A replaceable cartridge coating assembly and method of coating a photosensitive material using the same

Abstract: The present invention relates to a replaceable coating cartridge (1000) and a method of coating at least one surface of a photosensitive material using the replaceable coating cartridge. The method and apparatus can be used in a photographic processing device (200), and the apparatus can be built into an existing or new photographic processor or added on as an accessory. The method and apparatus are utilized to apply a viscous solution (3) to at least one surface of processed photosensitize materials (5) prior to drying in a manner that allows the solution to be uniformly applied (65,67) to the at least one surface at a specific thickness. The viscous solution after drying functions as a protective coating which can protect the processed photosensitive material against scratches and moisture.

Description: The present invention relates to the photoprocessing field. More particularly, the present invention relates to a replaceable cartridge coating assembly and method of coating at least one surface of a photosensitive material with a protective coating using the same. When photosensitive material is processed in a processing tank using current photographic processors, squeegees are typically used to remove as much of the processing surface liquid as possible to avoid contamination at the next processing tank. In some cases, no effort is made to remove the processing surface liquid. It is not common to apply a protective coating on a photosensitive material in a bath. In cases where a protective coating is applied to a photosensitive material, the residue left by the protective coating substance within a tank and on the components of the tank is messy and difficult to clean. This adversely affects maintenance of the tank and increases operating costs. Furthermore, these coating solutions tend to dry when exposed to air or when the apparatus which applies the coating is not running, such as during off-hours or a non-working cycle, which also adversely effects maintenance and cleaning. Also, in those cases where a protective coating is applied, there is little attempt to control the specific laydown of the coating onto the surface of the photographic material. For example, US-A-2,173,480 describes the concept of applying a protective coating, however, in this document there is no concern about controlling the specific laydown amount of the coating material applied. U.S. Patent 5,309,192 discloses a coating machine for providing a protective film coating. This discloses an apparatus for applying a coating onto a photosensitive media which utilizes a spray pipe 43 which sprays a solution between a pair of rollers which in turn provide a coating onto the photosensitive media. A disadvantage of this system is the ability to provide a constant uniform protective layer onto the photosensitive media. In addition, this device is designed to be used as a stand-alone device. The EPO publication 0 492 320 A is directed to a device for applying a spreadable product such as glue, paint etc. However, this does not teach or suggest the applying of a coating on a photosensitive media which requires uniformity such that the image there under will not be affected in any substantial manner. Thus, there is no way of controlling the thickness, uniformity lay down amount which is essential to a coating on a photosensitive media. Currently, in order to apply a solution to the surface of a web in uniform layer amounts, it is necessary that it be done in manufacturing under very controlled conditions and temperature. In the past, this has been difficult to do in minilab or. traditional lab photographic processing environment as an integral part of the process. In order to apply a protective coating to an emulsion surface of a photosensitive material, control over the thickness, uniformity and laydown amount of the layer being applied is needed in order to provide for adequate protection against moisture and scratches. The control is needed for several reasons: 1) the protective coating must be applied in a manner that insures that the surface is uniformly coated so that the coating can provide adequate protection to the entire surface; 2) the thickness of the coating must be controlled because if the coating is too thick, it could cause cracking due a non-uniform drying; 3) a thick coating could dull the surface and the underlying image; and 4) the coating solutions can be of different viscosities. Conventional methods of immersing the photosensitive materials into a bath and squeegeeing off the excess liquid will not provide for a uniform protective coating and may produce too thin a coating which would provide inadequate protection. The present invention provides for a novel coating cartridge assembly which is easily removable and transportable so as to facilitate cleaning and maintenance. The coating cartridge assembly of the present invention can be a stand-alone unit that can be easily attached to an existing or new processor and is designed to efficiently and controllably provide a protective coating on at least one surface of a photosensitive material. The present invention provides for a novel method and removable cartridge coating assembly which can apply a viscous solution of predetermined viscosity to the surface of a processed photosensitive material or sheet prior to the final drying of the material or sheet, in a manner that allows the solution to be uniformly applied to the surface at a specific thickness. The method and apparatus of the present invention also enables the control of the thickness of the applied solution to have a preferred specific thickness. The viscous solution when dried will form a protective coating on the photosensitive material to protect against scratches and damage due to spills. With the apparatus of the present invention, it is possible to remove the coating cartridge assembly at the end of a working cycle. After the cartridge coating assembly is removed, it can be easily inserted into a sealable enclosure and returned to the manufacturer for recycling or proper disposal. This eliminates the need for rinsing and the user can easily replace the old coating cartridge with a new cartridge. As an alternative, after removal of the coating cartridge the user can rinse out the coating cartridge, preferably three times, and then dispose of it himself. The present invention relates to a replaceable cartridge coating assembly for use in a photographic processor. The replaceable cartridge coating assembly comprises a cartridge which is adapted to hold a viscous solution of a predetermined viscosity therein; a sealable inlet and a sealable outlet located on the cartridge which permit a passage of photosensitive material into and out of the cartridge; and an applicator and control mechanism mounted within the cartridge. The applicator and control mechanism applies a layer of the viscous solution to at least one surface of a photosensitive material which passes through the cartridge. The applicator and control mechanism controls the thickness, uniformity and lay down amount of the applied viscous layer. The viscous layer forms a durable protective coating on the at least one surface. The present invention also relates to a method of coating at least one surface of a photosensitive material which comprises the steps of inserting a replaceable coating cartridge into a tank of a processor such that an sealable inlet and an sealable outlet of the coating cartridge are respectively aligned with an entrance and an exit of the tank, with the coating cartridge being adapted to hold a solution of a predetermined viscosity therein; conveying the photosensitive material through the inlet and the outlet of the coating cartridge so as to coat the photosensitive material with the viscous solution as the photosensitive material passes through the coating cartridge; and controlling a thickness, uniformity and laydown amount of the applied viscous solution on the at least one surface of the material as the material passes through the coating cartridge. The layer forms a durable protective coating on the at least one surface. The apparatus of the present invention can be used as part of an existing photographic processor by being built-in to the processor, can be designed into a new processor, or can be added as an add-on accessory. As a further option, the apparatus of the present invention can be incorporated into the last wash tank of an existing processor. Figure 1 is a schematic drawing of the apparatus of the present invention which applies a viscous solution to processed photosensitive materials prior to the drying of the materials; Figure 2A illustrates a metering roller which can be utilized to control the thickness, uniformity and laydown amount of the applied viscous solution; Figure 2B shows a doctor blade as an alternative for controlling the uniformity, thickness and laydown amount of the applied viscous solution; Figure 2C shows an air knife as an alternative embodiment for controlling the uniformity, thickness and laydown amount of the applied viscous solution; Figures 3A-3B illustrate features of the paper sheet guide of the dryer; Figures 4A-4C illustrate features of the paper sheet edge guide and edge drive of the dryer; Figure 5 is a variation of the apparatus of Figure 1; Figure 6 is a schematic drawing of the apparatus of the present invention; Figure 7 is a variation of the apparatus of Figure 6; Figure 8 is a schematic drawing similar to Figure 1 showing an alternate embodiment with respect to controlling the thickness, uniformity and laydown amount of the viscous solution; Figure 9 is a schematic illustration showing the apparatus of the present invention built into an existing processor; Figures 10A-10B, 11A-11B and 12 illustrate various options for placing the apparatus of the present invention; Figure 13 is a schematic illustration of a processor showing the apparatus of the present invention added at the end; Figure 14 is a schematic illustration of an embodiment of the system of the present invention; Figure 15 is a schematic illustration of a further embodiment of the system of the present invention; Figure 16 is a schematic illustration of a further embodiment of the system of the present invention; Figure 16A is an alternative arrangement of Figure 16; Figure 17 is a schematic illustration of a further embodiment of the system of the present invention; Figure 18 is a schematic illustration of a further embodiment of the system of the present invention; Figure 19 shows a by-pass system of the apparatus of the present invention; Figures 20A-20C illustrate a replaceable coating cartridge assembly of the present invention; Figures 21A-21C illustrate a sequence for preparing the replaceable coating cartridge of Figures 20A-20C for transportation; and Figures 22A-22B illustrate a further embodiment of the replaceable coating cartridge of Figures 20A-20C. Referring now to the drawings, wherein like reference numerals represent identical or corresponding parts throughout the several views, Figure 1 illustrates an apparatus 1 for applying a layer of viscous solution 3 to processed photosensitive material 5 prior to the drying of the photosensitive material 5. The apparatus 1 can be added to an existing processing device as an accessory or can be built-in as part of a new processor. The apparatus includes a tank 7 for holding the solution 3 to be applied. With respect to the viscous solution 3 which will form the protective coating on the photosensitive material 5, since the coating is to be applied in a minilab or photographic processing laboratory, water-based solutions that are substantially free of volatile organic compounds for the solution 3 are preferred for the disclosed embodiments. Preferred solutions can include combinations of one or more water-based latex solutions that can include at least one component which has a glass transition temperature T G (softening point) above 25° C and at least one component which has a T G (softening point) at or below 25° C. These solutions can include acrylic or acylate polymers, vinyl polymers, polyurethanes, polyesters and the like. Additional components may including surfactants, spreading agents, lubricants, anti-blocking agents, curing agents, and so forth. The solution 3 can have a specific viscosity, for example, ranging from .0001 Pa·s to .0025 Pa · s at a shear rate of around 2500 1/sec. It is recognized that numerous viscous solutions can be utilized and that the type of viscous solutions used is based on design considerations in view of the desired viscosity, water-proofing and scratch-proof properties of the applied coating. The present specification describes the concept of applying a viscous solution to a photosensitive material. It is recognized that the viscous solution can initially be in the form of a solid, semi-solid or powder and thereafter converted to a viscous solution of a desired viscosity. There are a variety of ways for achieving the conversion of a solid, semi-solid or powder to a viscous solution of a desired viscosity. For example, a self-dispersing polymer could be used in a liquid concentrate, a solid tablet or powder form. In this case, tank 7 would start with a low-viscosity liquid, for example, water, and the viscosity would build to a desired value dissolution or dispersion of the product via agitation. As a further example, two (or more) component systems could be added separately and mixed in-situ in tank 7. Either a chemical reaction or physical interactions between the components could result in the desired final viscosity of the solution. Agitation and/or temperature could be used to trigger this reaction or interaction. As a further example, a system in a low-viscosity state could be triggered to build viscosity via temperature, UV light or other radiation by undergoing polymerization or cross-linking reactions. Either of these will increase the molecular weight of the species in the solution to increase viscosity. As a still further example, thickening agents could be added to a lower-than-desired viscosity solution in order to arrive at the desired viscosity. These could be added as tablets or concentrates. A variation on this example would be the use of temperature-sensitive thickeners that would give you either too high or too low a viscosity at room temperature, but would deliver the desired viscosity at a certain tank/coating temperature. It could also be advantageous to consider shear-sensitive coating solutions. These are either too high or too low in viscosity under storage conditions, but change to a desired viscosity under shearing conditions seen under tank agitation conditions or coating flow conditions. Basically, the above examples are solid-to-liquid or liquid-to-liquid transformations of a product, as delivered to tank 7, to the desired coating solution. As an even further example, it is possible to sparge a gas into the solution tank to induce a change. The triggers would include mixing, heat or radiation. The above are representative examples indicating that the viscous solution can first be in the form of a solid tablet, powder, and so forth, and converted to the desired viscous solution to be used in the tank of the present invention. It is further recognized that other methods for the conversion of a coating product to a final viscous solution can be utilized within the context of the present invention. Referring again to Figure 1, the tank 7 includes transporting roller assemblies 9 and 11 for transporting the photosensitive material 5 from a tank entrance 7a to a tank exit 7b. The roller assemblies 9 and 11 are comprised of opposed rollers which are rotatably mounted within the tank 7 in the vicinity of a support 7c and can be drivingly connected to a drive mechanism. The apparatus 1 should also include a recirculation means 1a for circulating the solution 3 through the tank 7 with the circulating means comprising a pump 1b, a conduit 1c connected to the pump 1b and the tank 7, and the transporting roller assemblies 9, 11 for transporting the photosensitive material 5. The apparatus of Figure 1 can further include a filter module 1d connected to the pump 1b by means of a conduit 1c'. The filter module 1d can remove solid contaminates from the solution. A heat exchanger 1e can rapidly regulate the temperature of the solution 3 being applied. The disclosed embodiments of Figures 5-9 can also include a recirculation means as illustrated in Figure 1 and described with reference to Figure 1. The combination of the tank 7 and roller assemblies 9 and 11 define a coating section 15a in which the solution is applied to both sides of the photosensitive material. The apparatus 1 further includes a control section 15b which can include the combination of a transport roller 17 and a metering roller 19 which are rotatably mounted on the apparatus 1. The control section 15b is utilized to control the thickness, uniformity and laydown amount of the solution 3 applied to the material 5 and therefore provide for a protective coating with preferred and/or predetermined characteristics. In the embodiment of Figure 1, the viscous solution 3 is applied to both sides of the material 5 by dipping the material 5 within the solution 3 held in the tank 7, and transporting the coated material 5 by way of the roller assemblies 9 and 11 to the control section 15b. The control section 15b includes a guide blade 27b which extends from the coating section 15a into the control section 15b and leads the coated material 5 to a nip portion 21 between the metering roller 19 and the transport roller 17 which applies an opposing force to the metering roller 19. At this point, the metering roller 19 provides for a control of the characteristics of the protective coating by controlling the thickness, uniformity and laydown amount of the applied viscous solution 3 on the material 5 to a specific layer thickness which is a preferred thickness. Figures 2A-2C illustrate examples of devices for metering and thereby controlling the thickness, uniformity and laydown amount of the applied viscous solution 3 on the photosensitive material 5 which can be utilized in the disclosed embodiments. Figure 2A illustrates in detail the metering roller 19 which can be, for example, a wire wrapped roller bar that can be set across the material 5 and applied against the solution 3 coated on the material 5, to remove a desired amount of the solution 3 in a controlled manner, and leave a desired thickness of the solution 3 on the material 5. With respect to the preferred and/or predetermined characteristics of the protective coating, the desired range of dry coating thickness of the coating solution 3 on the material 5 is 0.3 to 6 micrometers. In terms of dry laydown which is expressed as mass per unit area, this corresponds to a range of 0.3 to 6g/sq. meter. The percent solids in the coating solution is a factor in the thickness of the protective coating. The desired range of percent solids is from 1% to 50%, for example, a 10% solids solution can have 10 parts film forming polymer and 90 parts water which evaporates upon drying. Therefore, the highest wet laydown corresponds to the thickest dry coating made from the most dilute solution, and the lowest wet laydown corresponds to the thinnest dry protective coating from the most concentrated solution. From this the range of wet laydown is 0.6 to 600 ml/sq meter (wet laydown being commonly expressed in units of volume per unit area). Accordingly, the preferred range of dry thickness is 0.3 to 6 micrometers, the preferred range of dry laydown is 0.3 to 6g/sq meter, and the preferred range of wet laydown is 0.6 to 600 ml/sq meter. Figure 2B is an alternate way of controlling the thickness, uniformity and laydown amount of the solution 3, as described above and illustrates a doctor blade 19' which can be controlled to come into contact with the material 5 with the solution 3 coated thereon to remove a desired amount of solution therefrom. Figure 2C illustrates an air knife 19" which can be used to blow air onto the solution 3 on the material 5. The air pressure distribution across the material 5 can be adjusted to control the thickness, uniformity and laydown amount of the applied viscous solution on the photosensitive material. Therefore, during use, as the material 5 leaves an existing processor, it is guided by a guide blade 27a toward the roller assemblies 9 and 11 which guide the material 5 as it is dipped and coated with a layer of the solution 3. In the embodiment of Figure 1, the photographic material 5 is dipped into the solution 3 which is applied to both sides (coating section 15a). As the photographic material 5 leaves the tank 7 at exit 7b, it enters the control section 15b having the metering roller 19 which controls the thickness, uniformity and laydown amount of the applied viscous solution on one side of the photosensitive material 5. Therefore, in the embodiment of Figure 1, the entire photosensitive material or print is dipped and one side is controlled or metered as described with reference to Figures 2A-2C. It is recognized that the material to be coated could be a rolled web as illustrated, cut sheets or prints. Since the present invention is concerned with applying a protective coating which prevents damage due to spills and protects against scratches, the metering and control feature of the present invention provides for a specific lay down control of the viscous solution 3 so as to provide for a specific layer thickness and a uniform coating. Figure I further illustrates a dryer 29 to which the coated material 5 is delivered after the coating section 15b. A guide 31 can be utilized to guide the. material 5 into the dryer 29. Therefore, after the material 5 passes through the control section 15b in which the thickness, uniformity and laydown amount of the applied viscous solution 3 is controlled, the material 5 is delivered to the dryer 29 while the viscous solution is still wet and tacky. As illustrated in Figure 1, the present invention provides for a spacing 33 between the control section 15b and a guide 35 positioned in the dryer 29. The guide 35 is connected in a known manner to air blowers 37 schematically illustrated in Figure 1. The air blowers 37 deliver air for drying by way of, for example, tubes or hoses to the guide 35. Air from the air blowers 37 is directed onto the coated material 5 at the guide 35 so as to dry the coated material and provide for a protective coating on the material. The spacing 33 between the exit of the control section 15b and the entrance to the guide 35 is such that it permits the material 5 with the solution applied thereon to be transported through part of the dryer 29 without the surface of the coated material 5 being disturbed or touched while drying is occurring. The illustrated guide 35 or other known mechanisms for transporting the photosensitive material by its edges can be utilized. After the material 5 has passed through the above-mentioned spacing 33, the material 5 is slowly transported between the guide 35 and the air-blowers 37 of the dryer 29 and transported out of the dryer 29 by way of transport roller assembly 39. Preferred drying ranges within the dryer are normal temperature ranges needed for drying photosensitive material. For example, a preferred drying range can be within, but not limited to, 29 °C (85° F) to 93 °C (200° F). Referring now to Figures 3A-3B and 4A-4C which illustrate the specifics of the guide 35, the guide 35 can include edge guide members 35a, 35b which serve to guide the material or sheet 5 through the dryer 29. In an alternative embodiment, the guide 35 can include drive rollers 39r (Figures 4A, 4B) which contact the edge surfaces of the material and work in combination with the edge guide members 35a, 35b to facilitate the transporting of the material or sheet 5 through the dryer 29 and to the roller assembly 39 so as to exit the dryer 29. As an alternative arrangement, as shown in Figure 4C, a roller and guide assembly 39' can be used. The roller and guide assembly 39' has a roller 39a' with a V-shaped opening 39" which contacts the edges of the material 5 and works in conjunction with guide members 39"' to guide the material 5 through the dryer. Referring now to Figure 5, this figure illustrates an alternate embodiment of the apparatus of the present invention. As illustrated in Figure 5, the apparatus 100 can comprise a tank 40 that includes the viscous solution 3. Rotatably mounted within the tank 40 is a roller assembly 41 and a guide blade 47. The guide blade 47 leads the material 5 to a pivotable or rotatable guide 49 which is pivotable to various angles to thereby control the angle by which the material 5 leaves the solution 3. By controlling the angle by which the material 5 leaves the solution 3, the amount of solution 3 remaining on the material 5 can be controlled. Therefore, during use of the embodiment of Figure 5, the material 5 is fed in the arrow direction 51 from an existing processing assembly into the tank 40 having the viscous solution 3 therein. The material 5 is completely immersed in the viscous solution 3 as illustrated in Figure 5 and then guided by way of the combination of the guide blade 47 and the pivotable guide 49. The amount of solution and thereby the thickness of the solution left on the material 5 is controlled by the pivotable guide 49. That is, in this embodiment the angle by which the material 5 leaves the solution is controlled by pivoting the guide 49. This thereby controls how much solution 3 is left on the material 5 as the material 5 leaves the solution 3 which permits a control over the thickness of the solution. the material thereafter exits the tank 40 at exit 53 and enters a dryer 55 which can be similar to the dryer described with reference to Figure 1. In the embodiment of Figure 6, the photosensitive material 5 is transported from a processor to the apparatus 200 which comprises a tank 60 that includes a rotatably mounted transport roller assembly 63. The roller assembly 63 delivers the photosensitive material 5 to a coating roller 65 which is partially immersed in the viscous solution 3. The coating roller 65 coats one side of the photosensitive material 5 which is then transported to a metering roller 67. The metering roller 67 meters or controls the one side of the material 5, as discussed with reference to Figure 1, to control and make uniform the thickness of the applied viscous solution 3. In this embodiment, instead of utilizing a transport roller opposing the metering roller 67 as shown in Figure 1, the transport roller assembly 63 and the first set of rollers 39 of the dryer 69, with respect to the transport direction of the material 5, act as tensioning rollers. The tensioning rollers tension the material 5 and apply a force on the material 5 that opposes the force of the metering roller 67. As an alternative, dedicated tensioning rollers could be placed at selected positions along the conveying path of the material 5. After the material 5 leaves the tank 60 it exits through 60a and is delivered to a dryer 69 which dries the coated material as previously discussed, and includes a guide 35 and rollers 39, 39' or 39r as discussed above and illustrated in Figures 4A-4C. The embodiment of Figure 7 is similar to the embodiment of Figure 6 except that instead of utilizing a combination of a coating roller 65 and a metering roller 67 as illustrated in Figure 6, the embodiment of Figure 7 utilizes a combined single coating and metering roller 70. Therefore, as illustrated in Figure 7, the combined coating and metering roller 70 is partially immersed in the viscous solution 3 such that when the material 5 is delivered by the roller assembly 63, the coating and metering roller 70 coats one side of the material 5 and at the same time it meters the one side of the material 5. The coated material 5 thereafter exits the tank 60 through exit 60a and is delivered to the dryer 69 which functions as described with respect to Figures 1 and 6. The embodiment of Figure 7 also utilizes tensioning rollers as described with reference to Figure 6 to tension the material 5 and apply an opposing force to the force applied by the combined coating and metering roller 70. The embodiment of Figure 8 is similar to the embodiment of Figure 1 but instead of metering one side of the coated material 5, in the embodiment of Figure 8, both sides of the coated material 5 are metered by way of metering rollers 19 in the manner described with reference to Figure 1. The metering rollers 19 in Figure 8 are located on opposing sides of the material 5 in the control section 15b. Therefore, in the embodiment of Figure 8, both sides of the material 5 are coated in the coating section 15a by dipping, and both sides of the material 5 are metered by metering rollers 19 so as to control the thickness, uniformity and laydown amount of the viscous solution 3 applied thereon. The coated material 5 is then conveyed to the dryer 29 in the same manner as described in Figure 1. Figure 9 illustrates an overview of a system to which the apparatus (1, 100, 200) of the present invention can be applied. As noted in Figure 9, a processor in which an exposed photosensitive material can be subjected to at least one processing solution and any excess solution is thereafter removed, can include a printer 500, a dryer 501, and adjacent processing tanks 502-507. The printer 500 provides an image on the photosensitive material prior to processing. The processing tanks 502-507 represent steps in the developing process and can include developer solution, bleach solution, fixer solution and washing solution, or a combination of bleach-fix solution and a wash/stabilizer solution. The apparatus (1, 100, 200) of the present invention can be built into the end of the existing processing system as noted in Figure 9 or built as part of a new processor. As an alternative embodiment, the apparatus (1, 100, 200) can be built into one of the existing wash tanks positioned at the end of the processor. Figure 10A illustrates an overview of a system in the same manner as Figure 9 to which the apparatus (1, 100, 200) of the present invention can be applied. In Figure 10A, movable bypass gates 509, 511 which are shown in detail in the view of Figure 10B can be utilized to bypass the apparatus (1, 100, 200). Therefore, during use, after the material 5 passes through the last wash tank 507, it can be delivered directly to the apparatus (1, 100, 200) by way of the gate 509 as illustrated in Figures 10A and 10B, and thereafter delivered to the dryer 501. As a further feature, the gate 509 can be closed and the gate 511 can be opened so as to bypass the apparatus (1, 100, 200) and deliver the material 5 directly from the last wash tank 507 to the dryer 511. Figure 11A is similar to Figure 10A but includes an additional dryer 515. In addition to the movable by-pass gates 509 and 511 as discussed with reference to Figures 10A and 10B, the embodiment of Figure 11A also includes an additional movable by-pass gate 517 as illustrated in the detailed view of Figure 11B. Therefore, during the use of the embodiment of Figure 11A, after the material passes from the last wash tank 507, it can be delivered to the apparatus (1, 100, 200) of the present invention by way of the gate 509. The material can thereafter be delivered to either the dryer 515 or 501. As a further route, the gate 509 can be closed and gate 511 opened so as to deliver the material from the last wash tank 507 to the dryer 501. If the gate 517 is open, the material can go from the first dryer 501 to the apparatus (1, 100, 200) and thereafter be delivered to a second dryer 515. Figure 12 illustrates an overview of a further embodiment of a system to which the apparatus (1, 100, 200) of the present invention can be applied. In the system of Figure 12, after the material 5 passes from the last wash tank 507 and through the dryer 501, the material having a dry surface can be delivered to the apparatus (1, 100, 200) of the present invention by way of movable gate 521, and thereafter delivered to second dryer 515. As an alternative, a user can select to have the material 5 cut in the dryer 501. The single cut print can then be transported to the apparatus (1, 100, 200), and thereafter transported to the second dryer 515. Figure 13 like Figure 9 illustrates an example of the apparatus of the present invention as it is applied to an auto-tray processor such as disclosed in U.S. Patent No. 5,400,106. Although Figure 13 as an example shows the apparatus 1 as illustrated in Figure 1, it is recognized that any of the apparatuses 100 or 200 can be applied to the processor of Figure 13. As noted in Figure 13, the auto-tray can include processing stations 601-606 which make up the specific points of the processing system, and can include developer solution, bleach solution, fixing solution, and washing solutions, or a combination of a bleach-fix solution and a wash/stabilizer solution in a known manner. The apparatus (1, 100, 200) of the present invention for applying a protective viscous solution to a photosensitive material and thereafter controlling the solution can be added to the end of an existing processing system or built into the last wash tank, and the coated material can thereafter be transported to a dryer as previously described. Depending on design considerations, the photosensitive material can pass through the processor at speeds necessary for standard processing in wholesale labs, minilabs, maxilabs, and so forth. Also, the photosensitive material in the form of a web or cut sheet can comprise film or final viewing media such as paper or resin coated paper, plastic papers such as polyethylene terephthalate, polyethylene naphthalate, Estar, Melinex, polyester and cellulose acetate or combinations of these materials, as described in co-pending U.S. application no. 08/862,708 filed May 23, 1997. Figure 14 illustrates a modification of the system of the present invention. As illustrated in Figure 14, the photosensitive material 5 can be delivered to a first tank 701 which includes a transport roller assembly 703 having opposing rollers rotatably mounted in the tank 701, and a coating roller 705 which is partially immersed in a viscous solution 711 held in the tank 701. The coating roller 705 is also rotatably mounted in the tank 701 and applies a layer of the viscous solution 711 to one side of the photosensitive material 5 which is thereafter transported between a transport roller 707 and an opposed metering roller 709. The metering roller 709 controls the thickness, uniformity and laydown amount of the applied viscous solution 711 in the manner previously described with reference to Figure 1. The photosensitive material 5 with the applied viscous solution 711 is thereafter delivered to a dryer 715 which dries the coated photosensitive material. After the material 5 leaves the dryer 715, it is transported to a second tank 717 which includes a second viscous solution 711'. The second tank 717 further includes a second rotatably mounted transport roller assembly 719 and a second coating roller 721 which applies a further layer of viscous solution 711' onto the material 5. The material 5 is then transported between a second transport roller 723 and a second metering roller 725 which controls the thickness, uniformity and laydown amount of the applied viscous solution 711'. The photosensitive material 5 is thereafter delivered to a second dryer 715a. The second viscous solution 711' can be the same as the first viscous solution 711, or can be modified based on design considerations. The system of Figure 14 as well as that of Figures 17-18 can be utilized when a double layer of coating protection is desired on one side of the material 5. Figure 14 only illustrates one example of applying and metering the viscous solution. As previously described, the photosensitive material 5 can be entirely dipped into the viscous solution and metered on one side; an application roller 705 as illustrated in Figure 14 can be utilized to apply the viscous solution on one side of the material and metering can be performed on the same one side; or the entire print or material can be entirely dipped and thereafter metered on both sides. Figure 15 illustrates a further variation of the system of the present invention. In Figure 15, the elements which are the same as those illustrated in Figure 14 are identified with the same reference numerals. Figure 15 differs from Figure 14 in that it includes a turn-over section 900 which flips or turns over the material 5 after it leaves the first dryer 715. Therefore, in Figure 15, the first side A is coated and metered in the first tank 701. After the material 5 leaves the first dryer 715, the material 5 is turned over or flipped such that the second side B of the material 5 is coated and metered in the second tank 717. This provides for a protective coating on both sides of the material 5 which is controlled and metered in the manner discussed with reference to Figure 1. Figure 16 shows a further variation of the system of the present invention. In Figure 16, the material 5 is delivered in the direction indicated by arrow 51 into a tank 730. A transport roller assembly 731 which includes opposing rollers is positioned in the tank 730 and delivers the material 5 to a coating roller 733. The coating roller 733 is partially dipped in a viscous solution 740. The coating roller 733 applies a layer of the viscous solution 740 onto the material 5, and the material is thereafter delivered to a metering roller 737 which is opposed to a transfer roller 735. The metering roller 737 controls the thickness, uniformity, and laydown amount of the applied viscous solution in a manner described with reference to Figure 1, and thereafter the photosensitive material 5 is transported to a curing section 739. The coating on the photosensitive material 5 is cured at the curing section 739 without disturbing the applied layer. The curing can include an ultraviolet light treatment, an infrared heating, air drying or other known curing agents and methods. Curing agents can include those conventionally used in the coating industry to cross-link functional groups such as carboxylic acids, amines, alcohols, epoxy, vinyl, and so forth. Such cross-linking agents may be incorporated into the coating or may be introduced via a second application of a coating solution. After the coating on the photosensitive material is cured in the curing section 739, it is transported by roller assembly 739' to a dryer 741 in which drying is performed as previously described. The present invention is not limited to the arrangement in which drying occurs after curing. It is recognized that within the context of the present invention curing can occur after drying as shown in Figure 16A. This concept also applies to the embodiment of Figures 17 and 18 which will now be described. Figure 17 is a further variation of the system of the present invention which includes multiple stations of coating, curing, coating, curing and drying. In Figure 17, the material 5 is delivered from the last processing station in the direction of the arrow 51 to the first tank 701. The first tank 701 includes rotatably mounted transport assembly 703, coating roller 705, transport roller 707 and metering roller 709. The coating roller 705 is partially immersed in the viscous solution 711 so as to apply a layer of the viscous solution onto the surface of the photosensitive material and thereafter, the thickness, uniformity, and laydown amount of the applied viscous solution is controlled by the metering roller 709 in a manner previously described with reference to Figure 1. The material 5 with the protective coating thereon is thereafter conveyed to curing section 739 as described in Figure 16, and after curing, is delivered to second tank 717 in which a further layer of viscous solution 711' is applied by way of second coating roller 721. The second tank 717 includes second transport roller assembly 719 which delivers the photosensitive material to second coating roller 721. The material with the second viscous solution 711' applied thereon is thereafter delivered between second transport roller 723 and second metering roller 725 which controls the thickness, uniformity and laydown amount of the applied second viscous solution in a manner described with reference to Figure 1. The photosensitive material is thereafter delivered to a second curing station 739a and after curing is delivered by rollers 739a' to dryer 715. Figure 18 shows a further variation of the system of the present invention which includes multiple stations for coating, curing, drying, coating, curing, and drying. In the embodiment of Figure 18, the material 5 is delivered to first tank 701 which includes first viscous solution 711. Transport roller assembly 703 rotatably mounted in the first tank 701 delivers the photosensitive material 5 to first coating roller 705 which coats one side of the photosensitive material 5 with a layer of viscous solution 711. The photosensitive material 5 is thereafter delivered to transport roller 707 and opposing metering roller 709 which controls the thickness, uniformity, and laydown amount of the applied viscous solution in a manner described with reference to Figure 1. The material 5 with the viscous solution coating is thereafter transported to curing section 739 as previously described and after the curing section 739 is delivered to first dryer 715. As further illustrated in Figure 18, after the first dryer 715, the photosensitive material 5 is transported to second tank 717 having transport roller assembly 719 rotatably mounted therein. The transport roller assembly 719 transports the photosensitive material 5 to second coating roller 721 which is partially immersed in the second viscous solution 711'. The second coating roller 721 applies a layer of the second viscous solution 711' on the facing surface of the photosensitive material 5. The photosensitive material 5 is thereafter delivered to transport roller 723 and metering roller 725 which controls the thickness, uniformity, and laydown amount of the applied viscous solution in a manner described with reference to Figure 1. The photosensitive material 5 with the protective coating that includes the first and second viscous solutions is thereafter delivered to second curing section 739a and second dryer 715a as illustrated in Figure 11. Figure 19 illustrates a further variation of the system of the present invention in which a bypass is established for bypassing the apparatus of the present invention. In the embodiment of Figure 19, the apparatus 200 as described with reference to Figure 6 is shown. However, it is recognized that the bypass as illustrated in Figure 19 can be applied to any of the apparatuses 1, 100 and 200 as described in the present specification. As illustrated in Figure 19, the bypass can include rollers 850 which guide the material 5 around apparatus 200 and directly into the dryer 69. The apparatus further includes rotating guides 900 at the entrance and exit of the apparatus 200, as well as oxidation doors 23 which close the apparatus 200 when the material bypasses the apparatus so as to provide for a substantially closed chamber. The oxidation doors 23 can be spring-loaded doors which can be automatically and/or externally activated. In a bypass mode, the oxidation doors 23 are closed and the guides 900 are rotated in the direction indicated by the arrows 950 to guide the material 5 in a bypass path utilizing the rollers 850. In a non by-pass mode, the doors 23 are opened and the guides 900 are rotated to the position illustrated in Figure 19 to lead the material 5 through the apparatus 200. Therefore, the system of the present invention can include a curing section for curing the applied viscous solution and a drying section with a mechanism for transporting the coated material through either the curing or drying sections or both, in such a manner that the surface to which the viscous solution has been applied is not disturbed until the solution has dried sufficiently to prevent defects. The system of the present invention can also provide solutions of different viscosities to one or both surfaces of processed photosensitize materials prior to drying in a manner that allows the solution to be uniformly applied to the surface at specific layer thicknesses under conditions found in a photographic processor. The coating solutions as described tend to leave a messy residue within the tank or container, as well as on the internal mechanisms of the tank or container, which is difficult to clean and adversely affects maintenance. The following embodiments describe a replaceable coating cartridge assembly which minimizes the need to constantly clean the container or tank. Figure 20A illustrates a replaceable coating cartridge which can be applied to all of the disclosed embodiments and arrangements of the present application. Figure 20A as a representative example illustrates the apparatus 200 as illustrated, for example, in Figure 6. However, the structure of the replaceable coating cartridge is not limited to the apparatus 200 but is also applicable to the disclosed apparatuses 1 and 100, as well as all of the disclosed arrangements. As illustrated in Figures 20A-20C, a replaceable coating cartridge 1000 is insertable into a body 1002 of the apparatus. For ease of insertion, the replaceable coating cartridge 1000 can include projections or slots 1001 which can engage or cooperate with corresponding projections or slots 1001' on the body 1002. This provides for an accurate insertion and locking of the cartridge assembly 1000 within the body 1002. However, the structure of the present invention is not limited to the disclosed projections or slots and any means which permit the accurate insertion of the coating cartridge 1000 within the body 1002 can be utilized within the context of the present invention. As illustrated in Figure 20A, when the coating cartridge 1000 is inserted within the body 1002, openings 1000a, 1000b on the coating cartridge 1000 are respectively aligned with an entrance 1002a and an exit 1002b of the body 1002. This provides for a passage of photosensitive material through the body 1002, through the coating cartridge 1000 and into the dryer 69. The body 1002 includes a transport roller assembly 63 which delivers the photosensitive material 5 to the coating cartridge 1000, and then to coating roller 65 which is partially immersed in viscous solution 3 in the coating cartridge 1000. The coating roller 65 coats a side of the photosensitive material 5 which is then transported to a metering roller 67 which meters or controls the one side of the material 5, as discussed with reference to Figure 1. It is noted that the operation of the coating and metering with respect to the embodiment that is disclosed in Figure 20A is similar to the embodiment as shown in Figure 6, however, as discussed above, the replaceable coating cartridge assembly as illustrated in Figure 20 is also applicable to the apparatus 1 and 100. Each of the rollers 63, 65 and 67 can be drivingly connected to a known drive unit which can include for example, a drive gear or drive belt and motor arrangement. In this type of arrangement, rollers 65 and 67 would engage with the drive unit upon insertion of the coating cartridge 1000 into the body 1002. As an alternative arrangement one or both of the rollers 65 and 67 can be free wheeling so as to rotate upon contact with the photosensitive material when the photosensitive material 5 is driven through the coating cartridge 1000 by way of the transport roller assembly 63. As illustrated in Figure 20C, the coating cartridge 1000 can include reusable sealing members or strips 1003 which cover the openings 1000a and 1000b. Therefore, during delivery or transportation of the coating cartridge 1000, the coating product or viscous solution is safely retained within the coating cartridge 1000 and is not exposed to air. Before use and prior to the insertion of the coating cartridge 1000 in the body 1002, the sealing members or strips 1003 are peeled away and the coating cartridge is inserted within the body 1002 as discussed above. The openings 1000a,1000b of the coating cartridge 1000 are then respectively aligned with the entrance 1002a and exit 1002b of the body 1002 to permit the use of the replaceable coating cartridge 1000 in a manner as described with respect to the previous embodiments, for example, Figure 6, so as to coat and meter at least one side of the photosensitive material, and deliver the coated photosensitive material to the dryer 69. After the solution 3 within the coating cartridge 1000 is consumed, the coating cartridge 1000 can be removed from the body 1002. The interior of the cartridge coating assembly 1000 including the internal mechanisms will include residue from the viscous coating solution. If the coating cartridge 1000 is to be returned to the manufacturer for recycling or disposal, the coating cartridge 1000 is placed within a sealable outer enclosure 1005 as illustrated in Figures 21A, 21B. The sealable outer enclosure 1005 with the coating cartridge 1000 positioned therein is then be placed within a box 1007 for transportation. It is recognized that a new coating cartridge can be delivered to the user within the box 1007 and enclosure 1005 and thereafter removed for subsequent use. As a further option, if the user desires to dispose of the coating cartridge 1000 himself, the user simply removes the coating cartridge 1000 as describe above, rinses out the interior of the coating cartridge 1000 (preferably three times), subjects the coating cartridge 1000 to an optional heat-treatment, and then disposes of the same. As a further option, if the enclosure 1005 is not used, the reusable sealing strips 1003 can be placed on the openings 1000a, 1000b so as to cover the same, and the coating cartridge 1000 can thereafter be placed within box 1007. Furthermore, as illustrated in Figure 1, the arrangement of the present invention can include a recirculation system. The insertion and/or removal of the coating cartridge 1000 into and from the body 1002 requires a connection and/or disconnection of the appropriate fluid connections between the coating cartridge 1000, the processor and the recirculation system. In order to facilitate the insertion and/or removal of the coating cartridge 1000, these fluid connections can include known closeable valves and/or dripless valves as disclosed in, for example, U.S. application Serial No. 08/557,884. These dripless valves eliminate leakage during fluid transfer between mating systems. As a further feature of the present invention, the coating cartridge 1000 as illustrated in Figure 22 can include an opening 1112 which is matable with a removable fluid tank 1009 containing new viscous solution 3' or a product which can be converted to the viscous solution. The fluid tank 1009 can include a valve assembly 1115 which can be similar to the above-mentioned dripless valve assembly disclosed in copending U.S. application Serial No. 557,884. The valve assembly 1115 includes a first member 1115a and a second member 1115b which form the dripless valve member for the fluid tank assembly 1009. It is recognized that other closable valve members can be used within the context of the present invention. With this arrangement, after the viscous solution within the coating cartridge 1000 is consumed, fluid tank 1009 is placed on the opening 1112 so as to introduce new viscous solution directly into the coating cartridge 1000. Therefore, the present invention permits the easy replacement of a coating cartridge and at the same time provides for an efficient and controlled application of a protective coating on a surface of a photosensitive material.

Claims: A replaceable cartridge coating assembly for use in a photographic processor, comprising: a cartridge (1000) which is adapted to hold a viscous solution (3) of a predetermined viscosity therein; a sealable inlet (1000a) and a sealable outlet (1000b) each of them covered by a removable sealing member and located on the cartridge (1000) which permit a passage of photosensitive material (5) into and out of the cartridge (1000); and an applicator (65) and control mechanism (67) mounted within the cartridge (1000), the applicator (65) and control mechanism (67) capable of applying a layer of the viscous solution (3) to at least one surface of a photosensitive material (5) which passes through the cartridge (1000), said applicator (65) and control mechanism (67) capable of controlling the thickness, uniformity and lay down amount of the applied viscous layer, said viscous layer forming a durable protective coating on said at least one surface. A coating assembly as claimed in claim 1, wherein the removable sealing members (1003) located at the inlet (1000a) and the outlet (1000b) of the cartridge (1000) for sealing the inlet (1000a) and the outlet (1000b) are adapted to minimize exposure to air of viscous solution (3) contained therein and to prevent spilling of the viscous solution (3) during transportation of the cartridge (1000) and during insertion of the cartridge (1000) into a working position in a processing tank (7) of a processor, wherein the inlet (1000a) and the outlet (1000b) of the cartridge (1000) are respectively aligned with an entrance (1002a) and an exit (1002b) of the processing tank when the cartridge (1000) is positioned in the working position in the processing tank, and the sealing members (1003) are removable before insertion of the cartridge (1000) into the working position in the processing tank (7). A coating assembly as claimed in claim 1, further comprising: a sealable enclosure (105) which is sized to receive the cartridge (1000) after the viscous solution (3) within the cartridge (1000) has been consumed; and a container (1007) which is sized to receive the sealable enclosure. A processor for developing photosensitive material and for applying a protective layer to the surface of the photosensitive material using a coating assembly of claim 1, comprising: a processing section for developing the photosensitive material (5), the processing section comprising at least one processing tank (7) containing a processing solution through which the photosensitive material (5) passes for development, said processing solution being separate and apart from the viscous solution (3), said coating assembly being positioned within said tank (7) such that the sealable inlet (1000a) and sealable (1000b) outlet are respectively aligned with the entrance (1002a) and exit (1002b) of the at least one processing tank (7) when the coating assembly is positioned in the at least one processing tank (7), the inlet (1000a) and outlet (1000b) permitting a passage of a photosensitive material (5) therethrough. A processor as claimed in claim 4, further comprising removable sealing members positioned on the inlet and the outlet of the cartridge. A processor as claimed in claim 4, further comprising a dryer positioned downstream of the coating section which dries the layer of applied viscous solution so as to provide for a protective coating on the at least one surface of the material. A method of coating at least one surface of a photosensitive material, the method comprising the steps of: inserting a replaceable coating cartridge (1000) according to claim 1 into a tank (7) of a processor such that a sealable inlet (1000a) and a sealable outlet (1000b) of the coating cartridge (1000) are respectively aligned with an entrance (1002a) and exit (1002b) of the tank (7), the coating cartridge (1000) being adapted to hold a solution of a predetermined viscosity therein; conveying the photosensitive material (5) through the inlet (1000a) and the outlet (1000b) of the coating cartridge (1000) so as to coat at least one surface of the photosensitive material (5) with the viscous solution (3) as the photosensitive material (5) passes through the coating cartridge (1000); and controlling a thickness, uniformity and laydown amount of the applied viscous solution (3) on the at least one surface of the photosensitive material as the photosensitive material passes through the coating cartridge (1000), said layer forming a durable protective coating on said at least one surface. A method as claimed in claim 7, comprising the further steps of: removing the coating cartridge (1000) from the tank (7) after the viscous solution (3) in the coating cartridge (1000) has been consumed; placing the removed coating cartridge (1000) into at least one sealable outer enclosure (105) for transportation of the coating cartridge (1000); and replacing the removed coating cartridge (1000) with a further coating cartridge (1000) which is adapted to hold a further viscous solution (3) therein.

Inventors: BOHAN ANNE E, O'CONNOR KEVIN M, PATTON DAVID LYNNE, PICCININO RALPH LEONARD JR, BOHAN, ANNE E., O'CONNOR, KEVIN M., PATTON, DAVID LYNNE, PICCININO, RALPH LEONARD, JR.
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1998
Main classification: G03D15
IPC codes: G03D15, B05C1