Process for preparing a photographic film cassette

Abstract: A cassette shell (6) of a photographic film cassette (2) is made up of a first steel material (21). The first steel material (21) comprises a steel plate (22). On one face of the steel plate (22), a black resin layer (23) is formed. On the other face of the steel plate(22), a print layer (24) and a transparent resin layer (25) are formed. When the cassette shell (6) is formed by using the first steel material (21), the side of the black resin layer (23) becomes an inner face of the cassette shell (6) and the side of the transparent resin layer (25) becomes an outer face thereof. Moreover, a cap (10a, 10b) of the photographic film cassette (2) is made up of a second steel material (26). The second steel material (26) comprises the steel plate (22). On both sides of the steel plate (22), black resin layers (23) are respectively formed.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a process for preparing a photographic film cassette comprising a cassette body in which a spool for winding a photographic film is rotatably contained, and more particular to a material for forming the cassette body. 2. Description of the Related Art At present, various photographic films are used. However, for general photographing, a 135-type photographic film cassette is widely used. In the 135-type photographic film cassette, a spool is rotatably provided in a cassette body made of steel material. Further, an end edge of a photographic film having a'width of 35mm is fixed to the spool and the photographic film is wound onto the spool. As well known, such a 135-type photographic film cassette comprises a cylindrical cassette shell made of steel material and a pair of caps made of steel material. The caps are respectively fitted to both opening sides of the cassette shell. Inside the photographic film cassette, the 35mm-width photographic film wound onto the spool made of plastic is rotatably contained. Moreover, on the cassette shell of the photographic film cassette, photographable number, film sensitivity, original design of each manufacturer and so forth are printed by paint. However, the above mentioned conventional cassette shell and cap are formed by processing a sheet-like steel material on which the design and so on are printed by paint. Accordingly, when the printed steel material is cut into a predetermined size, paint splinters are generated. The paint splinter remains in the photographic film cassette as it is and sticks to the photographic film. Therefore, there arises a problem in that the paint splinter affects the photography. Moreover, when the design and so forth are printed on the steel material by the paint, an organic solvent is used. The organic solvent remains in the print layer by a little and volatilizes in a case for containing the photographic film cassette. Accordingly, there arises a problem in that the organic solvent affects an emulsion face of the photographic film and causes the fog of the photographic film and change of the sensitivity, for example. JP-A6301158 describes a cartridge main body for photographic film which is constituted of a metal base, a paint coating, a coloured coating and a transparent protective coating of a resin composition. SUMMARY OF THE INVENTION In view of the foregoing, it is a primary object of the present invention to provide a process for preparing a photographic film cassette in which a bad influence is not given to photographic property by preventing paint splinters from generating when a cassette shell and a cap constituting the photographic film cassette are formed. It is a second object of the present invention to provide a process for preparing a photographic film cassette in which the bad influence is not given to the photographic property by preventing a solvent remaining on a print face from volatilizing. In order to achieve the above and other objects a process for preparing a photographic film cassette (2) is provide in which a spool (4) wound up in a photographic film (5) is rotatably contained, said photographic film cassette (2) comprising a cylindrical cassette shell (6) and a pair of caps (10a, 10b) fitted to both ends of said cassette shell (6), said cassette shell (6) comprising a first steel plate (22) and a first resin layer (23) formed on at least one surface of said first steel plate (22), said caps (10a, 10b) comprising a second steel plate (22) and a second resin layer (23) formed on both surfaces of said second steel plate (22), said process comprising the steps of providing a cold-rolled or hot-rolled first steel plate (22), and forming a first resin layer (23) on at least one surface of said first steel plate (22) by welding a first plastic film onto at least one surface of said first steel plate (22). The cap is fixed to each of two opening sides of the cassette shell. In a preferred embodiment the cassette shell is made up of a first steel material. The first steel material comprises a steel plate, a black resin layer, a print layer and a transparent resin layer. The black resin layer is formed on one face of the steel plate. The print layer and the transparent resin layer are formed on the other face of the steel plate. When the cassette shell is made with the first steel material, the black resin layer side of the first steel material becomes an inner face of the cylindrical cassette shell and the transparent resin layer side of the first steel material becomes an outer face thereof. The cap is made up of a second steel material. The second steel material comprises a steel plate and a black resin layer. The black resin layer is formed on both faces of the steel plate. According to the present invention, the resin layer is formed on the print layer so that paint splinters of the print layer is prevented from generating when a cassette body constituted of the cassette shell and the cap is made up. Further, a solvent remaining on the print layer is prevented from volatilizing by the resin later. Therefore, the photographic film cassette in which bad influence is not given to the photographic property may be provided. BRIEF DESCRIPTION OF THE DRAWINGS The above objects and advantages of the present invention will become apparent from the following detailed description of the preferred embodiments of the invention when read in conjunction with the accompanying drawings, in which: Figs. 1A and 1B are sectional views showing layer structure of a steel material for forming a photographic film cassette according to the present invention; Fig. 2 is a perspective view of the photographic film cassette; Fig. 3 is a sectional view of the photographic film cassette shown in Fig. 2; and Fig. 4 is a graph showing relationships between a thickness of a black resin layer and fog due to adhesive, and between the thickness of the black resin layer and a burr amount of resin at a time of blanking. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) Fig. 2 is a perspective view of a photographic film cassette according to the present invention and Fig. 3 is a sectional view thereof. The 135-type photographic film cassette 2 is constituted of a cassette body 3, a spool 4 and a photographic film 5 having a width of 35mm. The cassette body 3 is constituted of a cylindrical cassette shell 6 and a pair of caps 10a and 10b for covering both opening faces of the cassette shell 6. Both ends of the spool 4 are rotatably attached to the caps 10a and 10b and the photographic film 5 is wound onto the spool 4. The cassette shell 6 is provided with a film passage mouth 11 for getting the photographic film 5 in and out. The film passage mouth 11 is provided with a plush (not shown) for light-tightly shielding inside of the photographic film cassette 2. Figs. 1A and 1B are sectional views respectively showing a layer structure of a steel material constituting the cassette shell of the photographic film cassette or the cap thereof. The steel material 21 constituting the cassette shell 6 is shown in Fig. 1A. A black resin layer 23 which is a sheet made of a black resin is formed on one face of a steel plate 22. A print layer 24 and a transparent resin layer 25 which is a sheet made of a transparent resin are formed on the other face of the steel plate 22. When the cassette shell 6 is formed by using such steel material 21, the side of the black resin layer 23 becomes an inner face of the cylindrical cassette shell 6 and the side of the transparent resin layer 25 becomes an outer face thereof. Moreover, a steel material 26 constituting the caps 10a and 10b is shown in Fig. 1B. The steel material 26 comprises black resin layers 23 formed on both faces of the steel plate 22. The steel plate 22 is a cold-rolled steel plate or a hot-rolled steel plate. In other words, the steel plate is made by cold-rolled process or hot-rolled process. The thickness of the steel plate 22 is 0.25mm, for example. After the steel plate 22 was rolled, surface treatment thereof is performed with high frequency in order to improve fusing force relative to the resin layer described in detail later. As the resin constituting the black resin layer 23 and the transparent resin layer 25, a thermoplastic resin of uniaxial orientation or biaxial orientation, for example, is used. As the typical materials, there are polyester, nylon, polyethylene terephthalate, olefin, fluoroplastic, polyethylene naphthalate, polystyrene, polypropylene, polyethylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polymethacrylate, polyacrylonitrile, polycarbonate, polyamide and so forth. It is possible to use any resin having thermoplasticity. Especially, biaxially oriented polyester, biaxially oriented polyamide and biaxially polypropylene are preferable. The biaxially oriented polyester having a thickness of 7.5µm to 15µm is more preferable. In order to weld the above resin to the steel plate 22, sometimes, preliminary adhesion is performed in advance. As the typical adhesive used for the preliminary adhesion, there are, for example, polyolefine thermoplastic resin hot-melt adhesive including various polyethylene resins, various polypropylene resins, thermoplastic resin hot-melt adhesive including ethylene propylene copolymer resin, ethylene vinylacetate copolymer resin, ethylene ethyl acrylate copolymer resin, ionomer resin and so forth, and hot-melt rubber adhesive. The surface of the steel plate is heated by specialty process of metal material, for example, high-frequency heating process, magnetic induction heating process, microwave process to melt the resin directly and to adhere it to the steel plate. In order to improve adhesion properties between the resin and the steel plate, an anchor coating agent may be used. As the anchor coating agents, there are, for example, organic titanate anchor coating agent (Tetra-propyl-titanate, Ters-iso-butyl-titanate), polyethylene-imine anchor coating agent (polyethylene-imine (CH 2 -CH 2 -NH) n having high polymerization degree), isocyanate anchor coating agent (there are one-pack type in which polymer having isocyanate group is used alone and two-pack type in which polyester and so on having hydroxyl group is combined. In both types, the adhesive effect is obtained by causing crosslinking reaction, polyester anchor coating agent, polyurethane anchor coating agent, polyolefin anchor coating agent, and polybutadiene anchor coating agent. As to the black resin layer 23 constituting the steel materials 21 and 26, the resin is blacked in order to give a light shielding property to the resin layer. With respect to blacking method, an integral coloring type or a printing type is available. An ink used in the printing type is selected so as not to affect a photosensitive material of a photographic film. It is possible to select the ink from among an offset printing ink, a gravure printing ink and an ultraviolet ink which are generally used. As typical resins used for the printing ink of the black resin layer 23, there are, for example, vinyl chloride vinyl acetate, pyroxylin, polyester, polyamide urethane, polyacryl, rosin modification maleic acid, ethylene-vinyl acetate, vinyl ether, urethane-vinyl acetate, vinyl chloride vinyl acetate urethane resin, modified alkyd resin , modified phenolic resin, alkaline soluble resin (rosin modification maleic acid resin, styrene maleic acid resin, styrene acrylic resin, acryl ester acrylic resin, and methacrylate acrylic resin), hydro sol resin (styrene maleic acid resin, styrene acrylic resin, α-methylstyrene acrylic resin, acryl ester acrylic resin, and methacrylate acrylic resin), and emulsion resin (styrene resin, styrene acrylic ester resin, acryl ester copolymer resin, methacrylate copolymer resin). As typical resins used for the ultraviolet ink of the black resin layer 23, polymer having acryl unsaturated group, for example, is generally used. As typical examples, there are polyester/acryl ester, polyester/urethane/acryl ester, epoxy resin/acryl ester, pentaerythritol acrylate, trimetylolpropane triacrylate, hexanediol dieacrylate, neopentyl glycol dieacrylate, triethylene glycol dieacrylate, and hydroxyethyl methacrylate. For blacking the resin, carbon black is mainly used. As articles on the market, there are, for example, carbon black #5, #20, #33, #40, #44, #45, #52, #900, #1000, #2200B, #2400B, #2350, MA8, and MA100 which are respectively manufactured by Mitsubishi Chemical Co., Ltd. When the thickness of the black resin layer 23 is properly set, influence of the adhesive used for adhesion with the steel plate may be reduced. For example, when the thickness of the black resin layer 23 is set more than 5µm, there are no influence of the adhesive due to entrapment effect of the resin. On the other hand, if the thickness of the black resin layer 23 is set more than 20µm, the burr breaks out when the steel material 21 and 26 are cut. Further, if the thickness of the black resin layer 23 is more than 50µm, the burr increases abruptly. In view of this, with respect to the thickness of the black resin layer 23, the range from 5µm to 50µm is preferable and the range from 5µm to 15µm is more preferable. The transparent resin layer 25 formed on the steel material 21 is provided to improve the printing property, to prevent the rise of temperature under the sun light, and to improve an outward appearance of the photographic film cassette 2, for example. White pigment may be included in the above resins used for the black resin layer. The white pigment in which white inorganic particle having an average particle diameter of 0.01-50µm is included by 0.3-30 wt.% is preferable. If the average particle diameter of the white inorganic particle is less than 0.01µm, dispersal becomes bad so that lamps tends to be generated by flocculation. Moreover, if the average particle diameter is more than 50µm, dispersal property is improved. However, hiding power is lowered and physical strength of the resin layer is also lowered. If admixture amount of the white inorganic particle is less than 0.3 wt.%, hiding power is lowered. Moreover, if the white inorganic particle is more than 30 Wt.%, the physical strength of the resin layer is lowered. Further, the white inorganic particle is separated and dispersed by vibration and friction so that the photographic film 5 is soiled with that as a white powder. As examples of the white inorganic particle, there are titanium oxide, clay, mica, aluminum oxide, calcium silicate, aluminum hydroxide, calcium carbonate, barium sulfate. Besides that, titanium dioxide, silicon dioxide, magnesium oxide which have white appearance in visible light range may be used. Incidentally, titanium dioxide is especially preferable among these white inorganic particles. As typical synthetic resins used for the printing ink of the print layer 24 of the steel material 21, there are, for example, vinyl chloride vinyl acetate, pyroxylin, polyester, polyamide urethane, polyacryl, rosin modification maleic acid, ethylene-vinyl acetate, vinyl ether, urethane-vinyl acetate, vinyl chloride vinyl acetate urethane resin, modified alkyd resin, modified phenolic resin, alkaline soluble resin (rosin modification maleic acid resin, styrene maleic acid resin, styrene acrylic resin, acryl ester acrylic resin, and methacrylate acrylic resin), hydro sol resin (styrene maleic acid resin, styrene acrylic resin, α-methylstyrene acrylic resin, acryl ester acrylic resin, and methacrylate acrylic resin), and emulsion resin (styrene resin, styrene acrylic ester resin, acryl ester copolymer resin, methacrylate copolymer resin). As resins used for the ultraviolet ink of the print layer 24, polymer having acryl unsaturated group, for example, is generally used. As typical examples, there are polyester/acryl ester, polyester/urethane/acryl ester, epoxy resin/acryl ester, pentaerythritol acrylate, trimetylolpropane triacrylate, hexanediol dieacrylate, neopentyl glycol dieacrylate, triethylene glycol dieacrylate, and hydroxyethyl methacrylate. For the printing ink of the print layer 24 of the steel material 21, well-known various colorants are used. As typical organic colorants, there are pigments of various types disclosed in Japanese Patent Laid-Open Publication No. 63-44653, for example. Besides that, there are azo-pigment (azo-lake; carmine 6B, red 2B, insoluble azo; monoazo yellow (PY-1, -3), disazo yellow (PY-12, -13, -14, -17, -83), pyrazolone orange (PO-B-34), vulcan orange (PO-16), condensation azo; chromophthal yellow (PY-93, -95), chromophthal red (PR-144, -166), polycyclic pigment [phthalocyanine; copper phthalocyanine blue (PB-15, -15-1, -15-3), copper phthalocyanine green (PG-7), dioxazine; dioxazine violet (PV-23), isoindolinone; isoindolinone yellow (PY-109, -110), perylene-based; perylene, perinone, flavanthrone, thioindigo, lake pigment (malachite green, rhodamine B, rhodamine G, victoria blue B). As inorganic colorants, there are, for example, oxide (titanium dioxide, red oxide), sulfate (precipitated barium sulfate), carbonate (precipitated calcium' carbonate), silicate (water-containing silicate, water-free silicate), metallic flake (aluminum flake, bronze powder, zinc dust, carbon black, chrome yellow, Prussian blue). These colorants may be loaded with the black resin layer 23 as a light shielding material. Besides that, oil-soluble dye, disperse dye are usable. As raw materials constituting the ink, various solvents, dispersant, wetting agent, anti-foaming agent, leveling agent, thickening agent, stabilizer, crosslinker, and addition agent including wax and drier are used at need. [Example] In a first Example of the photographic film cassette according to the present invention, as the steel plate constituting the steel material, T.F.S. steel plate having a thickness of 0.25mm was used. The surface treatment of the steel plate was performed with the high frequency in order to carry out the heat fusing of the resin layer easily. Polyethylene terephthalate resin layer being a sheet colored in black with the carbon black and having a thickness of 15µm was formed on one face of the T.F.S. steel plate as the black resin layer. The print layer in which the design was printed was formed on the other face of the steel plate. Further, polyethylene terephthalate resin layer having a thickness of 20µm, in which titanium white was kneaded, was formed on the print layer as the transparent resin layer. The cassette body of the photographic film cassette was formed by using such steel material. As a consequence that the photographic film cassette was formed by using the above-described steel material, the resin layer became a barrier so that the residual solvent did not separate out. Moreover, off-cut due to peeling and so forth was not generated when the steel plate was cut, because the steel plate treated with the high frequency was used in order to improve the fusing characteristics. In a second Example of the photographic film cassette according to the present invention, for the steel plate constituting the steel material, the cold-rolled material having a thickness of 0.25mm was used. Further, nylon resin colored in black with the carbon black and having a thickness of 15µm was formed on both faces of the cold-rolled material. The cap of the photographic film cassette was formed by using such cold-rolled material. With respect to the adhesive, the adhesive in which a volatile content is not contained was used. As a consequence that the photographic film cassette was made up of the above steel material, off-cut due to peeling was not generated when the steel plate was punched. As the conclusion of the Examples, a test result of the photographic characteristic, the off-cut and the waste of punching relative to each thickness of the resin layer is shown in Table 1. Thickness of Resin Layer Photographic Characteristic Offcut Waste of Punching 5 Δ ○ Δ 10 ○ ○ ○ 15 ○ ○ ○ 20 ○ ○ ○ 25 ○ ○ Δ 50 ○ Δ Δ 100 ○ Δ Δ 200 ○ × × 300 ○ × × Unit of the thickness is µm. Mark "○" represents a good result. Mark "Δ" represents an ordinary result. Mark "×" represents a bad result. Fig. 4 is a graph showing a relationship between the thickness of the black resin layer and the fog due to the adhesive. Further, Fig. 4 shows a relationship between the thickness of the black resin layer and the burr amount of resin at the time of punching as well. As stated above, when the thickness of the black resin layer is set more than 5µm, there are no influence of the adhesive by entrapment effect of the resin. On the other hand, if the thickness of the black resin layer is set more than 20µm, the burr breaks out when the steel material is punched. Further, if the thickness of the black resin layer is more than 50µm, the burr amount increases abruptly. From the graph, it is understood that the fog and the burr amount of the resin may be reduced by setting the thickness of the black resin layer in a range of 5-50µm. Furthermore, the fog and the burr amount become more preferable by setting the thickness of the black resin layer in a range of 5-15µm. As described above, in the photographic film cassette according to the present invention, the cassette body is made up of the steel material in which the sheet made of resin, or a plastic film welds to one face or both faces of the steel plate. Accordingly, the paint splinters is prevented from generating when the cassette shell and the cap constituting the cassette body are formed. Further, the solvent remaining on the print face is prevented from volatilizing. Therefore, the photographic film cassette in which bad influence is not given to the photographic characteristic may be provided. Although the present invention has been fully described by way of the preferred embodiments thereof with reference to the accompanying drawings, various changes and modifications will be apparent to those having skill in this field. Therefore, unless otherwise these changes and modifications depart from the scope of the present invention, they should be construed as included therein.

Claims: A process for preparing a photographic film cassette (2) in which a spool (4) wound up in a photographic film (5) is rotatably contained, said photographic film cassette (2) comprising a cylindrical cassette shell (6) and a pair of caps (10a, 10b) fitted to both ends of said cassette shell (6), said cassette shell (6) comprising a first steel plate (22) and a first resin layer (23) formed on at least one surface of said first steel plate (22), said caps (10a, 10b) comprising a second steel plate (22) and a second resin layer (23) formed on both surfaces of said second steel plate (22), said process comprising the steps of providing a cold-rolled or hot-rolled first steel plate (22), and forming a first resin layer (23) on at least one surface of said first steel plate (22) by welding a first plastic film onto at least one surface of said first steel plate (22). The process of claim 1, wherein said first plastic film is a material selected from a polyester resin, nylon resin, polyethylene terephthalate resin, olefin resin, fluoroplastic resin, polyethylene resin, polystyrene resin and polyethylene naphthalate resin. The process of claim 2, wherein the thickness of said first resin layer (23) is 5 to 50 µm. The process of claim 3, wherein the thickness of said first resin layer (23) is 5 to 15 µm. The process of claim 2, wherein said first resin layer (23) includes carbon black in order to blacken its color. The process of claim 5, further comprising the steps of forming a print layer (24) on a second surface of said first steel plate (22) on which said first resin layer (23) is not formed, and forming a transparent resin layer (25) on the surface of said print layer (24). The process of claim 6, wherein said transparent resin layer (25) includes a titanium white kneaded therein. The process of claim 1, further comprising the steps of providing a cold-rolled or hot-rolled second steel plate (22), and forming a second resin layer (23) on both surfaces of said second steel plate (22) by welding a second plastic film onto both surfaces of said second steel plate (22). The process of claim 8, wherein said second plastic film is a material selected from a polyester resin, nylon resin, polyethylene terephthalate resin, olefin resin, fluoroplastic resin, polyethylene resin, polystyrene resin and polyethylene naphthalate resin. The process of claim 9, wherein the thickness of said second resin layer (23) is 5 to 50 µm. The process of claim 10, wherein the thickness of said second resin layer (23) is 5 to 15 µm. The process of claim 11, wherein said second resin layer (23) includes carbon black in order to blacken its color.

Inventors: MATSUURA OSAMU, MATSUURA, OSAMU
Applicants: FUJI PHOTO FILM CO LTD, FUJI PHOTO FILM CO., LTD.
Application year: 1997
Main classification: G03C3
IPC codes: G03C3, G03B17