[0001] The present invention relates to photographic elements and particularly to photographic
elements having surface roughening agents in their topcoats. Displacement of silver
halide grains by matting agents is prevented and image quality improved.
[0002] Matting agents are commonly applied to the top layer in photographic elements for
a number of purposes. The matting agents can improve the ability of the surface to
accept writing, adjust the coefficient of friction for mechanical handling of the
element, reduce Newton's rings formation during printing and enlarging, and create
air pockets to facilitate drawdown of layers against the element in a vacuum system.
[0003] A significant problem has often been encountered in the use of surface matting agents
in photographic elements. This problem is referred to as the "starry night" effect
in the photographic trade. The effect is small areas of greatly diminished optical
density. On a solid black image, the defect looks very much like a starry night, with
many white dots on a black background. This effect has been determined to result from
physical effects occurring during manufacture of the film. As noted in U.S. Patent
No. 4,172,731, modern production of photographic elements coat more than one layer
at a time. Drying of the last coated layers, the last of which contains matting agents,
generates the starry night effect. As the layers dry, they shrink. The bottom portion
of matting agents is forced into adjacent layers (e.g., silver halide emulsion layers)
during this drying period. The movement of the matting particles into emulsion layers
forces the silver halide grains out of small areas. As there is no silver halide in
these areas, no optical density can be provided upon exposure and development. It
is the absence of silver halide grains and the absence of developable optical density
that show up as the starry night effect.
[0004] U.S. Patent No. 4,172,731 attempts to solve the starry night problem by using pigmented
polymeric particles as the matting agent. The pigments are to be of the same color
as the image to be formed in the adjacent emulsion layer. These agents merely mask
the effect and do not change the undesirable distribution of silver halide in the
adjacent layer.
[0005] U.S. Patent No. 4,232,117 does not address the problem of the starry night effect
but uses both a matting agent of 1 to 5 microns and colloidal silica of 7 to 120 microns
for antiadhesive properties.
[0006] U.S. Patent No. 3,411,907 combines two different types of matting agents, a soft
and a hard matting agent, at least 90% by weight of said hard particle matting agents
having a diameter of at least about 1 micron and at least 40% by weight of said soft
matting agents having a diameter in excess of 4 microns.
[0007] U.S. Patent No. 4,343,873 discloses the use of a light-scattering topcoat layer containing
both light-scattering particles having dimensions between 0.32 and 1.9 microns and
matting agent particles having average diameters between 2 and 5 microns. The light-scattering
particles are present in a concentration of from 0.7 to 10 g/m² in the coating and
must be dissolved from the element during development.
[0008] Radiation sensitive photographic elements are provided with an improved matte layer
construction which provides a short contact vacuum drawdown time, acceptable starry
night effect levels, good surface friction properties, and acceptable haze. Two different
size non-developmentally dissolvable particle components in critical weight proportions
are used. The larger particles provide the matte finish and the smaller particles
buoy the larger particles in the topcoat layer, reducing the starry night effect.
[0009] Radiation sensitive silver halide photographic elements are provided with an improved
surface roughening or matte composition on their outer face. The outer face is a surface
of the photographic element over a silver halide emulsion layer, usually the surface
furthest from the backing layer. The photographic element may be a black-and-white
photographic element or a color photographic element and may be sensitive to any actinic
portion of the electromagnetic spectrum such as the ultraviolet, visible or infrared
regions.
[0010] The surface roughening topcoat comprises a hydrophilic colloidal binder containing
two sets of particles having different size distributions and concentrations. One
of the sets of particles is a matting agent having average particle diameters of greater
than 1.0 micron and less than 10 micron in a coating weight of greater than 0.015
g/m² and less than 0.15 g/m². The other set of particles comprises a buoying agent
having an average particle size of between 0.20 and 0.75 microns in a coating weight
of between 0.2 and 0.7 g/m² or 1.0 g/m². Both particles must be non-dissolvable during
development to provide the final characteristics to the product. The buoying particles
may even be separately included in the emulsion layer. Their size will not create
starry night effects in the image, but they still offer some support against penetration
by the larger particles into the emulsion layer.
[0011] The particles may be selected from the same or different materials, may be hard or
soft, colored or colorless (preferred), and organic or inorganic. They should be
light insensitive in that they should not be silver halide particles which are developable
to form a visual image. The particles may not be soluble during the development process.
If the smaller particles were soluble, the large particles could "fall" during development
and force their way into lower layers during drying and rethinning of the topcoat
layer during drying. The particles may be selected from amongst inorganic particles
such as barium sulfate, silica, calcium, carbonate, baria, titania, calcium sulfate,
barium carbonate, and the like, or organic particles such as cellulose esters, cellulose
ethers, acrylic or methacrylic resins (such as polymers or copolymers or methylmethacrylate,
acrylic acid, methacrylic acid, n-butylmethacrylate, etc.), polyvinyl resins, polymers
and copolymers of ethylenically unsaturated resins such as styrene, butadiene, and
the like, polycarbonates, etc.
[0012] The size range of the particles and their coating weights are critical to the practice
of the present invention. If the small particle sizes are less than 0.20 microns
or if their coating weight is less than 0.2 g/m², there will be no buoying effect.
If the size of the small particles exceeds an average of 0.75 microns, the particles
will contribute to the starry night effect. If the coating weight of small particles
exceeds 0.7 g/m², increased haze will be produced in the photographic element. The
proportions and size of the larger particles are important in providing the matte
finish and minimizing the starry night effect.
[0013] Any of the various types of photographic silver halide emulsions may be used in the
practice of the present invention. Silver chloride, silver bromide, silver iodobromide,
silver chlorobromide, silver chlorobromide and mixtures thereof may be used for example.
Any configuration of grains, cubic orthorhombic, hexagonal, epitaxial, lamellar, tabular
or mixtures thereof may be used. These emulsions are prepared by any of the well-known
procedures, e.g., single or double jet emulsions as described by Wietz et al., U.S.
Patent 2,222,264, Illingsworth, U.S. Patent 3,320,069, McBride, U.S. Patent 3,271,157
and U.S. Patents 4,425,425 and 4,425,426.
[0014] The silver halide emulsions of this invention can be unwashed or washed to remove
soluble salts. In the latter case the soluble salts can be removed by chill-setting
and leaching or the emulsion can be coagulation washed e.g., by the procedures described
in Hewitson et al., U.S. Patent 2,618,556; Yutzy et al., U.S. Patent 2,614,928; Yackel,
U.S. Patent 2,565,418; Hart et al., U.S. Patent 3,241,969; and Waller et al., U.S.
Patent 2,489,341.
[0015] Photographic emulsions can be sensitized with chemical sensitizers, such as with
reducing agents; sulfur, selenium or tellurium compounds; gold, platinum or palladium
compounds; or combinations of these. Suitable chemical sensitization procedures are
described in Shepard, U.S. Patent 1,623,499; Waller, U.S. Patent 2,399,083; McVeigh,
U.S. Patent 3,297,447; and Dunn, U.S. Patent 3,297,446.
[0016] The silver halide emulsions of this invention can contain speed increasing compounds
such as polyalkylene glycols, cationic surface active agents and thioethers or combinations
of these as described in Piper, U.S. Patent 2,886,437; Chechak, U.S. Patent 3,046,134;
Carroll et al., U.S. Patent 2,944,900; and Goffe, U.S. Patent 3,294,540.
[0017] Silver halide emulsions can be protected against the production of fog and can be
stabilized against loss of sensitivity during keeping. Suitable antifoggants and stabilizers
which can be used alone or in combination, include the thiazolium salts described
in Staud, U.S. Patent 2,131,038 and Allen U.S. Patent 2,694,716; the azaindenes described
in Piper, U.S. Patent 2,886,437 and Heimbach, U.S. Patent 2,444,605; the mercury salts
described in Allen, U.S. Patent 2,728,663; the urazoles described in Anderson, U.S.
Patent 3,287,135; the sulfocatechols described in Kennard, U.S. Patent 3,235,652;
the oximes described in Carrol et al., British Patent 623,448; nitron; nitroindazoles;
the polyvalent metal salts described in Jones, U.S. Patent 2,839,405; the thiuronium
salts described in Herz, U.S. Patent 3,220,839; and the palladium, platinum and gold
salts described in Trivelli, U.S. Patent 2,566,263 and Damschroder, U.S. Patent 2,597,915.
[0018] Silver halide can be dispersed in colloids that can be hardened by various organic
or inorganic hardeners, alone or in combination, such as the aldehydes, and blocked
aldehydes, ketones, carboxylic and carbonic acid derivatives, sulfonate esters, sulfonyl
halides and vinyl sulfones, active halogen compounds, epoxy compounds, aziridines,
active olefins, isocyanates, carbodiimides, mixed function hardeners and polymeric
hardeners such as oxidized polysaccharides e.g., dialdehyde starch, oxyguargum, etc.
[0019] Photographic emulsions can contain various colloids alone or in combination as vehicles
or binding agents. Suitable hydrophilic materials include both naturally-occurring
substances such as proteins, for example, gelatin, gelatin derivatives (e.g., phthalated
gelatin), cellulose derivatives, polysaccharides such as dextran, gum arabic and the
like; and synthetic polymeric substances such as water soluble polyvinyl compounds,
e.g., poly(vinylpyrrolidone) acrylamide polymers or other synthetic polymeric compounds
such as dispersed vinyl compounds in latex form, and particularly those which increase
the dimensional stability of the photographic materials. Suitable synthetic polymers
include those described, for example, in U.S. Patents 3,142,568 of Nottorf; 3,193,386
of White; 3,062,674 of Houck, Smith and Yudelson; 3,220,844 of Houck, Smith and Yudelson;
Ream and Fowler, 3,287,289;' and Dykstra, U.S. Patent 3,411,911; particularly effective
are those water- insoluble polymers of alkyl acrylates and methacrylates, acrylic
acid, sulfoalkyl acrylates or methacrylates, those which have cross linking sites
which facilitate hardening or curing and those having recurring sulfobetaine units
as described in Canadian Patent 774,054.
[0020] Emulsions in accordance with this invention can be used in photographic elements
which contain antistatic or conducting layers, such as layers that comprise soluble
salts, e.g., chlorides, nitrates, etc., evaporated metal layers, ionic polymers such
as those described in Minsk, U.S. Patents 2,861,056 and 3,206,312 or insoluble inorganic
salts such as those described in Trevoy, U.S. Patent 3,428,451.
[0021] Photographic emulsions can be coated on a wide variety of supports. Typical supports
include polyester film, subbed polyester film, poly(ethylene terephthalate) film,
cellulose nitrate film, cellulose ester film, poly(vinyl acetal) film, polycarbonate
film and related or resinous materials, as well as glass, paper, metal and the like.
Typically, a flexible support is employed, especially a paper support, which can be
partially acetylated or coated with baryta and/or an alpha-olefin polymer, particularly
a polymer of an alpha-olefin containing 2 to 10 carbon atoms such as polyethylene,
polypropylene, ethylenebutene copolymers and the like.
[0022] Emulsions of the invention can contain plasticizers and lubricants such as polyalcohols,
e.g., glycerin and diols of the type described in Milton, U.S. Patent 2,960,404; fatty
acids or esters such as those described in Robins, U.S. Patent 2,588,765 and Duane,
U.S. Patent 3,121,060; and silicone resins such as those described in DuPont British
Patent 955,061.
[0023] The emulsions as described herein can contain surfactants such as saponin, anionic
compounds such as the alkylarylsulfonates described in Baldsiefen, U.S. Patent 2,600,831
fluorinated surfactants, and amphoteric compounds such as those described in Ben-Ezra,
U.S. Patent 3,133,816.
[0024] Photographic elements as described herein can contain matting agents such as starch,
titanium dioxide, zinc oxide, silica, polymeric beads including beads of the type
described in Jelley et al., U.S. Patent 2,992,101 and Lynn, U.S. Patent 2,701,245.
[0025] Emulsions of the invention can be utilized in photographic elements which contain
brightening agents including stilbene, triazine, oxazole and coumarin brightening
agents. Water soluble brightening agents can be used such as those described in Albers
et al., German Patent 972,067 and McFall et al., U.S. Patent 2,933,390 or dispersions
of brighteners can be used such as those described in Jansen, German Patent 1,150,274
and Oetiker et al., U.S. Patent 3,406,070.
[0026] Photographic elements containing emulsion layers according to the present invention
can be used in photographic elements which contain light absorbing materials and
filter dyes such as those described in Sawdey, U.S. Patent 3,253,921; Gaspar, U.S.
Patent 2,274,782; Carroll et al., U.S. Patent 2,527,583 and Van Campen, U.S. Patent
2,956,879. If desired, the dyes can be mordanted, for example, as described in Milton
and Jones, U.S. Patent 3,282,699.
[0027] Contrast enhancing additives such as hydrazines, rhodium, iridium and combinations
thereof are also useful.
[0028] Photographic emulsions of this invention can be coated by various coating procedures
including dip coating, air knife coating, curtain coating, or extrusion coating using
hoppers of the type described in Beguin, U.S. Patent 2,681,294. If desired, two or
more layers may be coated simultaneously by the procedures described in Russell, U.S.
Patent 2,761,791 and Wynn British Patent 837,095.
[0029] The couplers may be present either directly bound by a hydrophilic colloid or carried
in a high temperature boiling organic solvent which is then dispersed within a hydrophilic
colloid. The colloid may be partially hardened or fully hardened by any of the variously
known photographic hardeners. Such hardeners are free aldehydes (U.S. Patent 3,232,764),
aldehyde releasing compounds (U.S. Patent 2,870,013 and 3,819,608), s-triazines and
diazines (U.S. Patent 3,325,287 and 3,992,366), aziridines (U.S. Patent 3,271,175),
vinylsulfones (U.S. Patent 3,490,911), carbodiimides, and the like may be used.
[0030] The silver halide photographic elements can be used to form dye images therein through
the selective formation of dyes. The photographic elements described above for forming
silver images can be used to form dye images by employing developers containing dye
image formers, such as color couplers, as illustrated by U.K. Patent No. 478,984;
Yager et al., U.S. Patent No. 3,113,864; Vittum et al., U.S. Patent Nos. 3,002,836,
2,271,238 and 2,362,598. Schwan et al. U.S. Patent No. 2,950,970; Carroll et al.,
U.S. Patent No. 2,592,243; Porter et al., U.S. Patent Nos. 2,343,703, 2,376,380 and
2,369,489; Spath U.K. Patent No. 886,723 and U.S. Patent No. 2,899,306; Tuite U.S.
Patent No. 3,152,896 and Mannes et al., U.S. Patent Nos. 2,115,394, 2,252,718 and
2,108,602, and Pilato U.S. Patent No. 3,547,650. In this form the developer contains
a color-developing agent (e.g., a primary aromatic amine which in its oxidized form
is capable of reacting with the coupler (coupling) to form the image dye. Also, instant
self-developing diffusion transfer film can be used as well as photothermographic
color film or paper using silver halide in catalytic proximity to reducable silver
sources and leuco dyes.
[0031] The dye-forming couplers can be incorporated in the photographic elements, as illustrated
by Schneider et al.
Die Chemie, Vol. 57, 1944, p. 133, Mannes et al. U.S. Patent No. 2,304,940, Martinez U.S. Patent
No. 2,269,158, Jelley et al. U.S. Patent No. 2,322,027, Frolich et al. U.S. Patent
No. 2,376,679, Fierke et al. U.S. Patent No. 2,801,171, Smith U.S. Patent No. 3,748,141,
Tong U.S. Patent No. 2,772,163, Thirtle et al. U.S. Patent No. 2,835,579, Sawdey et
al. U.S. Patent No. 2,533,514, Peterson U.S. Patent No. 2,353,754, Seidel U.S. Patent
No. 3,409,435 and Chen Research Disclosure, Vol. 159, July 1977, Item 15930. The dye-forming
couplers can be incorporated in different amounts to achieve differing photographic
effects. For example, U.K. Patent No. 923,045 and Kumai et al. U.S. Patent No. 3,843,369
teach limiting the concentration of coupler in relation to the silver coverage to
less than normally employed amounts in faster and intermediate speed emulsion layers.
[0032] The dye-forming couplers are commonly chosen to form subtractive primary (i.e., yellow,
magenta and cyan) image dyes and are non-diffusible, colorless couplers, such as two
and four equivalent couplers of the open chain ketomethylene, pyrazolone, pyrazolone,
pyrazolotriazole, pyrazolobenzimidazole, phenol and naphthol type hydrophobically
ballasted for incorporation in high-boiling organic (coupler) solvents. Such couplers
are illustrated by Salminen et al. U.S. Patent Nos. 2,423,730, 2,772,162, 2,895,826,
2,710,803, 2,407,207, 3,737,316 and 2,367,531; Loria et al. U.S. Patent Nos. 2,772,161,
2,600,788, 3,006,759, 3,214,437 and 3,253,924; McCrossen et al., U.S. Patent No. 2,875,057;
Bush et al. U.S. Patent No. 2,908,573; Gledhill et al. U.S. Patent No. 3,034,892;
Weissberger et al. U.S. Patent Nos. 2,474,293, 2,407,210, 3,062,653, 3,265,506 and
3,384,657; Porter et al. U.S. Patent No. 2,343,703; Greenhalgh et al. U.S. Patent
No. 3,127,269; Feniak et al., U.S. Patent 2,865,748, 2,933,391 and 2,865,751; Bailey
et al. U.S. Patent 3,725,067; Beavers et al. U.S. Patent No. 3,758,308; Lau U.S. Patent
No. 3,779,763; Fernandez U.S. Patent No. 3,785,829; U.K. Patent No. 969,921; U.K.
Patent No. 1,241,069; U.K. Patent No. 1,011,940, Vanden Eynde et al. U.S. Patent No.
3,762,921; Beavers U.S. Patent No. 2,983,608; Loria U.S. Patent Nos. 3,311,476, 3,408,194,
3,458,315, 3,447,928, 3,476,563; Cressman et al. U.S. Patent No. 3,419,390; Young
U.S. Patent No. 3,419,391; Lestina U.S. Patent No. 3,519,429; U.K. Patent No. 975,928;
U.K. Patent No. 1,111,554; Jaeken U.S. Patent No. 3,222,176 and Canadian Patent No.
726,651; Schulte et al. U.K. Patent No. 1,248,924 and Whitmore et al. U.S. Patent
No. 3,227,550. Dye-forming couplers of differing reaction rates in single or separate
layers can be employed to achieve desired effects for specific photographic applications.
[0033] The dye-forming couplers upon coupling can release photographically useful fragments,
such as development inhibitors or accelerators, bleach accelerators, developing agents,
silver halide solvents, toners, hardeners, fogging agents, antifoggants, competing
couplers, chemical or spectral sensitizers and desensitizers. Development inhibitor-releasing
(DIR) couplers are illustrated by Whitmore et al. U.S. Patent No. 3,148,062; Barr
et al. U.S. Patent No. 3,227,554; Barr U.S. Patent No. 3,733,201; Sawdey U.S. Patent
No. 3,617,291; Groet et al. U.S. Patent No. 3,703,375; Abbott et al., U.S. Patent
No. 3,615,506; Weissberger et al. U.S. Patent No. 3,265,506; Seymour U.S. Patent No.
3,620,745; Marx et al. U.S. Patent No. 3,632,345; Mader et al. U.S. Patent No. 3,869,291;
U.K. Patent No. 1,201,110; Oishi et al. U.S. Patent No. 3,642,485; Verbrugghe, U.K.
Patent No. 1,236,767; Fujiwhara et al. U.S. Patent No. 3,770,435 and Matsuo et al.
U.S. Patent No. 3,808,945. Dye-forming couplers and non-dye-forming compounds which
upon coupling release a variety of photographically useful groups are described by
Lau U.S. Patent No. 4,248,962. DIR compounds which do not form dye upon reaction with
oxidized color-developing agents can be employed, as illustrated by Fujiwhara et al.
German OLS 2,529,350 and U.S. Patent Nos. 3,928,041, 3,958,993 and 3,961,959; Odenwalder
et al. German OLS No. 2,448,063; Tanaka et al. German OLS No. 2,610,546; Kikuchi et
al. U.S. Patent No. 4,049,455 and Credner et al. U.S. Patent No. 4,052,213. DIR compounds
which oxidatively cleave can be employed, as illustrated by Porter et al. U.S. Patent
No. 3,379,529; Green et al. U.S. Patent no. 3,043,690; Barr U.S. Patent No. 3,364,022;
Duennebier et al. U.S. Patent No. 3,297,445 and Rees et al. U.S. Patent No. 3,287,129.
Silver halide emulsions which are relatively light insensitive, such as Lipmann emulsions,
having been utilized as interlayers and overcoat layers to prevent or control the
migration of development inhibitor fragments as described in Shiba et al. U.S. Patent
No. 3,892,572.
[0034] The photographic elements can incorporate colored dye-forming couplers, such as those
employed to form integral masks for negative color images, as illustrated by Hanson
U.S. Patent No. 2,449,966; Glass et al. U.S. Patent No. 2,521,908; Gledhill et al.
U.S. Patent No. 3,034,892; Loria U.S. Patent No. 3,476,563; Lestina U.S. Patent No.
3,519,429; Friedman U.S. Patent No. 2,543,691; Puschel et al. U.S. Patent No. 3,028,238;
Menzel et al. U.S. Patent No. 3,061,432 and Greenhalgh U.K. Patent No. 1,035,959,
and/or competing couplers, as illustrated by Murin et al. U.S. Patent No. 3,876,428;
Sakamoto et al. U.S. Patent No. 3,580,722; Puschel U.S. Patent No. 2,998,314; Whitmore
U.S. Patent No. 2,808,329; Salminen U.S. Patent No. 2,742,832 and Weller et al. U.S.
Patent No. 2,689,793.
[0035] The photographic elements can include image dye stabilizers. Such image dye stabilizers
are illustrated by U.K. Patent No. 1,326,889; Lestina et al. U.S. Patent Nos. 3,432,300
and 3,698,909; Stern et al. U.S. Patent No. 3,574,627; Brannock et al. U.S. Patent
No. 3,573,050; Arai et al. U.S. Patent No. 3,764,337 and Smith et al. U.S. Patent
No. 4,042,394.
[0036] These types of imaging systems are well known in the art. Detailed discussions of
various dye transfer, diffusion processes may be found for example in "A Fundamentally
New Imaging Technology for Instant Photography", W. T. Harison, Jr., Photographic
Science and Engineering, Vol. 20, No. 4, July/August 1976, and Neblette's Handbook
of Photography and Reprography, Materials, Processes and Systems, 7th Edition, John
M. Stunge, van Nostrand Reinhold Company, N.Y., 1977, pp. 324-330 and 126. Detailed
discussion of dye-bleach color imaging systems are found for example in
The Reproduction of Colour, 3rd Ed., R. W. G. Hunt, Fountain Press, London, England 1975 pp. 325-330; and
The Theory of the Photographic Process, 4th Ed., Mees and James, Macmillan Publishing Co., Inc., N.Y., 1977 pp. 363-366.
Pages 366-372 of Mees and James, supra. also discuss dye-transfer processes in great
detail. Leuco dye oxidation in silver halide systems are disclosed in such literature
as U.S. Pat. Nos. 4,460,681, 4,374,821 and 4,021,240.
[0037] Other conventional photographic addenda such as coating aids, antistatic agents,
acutance dyes, antihalation dyes and layers, antifoggants, latent image stabilizers,
antikinking agents, and the like may also be present.
[0038] The following examples will further illustrate the practice of the present invention.
[0039] The measurement of haze in the examples and in the practice of the present invention
is done according to ASTM D1003-61 (Reapproved 1977). Percent haze is determined as

in which Td is diffuse transmittance and Tt is the total transmittance.
Examples 1-5
[0040] A photographic emulsion comprising 0.15 micron cubic chlorobromide grains (64/36,
Cl/Br) in a gelatin binder were coated on primed and subbed polyethyleneterephthalate
base at a silver coating weight of 4.0 g/m². Five different gelatin topcoats were
applied to samples of this coated emulsion to evaluate the effects of particle sizes
and coating weights on starry night, haze and drawdown time. The film was exposed
and conventionally developed and sensitometry readings on those three parameters were
taken. The results are shown in Table 1. 2.35 micron silica was used as the large
particles (LP) and 0.5 micron polymethylmethacrylate was used as the small particles
(SP).

The values for starry night are interpretable as meaning that 6 is unacceptable,
5 is poor, 4 is marginally acceptable, 3 is very good and 2 is excellent. Haze values
up to a maximum of 15 are acceptable.
[0041] The data show that by combining small particles with the matting agent, larger levels
of matting agent may be used to improve drawdown times without degradation of the
starry night effect. In fact, higher levels of matting agents may be used with lower
starry night effects present.