Patent Publication Number: US-5837012-A

Title: Dyeing method of photographic polyester support

Description:
This is a Continuation of application Ser. No. 08/549,178 filed Oct. 27, 1995, now abandoned. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a dyeing method of a photographic polyester support, more particularly, it relates to a simple dyeing method causing no uneven color easily. 
     BACKGROUND OF THE INVENTION 
     A polyester film generally has a high index of refraction as compared with TAC to be prone to a problem of light fogging due to so-called light piping and accordingly, needs to be dyed. Conventionally, in order to dye PET and the like, a dye may be added to the reaction system at the polymerization of pellets or pellets and a dye are in advance mixed and kneaded to formulate them into a master batch as described in JP-B-59-4174 (the term &#34;JP-B&#34; as used herein means an &#34;examined Japanese patent publication&#34;). However, these methods are cumbersome and costly and therefore, a simple method has been demanded. The simplest method is to blend pellets and dye powder immediately before melting two members to form a film, however, the dye powder is bad in handleability and involves troubles such that fluctuation of discharge (i.e., delivery) in the feeder is large and uneven density is generated. Also, in the case when two kinds of dyes are used, the color tone is changed due to the above-described troubles and the product cannot be used as a photographic support. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a method for dyeing a photographic polyester support simply and at the same time, uniformly. 
     The object of the present invention has been achieved by a method for dyeing a photographic polyester support comprising the use of transparent pellets and a dye granulated so as to satisfy the requirements that: 
     (1) the particle size is 50% or more; 
     (2) the angle of repose is 60° or less; and 
     (3) the particle hardness is from 160 to 400 g on average and has a lower limit of 50 g. 
     The particle size as used in the present invention is obtained by weighing about 100 g of a sample and sieving it out through JIS standard sieves of 16 mesh (hole size: about 1.0 mm) and 32 mesh (hole size: about 0.5 mm) to determine the weight of particles passed 16-mesh sieve and left on 32 mesh sieve and expressed by the ratio of the weight of particles to that of the sample. 
     The angle of repose as used in the present invention is obtained by falling about 100 g of a sample through a funnel having a hole size of 3 mm with the drop outlet of the funnel being positioned at the height of 50 mm from the table and determining the bottom angle of the sample accumulated by means of a protractor and expressed by the average of angles measured three times. 
     The particle hardness as used in the present invention is obtained by placing one particle of a sample on a flat glass plate, crushing it by means of a push-pull gauge and reading the load of the gauge and expressed by the average and by the minimum value of loads measured 20 times. 
     The granulated dye of the present invention has a particle size of 50% or more, preferably from 50 to 100%, more preferably 70 to 100%, most preferably 85 to 100%. The angle of repose is 60° or less, preferably from 5° to 60°, more preferably 5° to 50°, most preferably 5° to 45°. The particle hardness as the average is from 160 to 400 g, preferably from 220 to 340 g, more preferably from 240 to 320 g, and the particle hardness as the minimum value (i.e., the lower limit) is 50 g or more, preferably 75 g or more, most preferably 100 g or more. The maximum value (i.e., the upper limit) is 1,000 g. 
     There is no particular restriction on the granulation method of the dye. For example, the dye may be dissolved in a low boiling point solvent such as methylene chloride and then agglomerated by evaporating the solvent and thereafter, the dye may be directly granulated or by means of a roller compactor. The method using a roller compactor is preferred because no solvent is used. 
     The dye which can be used in the present invention is preferably a compound represented by the formula (I) or (II): ##STR1## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7  and R 8 , each represents a hydrogen atom, a hydroxyl group, an aliphatic group, an aromatic group, a heterocyclic group, a halogen atom, a cyano group, a nitro group, COR 9 , COOR 9 , NR 9  R 10 , NR 10  COR 11 , NR 10  SO 2  R 11 , CONR 9  R 10 , SO 2  NR 9  R 10 , COR 11 , SO 2  R 11 , OCOR 11 , NR 9  CONR 10  R 11 , CONHSO 2  R 11  or SO 2  NHCOR 11 , R 9  and R 10 , each represents a hydrogen atom, an aliphatic group, an aromatic group or a heterocyclic group, R 11  represents an aliphatic group, an aromatic group or a heterocyclic group, R 9  and R 10  may be combined to form a 5- or 6-membered ring, and R 1  and R 2  or R 2  and R 3  may be combined to form a ring; ##STR2## wherein R 21 , R 23  and R 24 , each represents a hydrogen atom, a hydroxyl group, a nitro group, a cyano group, an aliphatic group, an aromatic group, COR 29 , COOR 29 , NR 29  R 30 , NR 30  COR 31 , NR 30  SO 2  R 31 , R 22  represents an aliphatic group or an aromatic group, R 29  and R 30 , each has the same meaning as that of R 9  or R 10  in formula (I) and R 31  has the same meaning as that of R 11  in formula (I), provided that at least one of R 21 , R 22 , R 23  and R 24  is a group other than hydrogen. 
     The groups of formula (I) are described below in detail. 
     The aliphatic group represented by R 1  to R 11  includes an alkyl group having from 1 to 20 carbon atoms (e.g., methyl, ethyl, n-butyl, isopropyl, 2-ethylhexyl, n-decyl, n-octadecyl), a cycloalkyl group having from 1 to 20 carbon atoms (e.g., cyclopentyl, cyclohexyl) and an allyl group, and each group may have a substituent  for example, a halogen atom (e.g., F, Cl, Br, I), a hydroxyl group, a cyano group, a nitro group, a carboxylic acid group, an aryl group having from 6 to 10 carbon atoms (e.g., phenyl, naphthyl), an amino group having from 0 to 20 carbon atoms (e.g., NH 2 , NHCH 3 , N(C 2  H 5 ) 2 , N(C 4  H 9 ) 2 , N(C 8  H 17 ) 2 , anilino, 4-methoxyanilino), an amido group having from 1 to 20 carbon atoms (e.g., acetylamino, hexanoylamino, benzoylamino, octadecanoylamino), a carbamoyl group having from 1 to 20 carbon atoms (e.g., unsubstituted carbamoyl, methylcarbamoyl, ethylcarbamoyl, octylcarbamoyl, hexadecylcarbamoyl), an ester group having from 2 to 20 carbon atoms (e.g., methoxycarbonyl, ethoxycarbonyl, phenoxycarbonyl, n-butoxycarbonyl, dodecyloxycarbonyl), an alkoxy or aryloxy group having from 1 to 20 carbon atoms (e.g., methoxy, ethoxy, butoxy, isopropoxy, benzyloxy, phenoxy, octadecyloxy), a sulfonamido group having from 1 to 20 carbon atoms (e.g., methanesulfonamido, ethanesulfonamido, butanesulfonamido, benzenesulfonamido, octanesulfonamido), a sulfamoyl group having from 0 to 20 carbon atoms (e.g., unsubstituted sulfamoyl, methylsulfamoyl, butylsulfamoyl, decylsulfamoyl) and a 5- or 6-membered heterocyclic ring (e.g., pyridyl, pyrazolyl, morpholino, piperidino, pyrrolino, benzoxazolyl)!. 
     The aromatic group represented by R 1  to R 11  includes an aryl group having from 6 to 10 carbon atoms (e.g., phenyl, naphthyl) which may have a substituent  examples of the substituent include the groups described as the substituent which the above-described aliphatic group may have and in addition, an alkyl group having from 1 to 20 carbon atoms (e.g., methyl, ethyl, butyl, t-butyl, octyl)!. 
     The heterocyclic group represented by R 1  to R 11  includes 5- and 6-membered heterocyclic rings (e.g., pyridine, piperidine, morpholine, pyrrolidine, pyrazole, pyrazolidine, pyrazoline, pyrazolone, benzoxazole) which may have a substituent  examples of the substituent include the groups described as the substituent which the above-described aromatic group may have)!. 
     The 5- or 6-membered ring formed by combining R 9  and R 10  includes a morpholine ring, a piperidine ring and a pyrrolidine ring. The ring formed by combining R 1  and R 2  or R 2  and R 3  is preferably a 5- or 6-membered ring (e.g., benzene ring, phthalimido ring). 
     The groups of formula (II) are described below. 
     The aliphatic group represented by R 21  to R 24  has the same meaning as the aliphatic group represented by R 1  to R 11  of formula (I) and the aromatic group represented by R 21  to R 24  has the same meaning as the aromatic group represented by R 1  to R 11  of formula (I). 
     Specific examples of the compounds represented by formulae (I) and (II) are set forth below, but the present invention is by no means limited to these. ##STR3## 
     In the method of the present invention, the dye is used in an amount of preferably from 0.001 to 1 g/m 2 , more preferably from 0.005 to 0.5 g/m 2 . 
     These dyes may be used either individually or in combination of two or more thereof. 
     In case of combination use of dyes, the use amount is in terms of the increase of the transmission density preferably from 0.005 to 0.5, more preferably from 0.01 to 0.3, most preferably from 0.01 to 0.1. The method of the present invention is particularly effective when two or more kinds of dyes are used in combination. 
     The polyester support of the present invention comprises as main components a naphthalenedicarboxylic acid and/or an ester thereof and ethylene glycol. 
     Examples of the polyester support of the present invention include polymers such as polyethylene terephthalate (PET) and polyethylene 2,6-naphthalate (PEN). 
     The present invention is described below by referring to the Examples but the present invention should not be construed as being limited thereto. 
    
    
     EXAMPLE 
     1) Granulation of Dye 
     A dye was placed in a hopper, pressed by means of a compactor (&#34;Model WP160x60B&#34;, manufactured by Turbo Kogyo KK) and then shaken for 10 minutes in an automatic shaker having installed therein a 16-mesh sieve and a 32-mesh sieve at the upper portion and the lower portion, respectively. The dyes left on the 32-mesh sieve were taken out. 
     2) Film Formation and Dyeing of Support 
     PET (gray colored): 
     100 Parts by weight of polyethylene terephthalate having an intrinsic viscosity of 0.60, 0.005 part by weight of spherical silica having an average particle size of 0.3 μm and a length/breadth ratio of 1.07, 54 ppm of a dye of Compound I-24 and 54 ppm of a dye of Compound I-6, each dye being granulated as described above, were dried by an ordinary manner, melted at 300° C., extruded from a T-die, longitudinally stretched at 120° C. to 3.3 times, transversely stretched at 110° C. to 3.3 times and then heat-fixed at 250° C. for 6 seconds to obtain a sample having a thickness of 90 μm, a width of 1.5 m and a length of 3,000 m. 
     PET (blue colored): 
     100 Parts by weight of polyethylene terephthalate having an intrinsic viscosity of 0.60, 0.005 part by weight of spherical silica having an average particle size of 0.3 μm and a length/breadth ratio of 1.07, 65 ppm of a dye of Compound I-24 and 240 ppm of a dye of Compound II-3, each dye being granulated as described above, were dried by an ordinary manner, melted at 300° C., extruded from a T-die, longitudinally stretched at 120° C. to 3.3 times, transversely stretched at 110° C. to 3.3 times and then heat-fixed at 250° C. for 6 seconds to obtain a sample having a thickness of 90 μm, a width of 1.5 m and a length of 3,000 m. 
     PEN (grey colored): 
     100 Parts by weight of polyethylene-2,6-naphthalate having an intrinsic viscosity of 0.60, 0.005 part by weight of spherical silica having an average particle size of 0.3 μm and a length/breadth ratio of 1.07, 54 ppm of a dye of Compound I-24 and 54 ppm of a dye of Compound I-6, each dye being granulated as described above, were dried by an ordinary manner, melted at 300° C., extruded from a T-die, longitudinally stretched at 120° C. to 3.3 times, transversely stretched at 110° C. to 3.3 times and then heat-fixed at 250° C. for 6 seconds to obtain a sample having a thickness of 90 μm, a width of 1.5 m and a length of 3,000 m. 
     PEN (blue colored): 
     100 Parts by weight of polyethylene-2,6-naphthalate having an intrinsic viscosity of 0.60, 0.005 part by weight of spherical silica having an average particle size of 0.3 μm and a length/breadth ratio of 1.07, 65 ppm of a dye of Compound I-24 and 240 ppm of a dye of Compound II-3, each dye being granulated as described above, were dried by an ordinary manner, melted at 300° C., extruded from a T-die, longitudinally stretched at 120° C. to 3.3 times, transversely stretched at 110° C. to 3.3 times and then heat-fixed at 250° C. for 6 seconds to obtain a sample having a thickness of 90 μm, a width of 1.5 m and a length of 3,000 m. 
     3) Determination of Color Density 
     The thus-obtained films were measured on the transmission density for the grey-colored base by means of X-RITE Status M (manufactured by X-RITE Co., Ltd.) and for the blue-colored base by means of X-Rite Status A (manufactured by X-RITE Co., Ltd.). The measurement was made on 150 points at an interval of 1 cm in the width direction and on 200 points at the top to the last of 3,000 m in the length direction. The measurement results are shown in Tables 1 and 2. 
     
                                           TABLE 1                                 
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           Granulation                                                    
           Particle                                                       
               Angle of                                                   
                    Particle Color Density                                
           size                                                           
               repose                                                     
                    hardness (g)                                          
                             B density                                    
                                      G density                           
                                               R density                  
Base       (%) (°)                                                 
                    Average                                               
                        Minimum                                           
                             max-min                                      
                                  σ                                 
                                      max-min                             
                                           σ                        
                                               max-min                    
                                                    σ               
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Example 1                                                                 
      PET blue                                                            
           55  55   180 55   0.02 0.0091                                  
                                      0.02 0.0137                         
                                               0.03 0.0164                
Example 2                                                                 
      PET blue                                                            
           75  55   180 55   0.02 0.0082                                  
                                      0.02 0.0125                         
                                               0.02 0.0150                
Example 3                                                                 
      PET blue                                                            
           90  55   180 55   0.02 0.0072                                  
                                      0.02 0.0108                         
                                               0.02 0.0130                
Example 4                                                                 
      PET blue                                                            
           90  42   180 55   0.02 0.0059                                  
                                      0.02 0.0086                         
                                               0.02 0.0103                
Example 5                                                                 
      PET blue                                                            
           90  42   280 55   0.01 0.0041                                  
                                      0.02 0.0062                         
                                               0.01 0.0071                
Example 6                                                                 
      PET blue                                                            
           90  42   280 120  0.01 0.0031                                  
                                      0.01 0.0035                         
                                               0.01 0.0042                
Comparative                                                               
      PET blue                                                            
           45  65   140 45   0.09 0.023                                   
                                      0.1  0.0345                         
                                               0.1  0.0414                
Example 1                                                                 
Example 7                                                                 
      PET grey                                                            
           55  55   180 55   0.02 0.0099                                  
                                      0.02 0.0109                         
                                               0.03 0.0112                
Example 8                                                                 
      PET grey                                                            
           75  55   180 55   0.02 0.0091                                  
                                      0.02 0.0096                         
                                               0.02 0.0109                
Example 9                                                                 
      PET grey                                                            
           90  55   180 55   0.02 0.0082                                  
                                      0.02 0.009                          
                                               0.02 0.0098                
Example 10                                                                
      PET grey                                                            
           90  42   180 55   0.02 0.0063                                  
                                      0.02 0.0069                         
                                               0.02 0.0076                
Example 11                                                                
      PET grey                                                            
           90  42   280 55   0.01 0.0045                                  
                                      0.01 0.0051                         
                                               0.01 0.0053                
Example 12                                                                
      PET grey                                                            
           90  42   280 120  0.01 0.0021                                  
                                      0.01 0.0022                         
                                               0.01 0.0025                
Comparative                                                               
      PET grey                                                            
           45  65   140 45   0.08 0.026                                   
                                      0.09 0.0286                         
                                               0.11 0.0312                
Example 2                                                                 
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                                           TABLE 2                                 
__________________________________________________________________________
           Granulation                                                    
           Particle                                                       
               Angle of                                                   
                    Particle Color Density                                
           size                                                           
               repose                                                     
                    hardness (g)                                          
                             B density                                    
                                      G density                           
                                               R density                  
Base       (%) (°)                                                 
                    Average                                               
                        Minimum                                           
                             max-min                                      
                                  σ                                 
                                      max-min                             
                                           σ                        
                                               max-min                    
                                                    σ               
__________________________________________________________________________
Example 13                                                                
      PEN blue                                                            
           55  55   180 55   0.02 0.0089                                  
                                      0.02 0.0122                         
                                               0.03 0.0146                
Example 14                                                                
      PEN blue                                                            
           75  55   180 55   0.02 0.0083                                  
                                      0.02 0.0111                         
                                               0.02 0.0133                
Example 15                                                                
      PEN blue                                                            
           90  55   180 55   0.02 0.0074                                  
                                      0.02 0.0105                         
                                               0.02 0.0126                
Example 16                                                                
      PEN blue                                                            
           90  42   180 55   0.02 0.0059                                  
                                      0.02 0.0082                         
                                               0.02 0.0098                
Example 17                                                                
      PEN blue                                                            
           90  42   280 55   0.01 0.0042                                  
                                      0.02 0.0058                         
                                               0.01 0.0071                
Example 18                                                                
      PEN blue                                                            
           90  42   280 120  0.01 0.0029                                  
                                      0.01 0.0035                         
                                               0.01 0.0036                
Comparative                                                               
      PEN blue                                                            
           45  65   140 45   0.09 0.025                                   
                                      0.1  0.0375                         
                                               0.1  0.0444                
Example 3                                                                 
Example 19                                                                
      PEN grey                                                            
           55  55   180 55   0.02 0.0096                                  
                                      0.02 0.0106                         
                                               0.03 0.0109                
Example 20                                                                
      PEN grey                                                            
           75  55   180 55   0.02 0.0091                                  
                                      0.02 0.0096                         
                                               0.02 0.0109                
Example 21                                                                
      PEN grey                                                            
           90  55   180 55   0.02 0.0083                                  
                                      0.02 0.0091                         
                                               0.02 0.0096                
Example 22                                                                
      PEN grey                                                            
           90  42   180 55   0.02 0.0066                                  
                                      0.02 0.0073                         
                                               0.02 0.0079                
Example 23                                                                
      PEN grey                                                            
           90  42   280 55   0.01 0.0043                                  
                                      0.01 0.0051                         
                                               0.01 0.0053                
Example 24                                                                
      PEN grey                                                            
           90  42   280 120  0.01 0.0022                                  
                                      0.01 0.0022                         
                                               0.01 0.0025                
Comparative                                                               
      PEN grey                                                            
           45  65   140 45   0.08 0.032                                   
                                      0.09 0.0352                         
                                               0.11 0.0384                
Example 4                                                                 
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     It is clearly seen from the results in Tables 1 and 2 that by using the dye granulated according to the method of the present invention, a photographic polyester film free of uneven color can be obtained. 
     According to the present invention, the photographic polyester support can be dyed simply and safely to prevent light piping without causing any uneven color. 
     While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.