesorbitol. The container body of any of claims 1 to 6 wherein said stabilizer is selected from the group consisting of calcium stearate, aluminum stearate, zinc stearate, sodium stearate, magnesium stearate, calcium behenate, calcium stearyl lactate, calcium lauryl lactate, calcium lactate and barium lactate.

Inventors: AKAO MUTSUO FUJI PHOTO FILM CO, AKAO, MUTSUO FUJI PHOTO FILM CO., LTD.
Applicants: FUJI PHOTO FILM CO LTD, FUJI PHOTO FILM CO., LTD.
Application year: 1988
Main classification: G03C3
IPC codes: C08K5, C08K9, G03C3, C08L23