FIELD OF THE INVENTION
[0001] The present invention relates to photographic silver halide emulsion technology and
more specifically to the stabilization of tabular silver halide emulsion grains.
BACKGROUND OF THE INVENTION
[0002] Tabular grains are known in the photographic art for quite some time. As early as
1961 Berry et al described the preparation and growth of tabular silver bromoiodide
grains in Photographic Science and Engineering, Vol 5, No 6. A discussion of tabular
grains appeared in Duffin, Photographic Emulsion Chemistry, Focal Press, 1966, p.
66-72. Early patent literature includes Bogg US 4,063,951, Lewis US 4,067,739 and
Maternaghan US 4,150,994, US 4,184,877 and US 4,184,878. However the tabular grains
described herein cannot be regarded as showing a high diameter to thickness ratio,
commonly termed aspect ratio. In a number of US applications filed Sep. 30, 1982 and
issued in 1984 tabular grains with high aspect ratio and their advantages in photographic
applications are described. So Wilgus US 4,434,226 discloses tabular silver bromoiodide
grains having a thickness less than 0.3 micron, a diameter of at least 0.6 micron
and an average aspect ratio greater than 8:1 and accounting for at least 50 percent
of the total projected area of all the emulsion grains. Kofron US 4,439,520 discloses
similar grains which are spectrally sensitized. Abbott US 4,425,425 describes radiographic
materials containing tabular grains with aspect ratio of at least 8:1 and Abbott US
4,425,426 discloses similar grains with an aspect ratio between 5:1 and 8:1. Solberg
US 4,433,048 protects tabular silver bromoiodide grains with inhomogeneously distributed
iodide. A survey on high aspect ratio silver halide emulsions appeared in Research
Disclosure, Vol 225, Jan 1983, Item 22534.
[0003] High aspect ratio tabular grains exhibit several pronounced photographic advantages.
Thanks to their particular morphology greater amounts of certain spectral sensitizers
can be adsorbed per mole silver halide compared to classical globular grains. As a
consequence such spectrally sensitized tabular grains show a wide separation between
their blue speed and minus blue speed. Sharpness of photographic images can be improved
using tabular grains thanks to their lower light scattering properties again compared
to conventional globular emulsion grains. In color negative materials the conventional
sequence of the light sensitive layers can be altered and the yellow filter layer
can be omitted. In developed black-and-white images high covering power is obtained
even at high hardening levels; alternatively reduced silver halide coverages can be
achieved if wanted resulting again in improved sharpness. In the especially important
application field of radiographic materials where highly sensitive radiographic emulsions
are coated on both sides of a transparent support the high light absorption of tabular
grains in the spectrally sensitized region effectively reduces the "cross-over" which
is the dominant factor for sharpness in a screen-film pair. The "cross-over" is a
measure of the photographic reponse of the respective emulsion layers to the exposure
from the screen located at the opposite side of the double coated film. This emission
has penetrated the second emulsion layer and the support, resulting in a reduced sharpness
of the finally obtained radiographic image.
[0004] Like conventional emulsions tabular grain emulsions need to be stabilized by antifoggants
or stabilizers which minimize the fog increase during the processing of freshly coated
photographic elements and/or the fog increase during extended storage periods of the
said elements. Numerous classes of chemical compounds can be added as fog-inhibiting
agent or stabilizer to conventional silver halide emulsions. Suitable examples are
e.g. the heterocyclic nitrogen-containing compounds such as benzothiazolium salts,
nitroimidazoles, nitrobenzimidazoles, chlorobenzimidazoles, bromobenzimidazoles, mercaptothiazoles,
mercaptobenzothiazoles, mercaptobenzimidazoles, mercaptothiadiazoles, aminotriazoles,
benzotriazoles (preferably 5-methyl-benzotriazole), nitrobenzotriazoles, mercaptopyrimidines,
mercaptotriazines, benzothiazoline-2-thione and oxazoline-thione. A especially useful
class of compounds constitutute the azaindenes, e.g. triazaindenes, tetrazaindenes
and pentazaindenes, especially those described by Birr in Z. Wiss. Phot. 47 (1952),
pages 2-58 and the azaindenes disclosed by Heimbach in US 2,444,607, 2,444,609, 2,449,225
and 2,450,397. The best commonly known and most widely used azaindene is 4-hydroxy-6-methyl-1,3,3a,7-tetraazaindene,
furtheron abbreviated as TAI. Other classes include triazolopyrimidines such as those
described in GB 1,203,757, GB 1,209,146, JA-Appl. 75-39537, and GB 1,500,278 and other
compounds such as benzenethiosulphonic acid, benzenethiosulphinic acid and benzenethiosulphonic
acid amide compounds.
[0005] A widely used class of stabilizers is the class of mercaptotetrazoles, in particular
1-phenyl-5-mercaptotetrazole. A set of specific substituted 1-phenyl-mercaptotetrazoles
is disclosed as stabilizers for tabular grain emulsions in US 4,888,273.
[0006] A general survey of stabilizers and antifoggants is given in Research Disclosure
N° 17643 (1978), Chapter VI.
[0007] Particular problems arise in trying to stabilize highly sensitive silver bromoiodide
or bromide tabular grains. Several of the familiar classes of stabilizers, e.g. mercapto-compounds,
tend to desensitize the tabular grains too strongly in the concentration range where
they are effective as stabilizers. Tetraazaindenes too are deficient in stabilizing
high aspect ratio tabular grains, as was stated already in US 4,888,273, cited above.
Experimental evidence shows that tetraazaindenes, e.g. TAI partially desorb spectral
sensitizers from the grain surface, deteriorating in this way the speed in the corresponding
spectral region, and in the case of double coated radiographic elements, increasing
the cross-over due to a hypsochromic spectral shift of the desorbed green spectral
sensitizer in the gelatin phase. Lowering the tetraazaindene concentration renders
the stabilization ineffective. This problem with tetraazaindene stabilization gets
more important in the case of low iodide content of the silver bromoiodide grains
and is utmost severe with silver bromide emulsions containing no iodide at all. However,
for application in double-side coated radiographic materials, tabular grains with
minor or no iodide content are preferred because of their faster development and fixation
rate compared to emulsions containing substantial amounts of iodide. The desorption
of spectral sensitizer is partially overcome by adding at the finalling stage of the
emulsion preparation a certain amount of a soluble iodide salt but in this case the
grain surface is partially converted to AgBrl which results in an inferior sensitivity.
[0008] It is an object of the present invention to provide an effective stabilization system
for tabular grains.
[0009] It is a further object of the present invention to stabilize effectively highly sensitive
silver bromoiodide and silver bromide tabular grain emulsions without deteriorating
the cross-over percentage, when the emulsion is double-side coated in a radiographic
element.
SUMMARY OF THE INVENTION
[0010] Tabular grains, having a minimal average aspect ratio of 4:1, and accounting for
at least 50 % of the total projected area of all the emulsion grains are effectively
stabilized with a mercapto-substituted pyrimidine derivative represented by the following
general formula :
wherein :
R = hydrogen, a saturated or olefinically unsaturated aliphatic group or aryl;
Z = the ring members required for completing a condensed benzene, cyclopentene or
cyclohexene ring, or a heterocyclic ring selected from the group consisting of pyridine,
tetrahydropyridine, pyrimidine, pyrrole, furan, thiophene, oxazole, isoaxazole, imidazole
or pyrazole ring; on the condition that R or Z contains at least one carboxy or sulfo
group.
[0011] In a preferred embodiment the stabilizer of use according to the invention is combined
with another stabilizer of the tetraazaindene type e.g. 4-hydroxy-6-methyl-1,3,3a,7-tetraazaindene
(TAI).
[0012] Although the compounds of the present invention were already known in the art from
US 3,692,527 cited above, their specific and surprising effectiveness for stabilizing
tabular grains, surpassing more familiar classes of stabilizers is for the first time
recognized and disclosed. It was further very surprising to discover that partial
or total replacement of a tetraazaindene stabilizer by a compound according to the
invention could overcome the desorption of spectral sensitizer caused by the said
tetraazaindene.
DETAILLED DESCRIPTION OF THE INVENTION
[0014] The most effective stabilizing agent of these specific examples is Compound 1.
[0015] The stabilizers used according to the present invention can be added to a processing
solution, e.g. a development bath, but preferably they are added to the photographic
material itself. They can be added to any of the hydrophylic colloid layers of the
photographic material, e.g. a non-light-sensitive intermediate layer, but preferably
they are contained in the light-sensitive emulsion layer(s) where they are most easily
adsorbed to the tabular silver halide grains in order to exercise properly their stabilizing
function. They can be added in the form of an aqueous solution or a solution in an
organic solvent, e.g. a methanolic solution, or in the form of a dispersion, e.g.
a gelatineous dispersion possibly containing high-boiling oilformers. They are present
in a concentration ranging preferably between 10-
7 and 10-
3 mole per mole silver halide.
[0016] A compound according to the present invention can be used as the sole stabilizing
agent or it can be combined with any other representative substance of other known
stabilizer classes. Preferably it is combined with a tetraazaindene stabilizer, e.g.
4-hydroxy-6-methyl-1,3,3a,7-tetraazaindene (TAI). This tetrazaindene stabilizer is
preferably present in a concentration ranging from 10-
6 to 10-
3 mole per mole silver halide.
[0017] The photographic tabular silver halide emulsions can be used in various types of
photographic elements such as e.g. in photographic elements for graphic arts, for
so-called amateur or professional still black-and- white and color photography, diffusion
transfer reversal photographic elements, low-speed duplicating elements or high-speed
camera sensitive elements and in motion picture recording. In a preferred embodiment
of the present invention the emulsions are incorporated in a highly sensitive radiographic
element.
[0018] The photographic element can contain one single emulsion layer or it can be built
up by two or even more emulsion layers. In the case of color photography the material
contains blue, green and red sensitive layers each of which can be single or multiple.
Beside the light sensitive emulsion layer(s) the photographic material can contain
several non-light sensitive layers, e.g. a protective layer, one or more backing layers,
one or more subbing layers, and one or more intermediate layers. In the preferred
embodiment of a radiographic element an emulsion layer is provided on both sides of
a transparent support covered on each side by a protective layer.
[0019] The halide composition of the tabular silver halide emulsions used according to the
present invention is not specifically limited and may be any composition selected
from e.g. silver chloride, silver bromide, silver iodide, silver chlorobromide, silver
bromoiodide, and silver chlorobromoiodide. However in the preferred embodiment of
a highly sensitive radiographic material a tabular silver bromoiodide emulsion is
used, most preferably with a low iodide content up to 1 % or no iodide at all.
[0020] The tabular emulsion grains can be prepared by any method known in the art, e.g.
by the methods disclosed in Research Disclosure, Vol 225, Jan 1983, Item 22534 cited
above or by any similar or other method. Their minimal average aspect ratio is 4:1.
Preferably their minimal average diameter is 0.6 micron and their maximal average
thickness is 0.3 micron.
[0021] The emulsion can be desalted in the usual ways e.g. by dialysis, by flocculation
and re-dispersing, or by ultrafiltration.
[0022] Two or more types of tabular silver halide emulsions that have been prepared differently
can be mixed for forming a photographic emulsion for use in accordance with the present
invention.
[0023] The size distribution of the tabular silver halide particles of the photographic
emulsions to be used according to the present invention can be monodisperse or heterodisperse.
[0024] The tabular silver halide emulsions in connection with the present invention can
be chemically sensitized as described e.g. in "Chimie et Physique Photographique"
by P. Glafkides, in "Photographic Emulsion Chemistry" by G.F. Duffin, in "Making and
Coating Photographic Emulsion" by V.L. Zelikman et al, and in "Die Grundlagen der
Photographischen Prozesse mit Silberhalogeniden" edited by H. Frieser and published
by Akademische Verlagsgesellschaft (1968). As described in said literature chemical
sensitization can be carried out by effecting the ripening in the presence of small
amounts of compounds containing sulphur e.g. thiosulphate, thiocyanate, thioureas,
sulphites, mercapto compounds, and rhodamines. The emulsions can be sensitized also
by means of gold-sulphur ripeners or by means of reductors e.g. tin compounds as described
in GB 789,823, amines, hydrazine derivatives, formamidine-sulphinic acids, and silane
compounds.
[0025] The tabular silver halide emulsions can be spectrally sensitized with methine dyes
such as those described by F.M. Hamer in "The Cyanine Dyes and Related Compounds",
1964, John Wiley & Sons. Dyes that can be used for the purpose of spectral sensitization
include cyanine dyes, merocyanine dyes, complex cyanine dyes, complex merocyanine
dyes, hemicyanine dyes, styryl dyes and hemioxonol dyes. Particularly valuable dyes
are those belonging to the cyanine dyes, merocyanine dyes and complex merocyanine
dyes. A survey of useful chemical classes of spectral sensitizing dyes and specific
useful examples in connection with tabular grains is given in the already cited Research
Disclosure Item 22534.
[0026] In classical emulsion preparation spectral sensitization traditionally follows the
completion of chemical sensitization. However, in connection with tabular grains,
it is specifically considered that spectral sensitization can occur simultaneously
with or even precede completely the chemical sensitization step.
[0027] In the preferred embodiment of a radiographic element green sensitization is preferred
in connection with the actual tendency in medical X-ray practice to use screens containing
green light emitting phosphors. In this case preferred green sensitizing compounds
include anhydro-5,5'-dichloro-9-ethyl-3,3'-di-(3-sul- phobutyl)-oxacarbocyanine and
the sulfopropyl containing analogous compound.
[0028] It is specifically contemplated that epitaxial deposition can occur at any stage
of the emulsion preparation at the surface of the tabular grains, e.g by the addition
of soluble silver salts or by the addition of very fine silver halide grains capable
of Ostwald ripening. Epitaxial deposition at selected edge or corner sites is preferred.
In this case the presence of a so-called site director, e.g. iodide ions can be beneficial.
[0029] Besides the silver halide another essential component of a light-sensitive emulsion
layer is the binder. The binder is a hydrophilic colloid, preferably gelatin. Gelatin
can, however, be replaced in part or integrallly by synthetic, semi-synthetic, or
natural polymers. Synthetic substitutes for gelatin are e.g. polyvinyl alcohol, poly-N-vinyl
pyrrolidone, polyvinyl imidazole, polyvinyl pyrazole, polyacrylamide, polyacrylic
acid, and derivatives thereof, in particular copolymers thereof. Natural substitutes
for gelatin are e.g. other proteins such as zein, albumin and casein, cellulose, saccharides,
starch, and alginates. In general, the semi-synthetic substitutes for gelatin are
modified natural products e.g. gelatin derivatives obtained by conversion of gelatin
with alkylating or acylating agents or by grafting of polymerizable monomers on gelatin,
and cellulose derivatives such as hydroxyalkyl cellulose, carboxymethyl cellulose,
phthaloyl cellulose, and cellulose sulphates.
[0030] The gelatin can be lime-treated or acid-treated gelatin. The preparation of such
gelatin types has been described in e.g. "The Science and Technology of Gelatin",
edited by A.G. Ward and A. Courts, Academic Press 1977, page 295 and next pages. The
gelatin can also be an enzyme-treated gelatin as described in Bull. Soc. Sci. Phot.
Japan, N 16, page 30 (1966).
[0031] The binder of the photographic element, especially when the binder used is gelatin,
can be hardened with appropriate hardening agents such as those of the epoxide type,
those of the ethylenimine type, those of the vinylsulfone type e.g. 1,3-vinylsulphonyl-2-propanol,
chromium salts e.g. chromium acetate and chromium alum, aldehydes e.g. formaldehyde,
glyoxal, and glutaraldehyde, N-methylol compounds e.g. dimethylolurea and methyloldimethylhydantoin,
dioxan derivatives e.g. 2,3-dihydroxy-dioxan, active vinyl compounds e.g. 1,3,5-triacryloyl-hexahydro-s-triazine,
active halogen compounds e.g. 2,4-dichloro-6-hydroxy-s-triazine, and mucohalogenic
acids e.g. mucochloric acid and mucophenoxychloric acid. These hardeners can be used
alone or in combination. The binders can also be hardened with fast-reacting hardeners
such as carbamoylpyridinium salts as disclosed in US 4,063,952.
[0032] The photographic element of the present invention may further comprise various kinds
of surface-active agents in the photographic emulsion layer or in at least one other
hydrophilic colloid layer. Suitable surface-active agents include non-ionic agents
such as saponins, alkylene oxides e.g. polyethylene glycol, polyethylene glycol/polypropylene
glycol condensation products, polyethylene glycol alkyl ethers or polyethylene glycol
alkylaryl ethers, polyethylene glycol esters, polyethylene glycol sorbitan esters,
polyalkylene glycol alkylamines or alkylamides, silicone-polyethylene oxide adducts,
glycidol derivatives, fatty acid esters of polyhydric alcohols and alkyl esters of
saccharides; anionic agents comprising an acid group such as a carboxy, sulpho, phospho,
sulphuric or phosphoric ester group; ampholytic agents such as aminoacids, aminoalkyl
sulphonic acids, aminoalkyl sulphates or phosphates, alkyl betaines, and amine-N-oxides;
and cationic agents such as alkylamine salts, aliphatic, aromatic, or heterocyclic
quaternary ammonium salts, aliphatic or heterocyclic ring-containing phosphonium or
sulphonium salts. Such surface-active agents can be used for various purposes e.g.
as coating aids, as compounds preventing electric charges, as compounds improving
slidability, as compounds facilitating dispersive emulsification, as compounds preventing
or reducing adhesion, and as compounds improving the photographic characteristics
e.g higher contrast, sensitization, and development acceleration. Preferred surface-active
coating agents are compounds containing perfluorinated alkyl groups.
[0033] Development acceleration can be accomplished with the aid of various compounds, preferably
polyalkylene derivatives having a molecular weight of at least 400 such as those described
in e.g. US 3,038,805 - 4,038,075 - 4,292,400.
[0034] The photographic element of the present invention may further comprise various other
additives such as e.g. compounds improving the dimensional stability of the photographic
element, UV-absorbers, spacing agents and plasticizers.
[0035] Suitable additives for improving the dimensional stability of the photographic element
are e.g. dispersions of a water-soluble or hardly soluble synthetic polymer e.g. polymers
of alkyl(meth)acrylates, alkoxy-(meth)acrylates, glycidyl (meth)acrylates, (meth)acrylamides,
vinyl esters, acrylonitriles, olefins, and styrenes, or copolymers of the above with
acrylic acids, methacrylic acids, Alpha-Beta-unsaturated dicarboxylic acids, hydroxyalkyl
(meth)acrylates, sulphoalkyl (meth)acrylates, and styrene sulphonic acids.
[0036] In general, the average particle size of spacing agents is comprised between 0.2
and 10 um. Spacing agents can be soluble or insoluble in alkali. Alkali-insoluble
spacing agents usually remain permanently in the photographic element, whereas alkali-soluble
spacing agents usually are removed therefrom in an alkaline processing bath. Suitable
spacing agents can be made e.g. of polymethyl methacrylate, of copolymers of acrylic
acid and methyl methacrylate, and of hydroxypropylmethyl cellulose hexahydroph- thalate.
Other suitable spacing agents have been described in US 4,614,708.
[0037] The support of the photographic material may be opaque or transparent, e.g. a paper
support or resin support. When a paper support is used preference is given to one
coated at one or both sides with an alpha-olefin polymer, e.g. a polyethylene layer
which optionally contains an anti-halation dye or pigment. It is also possible to
use an organic resin support e.g. cellulose nitrate film, cellulose acetate film,
poly(vinyl acetal) film, polystyrene film, poly(ethylene terephthalate) film, polycarbonate
film, polyvinylchloride film or poly-alpha-olefin films such as polyethylene or polypropylene
film. The thickness of such organic resin film is preferably comprised between 0.07
and 0.35 mm. These organic resin supports are preferably coated with a subbing layer
which can contain water insoluble particles such as silica or titanium dioxide. In
the preferred embodiment of a medical radiographic element the two emulsion layers
are preferably coated on both sides of a transparent blue colored poly(ethylene terephthalate)
film.
[0038] The photographic material containing tabular grains stabilized according to the present
invention can be image-wise exposed by any convenient radiation source in accordance
with its specific application. For the preferred embodiment of green sensitized X-ray
materials, suitable commercially available green light emitting screens are KODAK
LANEX and AGFA CURIX ORTHO.
[0039] The photographic elements in connection with the present invention are preferably
processed in an automatically operated apparatus. For the case of the radiographic
application commercially available X-ray material processors are CURIX U 242, marketed
by AGFA-GEVAERT N.V. and KODAK RP-X-OMAT M6AN, marketed by EASTMAN KODAK Co.
[0040] The following example illustrates the invention without however limiting it thereto.
EXAMPLE
1.1 Preparation of emulsion samples :
[0041] To a vessel containing 3180 ml of deionized water, 18.54 g of KBr and 12.5 g of inert
gelatin at pH 5.8 and 70 ° C were added 25 ml of a 2.94 molar AgN0
3 solution and 25 ml of a 2.94 molar KBr solution in 28 seconds by a double jet precipitation
technique. Then 475 ml of a solution containing 47.5 g of phtaloylgelatin were added
followed by a physical ripening period of 10 min. In order to adjust the pBr to 2.03
a 2.94 molar solution of AgNO
3 was added at a rate of 5 ml/s during 564 seconds. Thereupon 928 ml of a 2.94 molar
AgN0
3 solution and a 2.94 molar KBr solution were added simultaneously at a rate being
initially 5 ml/s and increasing linearly to 49 ml/s. The pBr was maintained during
this precipitation stage at a fixed value of 2.03. Finally the pH was adjusted to
3.5 by means of a sulphuric acid solution and the temperature was decreased to 40
C. After washing 160 g of inert gelatin was added and the pH and pAg were adjusted
to 5.5 and 7.64 respectively.
[0042] The thus obtained tabular grains had an average thickness of 0.20 micron and an average
aspect ratio of 6.6 as determined by the method described by Abott et al in GB 2,110,402.
Of the total projected area 80 % was covered with tabular grains.
[0043] During the next stage of the preparation the emulsion was divided in aliquot portions.
Each portion was spectrally sensitized to the green spectral region with 935 mg of
anhydro-5,5'-dichloro-9-ethyl-3,3'-di-(3-sulphobutyl)-oxacarbocyanine and then chemically
sensitized by means of 15.1 umole/mole AgNO
3 of sodium thiosulphate, 1.73 umole/mole AgN0
3 of chloroauric acid and 1.32 mmole/mole AgN0
3 of potassium thiocyanate. The time of chemical senstization was adjusted for each
sample in order to obtain an optimal fog/density ratio after coating and processing.
Then the emulsion samples were cooled and to each sample the desired amount of stabilizer
was added (see table 1). Hereafter each emulsion sample was coated on both sides of
a polyethyleneterephtalate film at a silver coverage of 2 x 3.0 g expressed as AgN0
3/m
2. A protective layer containing 1.1 g gelatin/m
2 was applied on both sides and as a hardener formaldehyde was used.
1.2 Evaluation of photographic properties :
[0044] The coated samples were exposed to green light having a peak emission at 545 nm through
a continuous tone wedge. Part of the samples were stored at 57 ° C and 34 % relative
humidity in order to simulate an extended shelf life period. Processing was performed
in a X-ray film processor (90 s cycle) using following processing solutions : a developing
solution adjusted to pH 10.1 comprising hydrochinon, 1-phenyl-5-pyrazolidinone, potassium
sulphite, 5-nitroindazole and glutaric dialdehyde as mean ingredients and a conventional
fixing solution comprising ammonium thiosulphate adjusted to pH 4.3.
[0045] The cross-over percentage was determined as follows. A film-screen element, consisting
of a double side coated emulsion sample in close contact with a single green emitting
screen at the side of the X-ray source and a white paper replacing the second screen
at the other side was exposed to varying doses of X-rays. After processing these elements
the sensitometric curves (density as a function of the X-ray dose) were determined.
From the difference in sensitivity, log E, between those two layers the % cross-over
was calculated according to the following equation :
% cross-over = 100 / antilog ( log E)
[0046] Table 1 illustrates the sensitometric results of the stabilization of the described
tabular grains by 4-hydroxy-6-methyl-1,3,3a,7-tetraazaindene (TAI) and 2-mercapto-4-hydroxy-6-carboxy-quinazoline
(compound 1), a stabilizer of the present invention. Sensitivities are expressed as
relative arithmetic values, sample 1 having reference value 100. Table 2 presents
the procentual cross-over values.
[0047] The results of table 1 and 2 show that the use of TAI as sole stabilizer cannot limit
the fog increase after conditioning the materials for 3 days at 57 ° C and 34 % RH
without severely deteriorating the cross-over. On the contrary the quinazoline derivative
according to the present invention, combined with TAI, significantly reduces the fog
increase after conditioning without significant variation in cross-over percentage.