Horizontal Film Processing Apparatus

Reference is hereby made to commonly assigned, copending U.S. patent application Ser. No. 774,715, entitled PHOTOGRAPHIC CAMERAS, now abandoned: Ser. No. 774,716, entitled PHOTOGRAPHIC FILM UNIT AND CARTRIDGE ASSEMBLY, Ser. No. 774,719, now U.S. Pat. No. 4,132,469, entitled APPARATUS FOR SELECTIVELY VIEWING A PLURALITY OF RECORDING ELEMENTS, and Ser. No. 774,722, entitled METHOD AND APPARATUS FOR TREATING ELEMENTS OF PHOTOGRAPHIC FILM, now U.S. Pat. No. 4,112,454, all filed in the name of Donald Malcolm Harvey; Ser. No. 774,717, entitled IMPROVED ROTARY FILM PROCESSING APPARATUS, now U.S. Pat. No. 4,112,453, and Ser. No. 774,720, entitled IMPROVED VERTICAL PROCESSING APPARATUS, both filed in the name of William J. Hutchinson; and Ser. No. 774,721, entitled APPARATUS FOR PROCESSING PHOTOGRAPHIC FILM, now U.S. Pat. No. 4,112,452, filed in the name of David L. Patton, all filed on Mar. 7, 1977.

The present invention relates to the processing of photographic film and in particular to such processing in which batches of discrete, disc-shaped film elements are processed partially immersed in shallow processing trays. The elements can be moved sequentially through a plurality of treating stations at which different chemical processing is effected.

A multitude of devices have been heretofore devised for processing photographic film. Common concerns for processing film in any such devices are the desire to minimize mechanical contact with front and back surfaces of the film and the desire to obtain an intimate contact between the film surfaces to be processed and the processing solutions, in proper concentration and without external contaminates or carry-over between different processing solutions. A further desire from the economic viewpoint is to provide apparatus which is low in cost and simple in operation, yet capable of high quantity through-put with uniformly high quality results. The desire to minimize processing chemical usage is also a significant consideration.

Processing apparatus design is to a large extent constrained by the configuration or format of the film elements to be handled and to date most such apparatus have been adapted particularly for strip film. Two common general types of processors for strip film are (1) continuous processors in which the strip is fed by drive and guide rollers through the various processing stations and (2) reel processors in which film strips are wound spirally about a reel that are then manipulated into and out of the processing stations. Shorter strips are often spliced to form a longer strip.

Devices for processing film elements of other formats, e.g., chips, or small sheets, have not been so common. One popular approach is to support a plurality of film chips to be processed in a rack and sequentially dip the rack into treating reservoirs.

It is a purpose of the present invention to provide for processing of discrete film elements of a novel format in a manner which achieves the desirable characteristics mentioned above and offers significant advantages in various aspects over prior art devices.

Thus one object of the present invention is to improve the processing of photographic film.

Another object of the present invention is to provide improved processing of small, discrete film elements.

A more specific object is to provide such processing which minimizes mechanical contact with important image areas of the film.

Another more specific object is to enhance processing fluid contact with important image areas of the film.

Another more specific object is to provide apparatus and methods which minimizes processing liquid usage and the effects of contamination and concentration depletion.

The above and other objects and advantages are achieved in accordance with the present invention by apparatus and methods especially configured to process a plurality of disc-like film elements supported in spaced relation on a shaft passing generally through the center and normal to the face of each film disc. The image portions of the film element are located in an annular zone spaced slightly from the supporting aperture at the center of the element. When a plurality of the disc elements are arranged on the shaft, a cylindrical film unit comprising a batch of elements to be developed together is provided. In accordance with one aspect of the present invention, the elements are processed without total immersion in a reservoir configured to correspond to a portion of the film unit outline; thus minimizing the charge of processing liquid. In accordance with another aspect of the invention, film units are fed by transport means to a series of processing stations, supported with a bottom portion of the film cylinder in such processing reservoirs. A supported film unit is rotated about on its shaft by film drive means to effect thorough solution film contact without mechanical contact with image portions. After completion of the first processing treatment, the transport means moves the film unit to another station while continued rotation about its shaft by the film drive means controls the liquid from moving to the center of the film unit or discharges residual liquid. At a next processing station, the film unit is coupled to another drive means and similarly indexed into another processing solution reservoir.

The invention is hereinafter described in connection with the attached drawings which form a part hereof and in which:

FIG. 1 is a perspective view, with portions broken away, of one embodiment of automatic processing apparatus utilizing the present invention;

FIG. 2 is a top view illustrating the film unit drive system within the apparatus shown in FIG. 1;

FIG. 3 is a side view illustrating the film unit transfer system within the apparatus shown in FIG. 1;

FIG. 4 is an enlarged perspective view of an internal portion of the apparatus shown in FIG. 1;

FIG. 5 is a schematic illustration of the operation of a portion of the film unit transfer system of the embodiment shown in FIG. 1;

FIG. 6 is an enlarged view of a portion of the apparatus shown in FIG. 4 illustrating details of the control of the apparatus;

FIG. 7 is a perspective view of an alternative embodiment of the processing apparatus in accordance with the present invention, with the top pivoted away from its processing position to permit loading of the apparatus;

FIG. 8 is a perspective view of the apparatus of FIG. 7 with the top in a closed or processing position; and

FIG. 9 is a cross-sectional end view of the apparatus of FIG. 7 depicting the processing chamber and the level of processing solution therein.

The automated processing apparatus 1 shown in FIG. 1 comprises an inlet station 10 adapted to receive film units 2 of the type described with their longitudinal axis extending across the main feed path through the apparatus. Located in sequence along the film unit feed path from the inlet station 10 are a processing zone 11 including a plurality of liquid processing stations, a drying station 12 and an outlet 14. Located on one side of the apparatus are a plurality of conduits 15 which introduce and discharge processing liquid into respective processing stations in a timed sequence to be described subsequently in more detail. As shown, the apparatus 1 is adapted to be incorporated in a greater automated apparatus, illustrated schematically as including inlet and outlet conveyors 16 and 17.

Referring now to FIGS. 2, 3, and 4, the drive system for rotating the film units on their longitudinal axis during passage through the apparatus will be described. As shown, a film drive motor 20 has an output shaft 21 on which are affixed a plurality of worm gears 22. Gears 23 respectively drivingly mate with gears 22 for transmitting drive from the motor 20 beneath the film unit feed path, via shafts 24, to drive pulleys 25. Drivingly coupling pulleys 25 respectively with pulleys 26 are "O-ring" drive belts 27. Pulleys 26 are mounted for free rotation on (not keyed to) shafts 34 and of diameter such that the O-ring belt passing therearound can drivingly engage an end portion of a film unit, which is supported adjacent thereto by the film unit transport system in a manner next to be described with continued reference to FIGS. 2-4.

The film unit transport system comprises a transport drive motor 30 having a drive shaft 31 on which are affixed worm gears 32. Gears 33 respectively mate with each of the worm gears and are keyed on shafts 34 to transmit rotation to indexing discs 35, which likewise are keyed to shafts 34, one on each side of the film unit transport path as best shown in FIGS. 2 and 4. As also shown in FIGS. 3 and 4, each of the film unit transport discs have a pair of notches 35a and 35b extending diagonally inwardly from the disc periphery. The notches 35a are diametrically opposite notches 35b on the discs and all transport discs are of the same diameter and oriented on their shafts so that one notch on each disc will move to the aligned, film-unit-passing orientation shown in FIG. 3 during a one-half cycle of rotation of the disc 35. As shown in FIG. 3, the off radial slant of the slot in the disc is directed so as to assist retention of the shaft of a film unit in the upward transport of the film unit (clockwise rotation of the disc as viewed in FIG. 3) and assist in gravity discharge of the film unit shaft into the notch of the next contiguous disc during downward transport of the film unit.

As shown in FIGS. 2-4, a timing disc 40 is keyed to an extension 41 of one of the transport disc shafts 34 and rotates synchronously with the timing discs. The timing disc includes two switch actuating notches 42, diametrically opposed on the disc periphery. A control switch 43, shown in more detail in FIG. 6, is mounted for movement toward and away from the timing disc 40, and biased toward the disc. After movement to the dotted-line position shown in FIG. 6 by rotation of the disc 40, the switch 43 is retained in that position and follows the outer disc periphery until falling into the opposite slot, after a 180.degree. rotation of the shaft 41 (and of all transport discs 35). The movement back into a slot 42 actuates de-energization of motor 30 and of a transport cycle as will be explained in more detail after a description of the film units 2 utilized in apparatus 1. It will be appreciated that synchronization could be accomplished by optical sensors or other position detecting systems known in the art.

As best shown in FIGS. 2 and 4, the film unit 2 can comprise an elongated shaft 50, having on one end thereof a drive disc 51 having a serrated or otherwise roughened peripheral edge. The shaft 50 is of sufficient length and the drive disc 51 of sufficient diameter that the disc 51 can drivingly engage O-rings 27, when supported by transport discs 35 as shown in FIG. 4. On the shaft 50, a plurality of film discs 54 are mounted by a central aperture. A central portion of the film disc provides frictional or keyed engagement between the shaft and film disc and also spaces adjacent film discs sufficiently to avoid inter-film contact and allow processing solution access.

In operation, a film unit is released through the inlet 10 and can roll into a nested position in slots 25a of the first pair of transport discs as shown in FIG. 3. A cycle of operation is then actuated by the operator and motor 30 is energized to move transport discs 35 and timing disc 40 through a 180.degree. rotation. This rotation locates the film unit in a supported position in the next transport disc 35 which, as will be apparent from FIGS. 1 and 4, will locate the lower portion of the film discs in the first processing tray. Motor 20 can be energized simultaneously with motor 30 and drive is thus transmitted to the film unit via "O-ring" belt 27 and drive disc 51 of the film unit; however, motor 20 is not de-energized after the 180.degree. rotation and continues to rotate the film unit in the first processing tray 60. After a predetermined period of treatment in the first processing tray, the motor 30 is again energized to transport the film unit to the next processing tray in the same manner described above. Concurrently, a new film unit can be fed into the processing position in the first processing tray. The motor 20 can desirably remain energized during the film unit transport and continues to rotate the film unit during transport between processing trays. Control means, of a type readily understood by one skilled in the art and not described herein in detail, continue to sequentially initiate successive film transport cycles of motor 30 between predeterminedly times processing cycles until the film unit has passed through drying section 12 and exits the apparatus with film fully processed.

In timed relation with the film unit transport between processing trays, predetermined quantities of processing solutions, such as developer, fix and wash solutions, are introduced into the processing trays by conduits 15. More specifically, a predetermined quantity of developer is introduced into processing tray 60 prior to each processing cycle and discharged after completion of the cycle. The discharge and replenishment desirably is effected during film unit transport to the next tray, which may contain, e.g., a newly introduced fix solution. It will be noted that the rotation of the film unit during processing allows substantially less than total immersion of the film and thus the liquids for a single processing cycle can be introduced and discharged for each film unit treatment. The electrically-controlled plumbing system for performing these functions is of a type readily understood and is not described herein in detail. However, larger liquid reservoirs could be provided for processing the film units or recirculating liquid to the shallow trays 60.

It will be apparent to one skilled in the art that the apparatus disclosed is admirably suited for continuous throughput of film requiring differing processing periods in the different solutions. That is, a plural number of developer, fix and/or wash trays can be provided so as to additively provide a selected processing time in a particular solution, e.g., the first two trays could be developer, the next two fix and last four wash if the chemistry of the developing process and film so required. Thus, with the cycle between inter-tray transports remaining constant to allow continuous throughput, the treatment time with a particular solution can differ by arrangement of solutions in the trays.

Referring now to FIG. 5, it will be seen that another important feature of the present invention provides for the continuous rotation of the film units during transport between processing trays. As shown, the drive disc 51 is maintained by gravity in driving engagement with a first belt 26 substantially until it moves into nesting position on the next successive transport discs 35. This spinning action is particularly advantageous in maintaining processing solution on the film surface so as not to accumulate in large masses during transport. Also, this spinning action can be utilized to effect removal of residual processing liquid from the previous tray prior to introduction of the film into a different solution tray, in which case appropriate baffle structure, of a type known in the art but not shown, may be desired.

As will be noted in FIG. 4, which for ease of illustration shows only five processing stations, a separate drive can be provided to particular stations. Thus, if it is desirable to provide a higher velocity rotation for drying, a separate faster drive can be supplied.

Although the embodiment of the invention just described employs a plurality of reservoirs 60 with different fluids, it will be appreciated that certain advantages of the present invention pertain to the use of a single tray embodiment. For example, the film unit could be supported and rotated in a single tray with different processing fluids sequentially introduced into, and discharged from, the tray. Such an approach is depicted in FIGS. 7-9.

In the single-tray embodiment, the processing apparatus 100 includes a processing zone 111 and a drying zone 112 which are coupled together, such as by hinge 113, to define a single processing and drying chamber. On the sides and bottom of the chamber, a plurality of conduits 115 are suitably located for introducing and discharging batches of the processing chemicals in a timed sequence. A motor 120, coupled to the film discs through a magnetic collar 124, at one end of the chamber, rotates the film discs in a sequence related to the solution sequence and including some time periods when the solutions are in the chamber, other time periods between the discharge of one batch of solutions and the introduction of a subsequent batch of solutions, and still other time periods after all of the solutions in a particular processing sequence have been discharged from the chamber. The top of the chamber includes a heating element 153, fan 154, and appropriate baffling structure 155 and 156 for drying the film discs at the completion of the processing sequence.

In operation, a film unit 2, including the film discs 54, mounted on shaft 50, are manually positioned in notches 168 in processing tray 160. A driving puck 151 at one end of the shaft is received within the magnetic collar 124 so that rotation of the motor 120 will magnetically induce rotation of the shaft 50 in notches 168, and film discs 54 in tray 160. It should be noted that the film discs are packed closely together in parallel relationship normal to the shaft, but the imaging surfaces of the film discs are axially spaced on the shaft sufficiently so they don't touch and to allow passage of the processing chemicals therebetween. Additionally, the tray 160 has the shape of a semi-cylinder or the sector of a cylinder which conforms to the circular periphery of the film discs 54 and film unit 2.

After the film discs are properly positioned in the tray, the chamber is closed by rotating the drying section 112 from the position depicted in FIG. 7 to the position overlying the processing section 112 as depicted in FIG. 8.

Baffle 155 is in the closed position (solid lines in FIG. 9) to reduce heat loss from the processing zone and to eliminate the need for solution heating elements around tray 160.

With the film discs fully enclosed, motor 120 is energized and a first solution, such as developer is introduced from reservoir tank 176 via one of the conduits 115. Merely removing the plug 177 is sufficient for a premeasured quantity of the developer to flow under the influence of gravity to a predetermined level in the tray. The conduit enters the tray at an angle (FIG. 9) to wash the sides of the tray and to direct the developer away from a core section 179 of the film discs without significantly wetting the core section. Similarly, the quantity of the developer is selected to fill the chamber to a level which immerses only a part of the film discs not including the core section. This level is sufficient to contact the entire annular imaging area of the film elements as the elements are rotated on edge in the tray, but insufficient to cover the hubs of the film elements during such rotation.

As the film discs rotate, successive portions of the imaging surfaces will be presented to the developer, thus wetting the imaging surfaces and agitating the developer. At the same time, however, the core section will remain essentially dry, except, perhaps, around its outermost edge.

After development is completed, the developer is drained from the tray and a second solution, such as a rinse 181, is added. The sequence is essentially the same as for the developer and is repeated several times for the several other solutions 182, 183, 184, and 185 until the processing solution cycle is completed. Rotation of the film discs in the chamber is continued or even increased between immersion in the successive solutions to spin-off any excess of the solutions.

Finally, the film discs are dryed, while they remain in the same tray 160, by opening the baffle 155 and energizing fan 154 and heater 153. At the same time, the rotational speed of the film elements may be increased to enhance the drying action.

Still other advantages of the present invention can result from combining features of the multiple chamber approach with features of the single chamber approach. For example, a two chamber processor might include one chamber for developer solution and another chamber for the remaining solutions. In such a case, the developer solution might be replenished as needed, while the other solutions might be supplied as sequential batches of chemicals which are not intended for reuse.

It should now be apparent that the structure and method of the present invention provides significant advantages not available from or taught by the prior art.

Chemical processing solutions can be utilized in such an efficient manner that it may be practical in many instances to use batch (not replenished) chemicals not intended for reuse. This will eliminate the need for recirculation pumps, heaters and concentration-sensing controls. In a similar respect, the small quantities of chemicals make it practical to use fewer processing chambers than there are solutions, by quickly interchanging several solutions in a single chamber. Equally important, a relatively high volume throughput is possible in very compact apparatus, whether manually or automatically operated, without sacrificing quality.

Other advantages will become apparent from the above description to those who are skilled in this art.

The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.