Patent Publication Number: US-6664033-B2

Title: Image forming assembly and method using a lamination apparatus

Description:
This is a Divisional application of U.S. Ser. No. 10/092,038 filed Mar. 6, 2002, now U.S. Pat. No. 6,555,302 which is a Divisional of parent application U.S. Ser. No. 09/592,818 filed Jun. 13, 2000 now U.S. Pat. No. 6,413,704. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to an improved image forming assembly and method using a lamination apparatus. More specifically, the present invention relates an image forming assembly and method using a lamination apparatus for camera formatted films which reduces or eliminates processing marks. 
     BACKGROUND OF THE INVENTION 
     The lamination development of imagewise exposed silver halide films is well known. Specific examples of lamination processing include instant photography as originally popularized by the Polaroid Corporation and a somewhat related print making process commercialized as Pictography by Fuji Photofilm Company. The processes all include the addition of moisture and the application of a laminate sheet to an imagwise exposed element silver halide element. Chemical ingredients necessary for photo processing can be delivered as solution components in the applied moisture or they can be delivered in the applied laminate sheet. Photo processing occurs in an apparently dry manner when the laminate sheet is then intimately contacted to the light sensitive material. 
     More recently, attempts have been made to extend this processing scheme to camera formatted silver halide films. Several specific examples are disclosed by Ishikawa et al. in U.S. Pat. No. 5,756,269, by Ishikawa in U.S. Pat. No. 6,022,673, by Kikuchi in U.S. Pat. No. 5,965,332, by Miyake in U.S. Pat. No. 6,017,684 and by Irving et al. in pending application Ser. No. 09/475,510, filed Dec. 30, 1999. This art discloses the application of moisture to either the sensitized photographic material or to the laminate processing sheet followed by the lamination of the laminate processing sheet to the sensitized good so as to effect photo-processing. 
     In a related art, laminate sheets pre-wetted with conventional photo-processing are disclosed by Clough in WO 98/40787 and WO 98/40788. These disclosures describe the application of developing agents, bleaching agents, fixing agents and clearing agents to imagewise exposed films. 
     The camera-formatted films described in these recent references differ from the sheet films used in instant photography and in Pictography in that the camera formatted films include sprocket holes to enable the film to be controllably advanced in a camera. FIG. 1A shows an imagewise exposed camera film  101  bearing a latent image and having sprocket holes  105  and a processing laminate sheet  103 . FIG. 1B shows a side view, through line a—a of FIG. 1A of the same components with an indication of application of moisture according to arrow  102  to the emulsion face of light sensitive film  101 . On contacting moistened film  101  to processing laminate sheet  103  photo processing occurs. It has been observed that a processed image  107  as illustrated in FIG. 1C regularly has processing marks  109  emanating from sprocket holes  105 . This is at least due to the fact that processing laminate sheet  103  extends over sprocket holes  105  in a width wise direction. Processing marks  109  associated with sprocket holes  105  are unique to camera formatted films and negatively impact the visually pleasing character of images that consumers desire and have come to expect. 
     SUMMARY OF THE INVENTION 
     The present invention provides for an image forming assembly and method which utilizes a laminate processing sheet. The method and apparatus of the present invention uses a unique laminate sheet that reduces or eliminates processing marks on photosensitive film having sprocket holes. 
     The present invention provides for an image forming assembly that comprises a laminate processing sheet that is adapted to be laminated on an emulsion side of an exposed photosensitive film. The laminate processing sheet comprises a processing component or solution for processing the photosensitive film. In one embodiment, the photosensitive film has first sprocket holes that extend longitudinally along a first side edge of the photosensitive film and second sprocket holes that extend longitudinally along a second side edge of the photosensitive film. A first widthwise distance on the photosensitive film is defined between the first sprocket holes and the second sprocket holes. The laminate processing sheet defines a second widthwise distance which is smaller than the first widthwise distance so as not to extend over the first and the second sprocket holes when the laminate processing sheet is laminated over the photosensitive film. 
     The present invention also provides for an image forming assembly which comprises a laminate processing sheet adapted to be laminated on an emulsion side of an exposed photosensitive film, with the laminate processing sheet comprising processing solution for processing the photosensitive film, and the photosensitive film having opposing longitudinally extending sprocket holes; and an absorbing sheet applied on a support side of the photosensitive film which is opposite the emulsion side, with the absorbing sheet absorbing excess processing solution from the opposing sprocket holes and an area in a vicinity of the opposing sprocket holes. 
     The present invention also provides for an image forming method which comprises the step of applying a laminate processing sheet onto an emulsion side of an exposed photosensitive film having opposing longitudinally extending sprockets holes. The laminate processing sheet comprises processing solution and the laminate processing sheet is applied in an area between the opposing sprocket holes so as not to extend over the sprocket holes. 
     The present invention also provides for an image forming method which comprises the steps of: applying a laminate processing sheet onto an emulsion side of an exposed photosensitive film having opposing longitudinally extending sprocket holes, with the laminate processing sheet comprising processing solution for processing of the photosensitive film; and applying an absorbing sheet onto a support side of the photosensitive film which is opposite the emulsion side, with the absorbing sheet absorbing excess processing solution from the opposing sprocket holes and an area in a vicinity of the opposing sprocket holes. 
     The present invention also provides for an image forming assembly which comprises a processing sheet adapted to be applied on an emulsion side of an exposed photosensitive film, with the processing sheet comprising processing solution for processing the photosensitive film. The photosensitive film comprises opposing sprocket holes and the processing sheet is applied on an area of the photosensitive film which is between the opposing sprocket holes. 
     In another embodiment, the photosensitive film has sprocket holes that extend longitudinally along a first side edge of the photosensitive film only. A first widthwise distance on the photosensitive film is defined between the sprocket holes and the second side edge of the photosensitive film. The laminate processing sheet defines a second widthwise distance which is smaller than the first widthwise distance so as not to extend over the sprocket holes when the laminate processing sheet is laminated over the photosensitive film. 
     The present invention also provides for an image forming method which comprises the steps of applying a processing sheet on an emulsion side of an exposed photosensitive film having longitudinally extending sprocket holes, with the laminate processing sheet comprising processing solution for processing of the photosensitive film; and applying a sumping member to a support side of the photosensitive film which is opposite the emulsion side, with the sumping member removing processing solution from the sprocket holes and an area in a vicinity of the sprocket holes. 
     The present invention also provides for an image forming assembly which comprises a processing sheet adapted to be applied onto an emulsion side of an exposed photosensitive film having longitudinally extending sprocket holes, with the laminate processing sheet comprising processing solution for processing of the photosensitive film; and a sumping member adapted to be applied onto a support side of the photosensitive film which is opposite the emulsion side, with the sumping member being adapted to remove processing solution from the sprocket holes and an area in a vicinity of the sprocket holes. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1A shows an imagewise exposed camera formatted film and a processing laminate sheet; 
     FIG. 1B is a side view of the film and processing laminate sheet illustrated in FIG. 1A; 
     FIG. 1C illustrates an image processed in accordance with the arrangement of FIGS. 1A and 1B; 
     FIG. 2 is an example of an apparatus for conveying photosensitive film; 
     FIG. 3A illustrates an imagewise exposed photosensitive film and an applied laminate processing sheet in accordance with one embodiment of the present invention; 
     FIG. 3B is a side view of the photosensitive film and laminate sheet of FIG. 3A; 
     FIG. 3C illustrates a further example of an exposed film and an applied laminate processing sheet; 
     FIG. 4A illustrates a photosensitive film, a laminate processing sheet and an absorbing sheet in accordance with a second embodiment of the present invention; 
     FIG. 4B is a side view of the photosensitive film, laminate processing sheet and absorbing sheet as illustrated in FIG. 4A; 
     FIG. 5 illustrates a resulting image processed in accordance with the arrangements shown in FIGS. 3A and 4A; 
     FIG. 6A illustrates a sumping member; 
     FIG. 6B illustrates an end view of the sumping member of FIG. 6A; 
     FIG. 7A illustrates a photosensitive film, a laminate processing sheet and a sumping member in accordance with a third embodiment of the present invention; and 
     FIG. 7B is a side view of the photosensitive film, laminate processing sheet and sumping member as illustrated in FIG.  7 A. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, wherein like reference numerals represent identical or corresponding parts throughout the several views, FIG. 2 illustrates a basic example of a development or processing system in accordance with the present invention. As illustrated in FIG. 2, exposed photosensitive film  5  which can be thermal film as disclosed in U.S. Pat. No. 6,048,110, is thrust in a known manner from, for example, a thrust cartridge as also illustrated in U.S. Pat. No. 6,048,110. The film is conveyed along a development path and under a wetting solution applicator  10  which moistens the exposed photosensitive film. 
     Typical wetting solutions include water and basic solutions. Useful methods and volumes are well known in the art and are specifically disclosed in the earlier cited references. In one preferred embodiment the wetting device is a head with multiple nozzles and the applied solution is a basic solution as disclosed by Makuta et al., U.S. Pat. No. 6,001,544. In another preferred embodiment, the wetting device is a dip tank and the applied solution is water as disclosed by Ishikawa et al., U.S. Pat. No. 5,756,269. In yet another preferred embodiment the wetting device is a dip tank and the applied solution is a basic activator solution as disclosed by Irving et al., U.S. Ser. No. 09/475,510 filed Dec. 30, 1999. In yet another embodiment, the applied solution is a developing solution and the applicator is a thermal jet head as described by Edgar, U.S. Pat. No. 5,988,896. In yet another embodiment, the laminate is wetted by dipping or by nozzle instead of the imagewise exposed photosensitive element. Additional methods of applying limited quantities of solution to light sensitive elements or laminate sheets through jetting orifices are disclosed by Ueda, U.S. Pat. No. 5,832,328, Ueda et al, U.S. Pat. No. 5,701,541, Kobayashi et al, U.S. Pat. No. 5,758,223. 
     A laminate  15  (which can be in roll form or separate sheets) is applied to a surface of photosensitive film  5 , and the film with the applied laminate thereon is conveyed passed a heater  20  for developing images on the film. Processing laminate sheet  15  includes a processing component or processing solution which is activated while passing through the heater  20  for developing images on the film. Downstream of heater  20 , film  5  can be scanned by scanner  25  and taken up by take-up roller  30 . Additionally, the spent laminate sheet  5  can also be taken up via take-up roller  35  and recycled. Again, FIG. 2 illustrates one example of a developing system which can be used in the present invention and other systems are possible. 
     When processing exposed photosensitive film having sprocket holes, the processing generally leaves distracting processing marks in the area of the image which corresponds to the sprocket holes as described above and shown in FIG.  1 C. 
     FIG. 3A illustrates a first embodiment of the present invention which addresses the unwanted processing marks by limiting the width of the processing laminate sheet to an image area of a camera formatted film having sprocket holes. More specifically, FIG. 3A shows an image-wise exposed camera formatted film  101  having first sprocket holes  105   a , second sprocket holes  105   b  and an applied laminate processing sheet  117 . In a first feature of the present invention, a width “b” of laminate processing sheet  117  is limited to the area between sprocket holes  105   a ,  105   b . That is, as illustrated in FIG. 3A sprocket holes  105   a  and  105   b  extend longitudinally along opposing side edges of photosensitive film  101 . A width-wise distance “c” is defined on film  101  between sprocket holes  105   a  and  105   b . Distance “b” of laminate processing sheet  117  is smaller than the distance “c” so as to confine laminate processing sheet  117  within an image area between sprocket holes  105   a ,  105   b.    
     FIG. 3B is a side view through line a—a of FIG.  3 A. FIG. 3B illustrates the application of moisture to an emulsion face of film  101  in a direction shown by arrow  102  and the intimate contact of laminate processing sheet  117  of limited width to the emulsion face of camera film  101 . As described with reference to FIG. 2, the solution can be a wetting solution which is applied via wetting solution applicator  10 . 
     With the arrangement as illustrated in FIGS. 3A and 3B, images as shown in FIG. 5 can be obtained. That is, by confining the width of laminate processing sheet  117  to an image area between sprocket holes  105   a  and  105   b , unwanted processing marks at sprocket holes  105   a ,  105   b , and in an area in the vicinity of sprocket holes  105   a  and  105   b  are reduced or eliminated, so as to provide for the clear image illustrated in FIG.  5 . 
     Further, with the arrangement illustrated in FIGS. 3A and 3B, the apparatus for applying processing laminates as illustrated in FIG. 2 can be modified to accept the narrower processing laminate sheets, and to constrain the processing laminate sheets to contacting the film in a central area by adjusting (narrowing) laminate transport guides which guide the laminate sheet onto the photosensitive film. 
     Of course, the present invention is not limited to film having sprocket holes that extend along both sides of the film. As illustrated in FIG. 3C, in a further feature of the invention, a film  101 ′ can include sprocket holes  105   a ′ that extend longitudinally along only one side  800  of film  101 . A first widthwise distance c′ on film  101 ′ is defined between sprocket holes  105   a ′ and a second side edge  900  of film  101 ′. Laminate processing sheet  117  defines a second widthwise distance b′ which is smaller than first widthwise distance c′ so as not to extend over sprocket holes  105   a  when laminate processing sheet  117  is laminated over film  101 ′. The results of the arrangement of FIG. 3C would be the same of FIG. 3A with respect to eliminating processing marks at sprocket holes  105   a ′ and in the area in the vicinity of sprocket holes  105   a′.    
     FIGS. 4A-4B illustrate a second embodiment of the present invention. Like FIG. 3A, FIG. 4A shows an image-wise exposed camera formatted film  101  having sprocket holes  105   a ,  105   b  with laminate processing sheet  103  applied to the emulsion side. Unlike the embodiment of FIG. 3A, in FIG. 4A laminate processing sheet  103  is not narrowed. In order to address the processing marks, in the embodiment of FIG. 4A an absorbing sheet  109  is applied to the support side of the film  101  which is opposite the emulsion side. FIG. 4B is a side view of the arrangement of FIG.  4 A and illustrates the application of a wetting solution to moisten the emulsion face of film  101  in the direction shown by  102 . FIG. 4B also shows the intimate contact of laminate processing sheet  103  to the emulsion face of film  101 , as well as the intimate contact of absorbing sheet  109  to the backside of film  101 . 
     Absorbing sheet  109  operates to absorb and or wick excess solution at or around sprocket holes  105   a ,  105   b , and thus is effective to suppress or reduce any unwanted processing marks or comets which can otherwise originate from the sprocket holes to mark the finished image. Image  107  as illustrated in FIG. 5 can also be obtained utilizing the arrangement of FIG. 4A. A known apparatus for applying processing laminates can be modified to apply an absorbent sheet to the backside of the camera film. With respect to the absorbing material, any type or form of absorbing material such as a gel or sheet can be employed. Further, the absorbing material can be supplied or applied onto the film in a one-time use form or as a continuous roll that can be readily regenerated, as for example, by solution evaporation. Further, it is preferable that the absorbing material be strong and resilient to facilitate transport through an apparatus such as shown in FIG.  2 . 
     FIG. 6A illustrates a sumping member  121  having a width adequate to support the photographic element during processing which includes channels  123  adapted to align with the sprocket holes of an applied photographic film. FIG. 6B shows a side view of FIG. 6A along line d—d. Channels  123  are connected by draining tube  125  which in turn exits the sumping member through an adapter  127  suitable for draining fluids as they accumulate in channels  123 . While drainage can be accomplished by any convenient means, including gravity, it is preferred that a sufficient vacuum be applied to the channels through adapter  127  to actively urge processing solutions from the sprocket holes during processing. The results of this arrangement would be the same as the previously described embodiments in that the processing marks at the sprocket holes or in the vicinity of the sprocket holes would be eliminated. 
     FIG. 7A illustrates the exposed photographic film  101 , the laminate sheet  103  and the sumping member  121  with channels  123  aligned to the sprocket holes  105  of the film. FIG. 7B shows an end view of the assembly of FIG.  7 A and illustrates the direction of application of moisture. The sumping member can be adapted to be a heating member. 
     The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.