FINAL REPORT PHASE I

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78B04747A002400060031-6
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 11
• Document Creation Date: December 28, 2016
• Document Release Date: May 7, 2003
• Sequence Number: 31
• Publication Date: June 20, 1966
• Content Type: REPORT

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Declass Review by NIMA/DOD
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This report describes the appraisals made of the problems
anticipated and experienced in the production of a breadboard model of a
wide film 1 -1 The problems were defined as being those of the
curl action of the wide film, uniformity of the air and liquid cushions
forming the main principles of the
system, and dependent upon.
this in part, the uniformity of chemical reaction in the different process
steps.
A test program was conducted to determine the actual severity
of these problems, and solutions proposed. Other secondary problems
such as the selection of basic construction materials were also considered,
test hardware manufactured and evaluation tests conducted. This work
essential to the success of the breadboard model was satisfactorily
completed, and the breadboard designed and constructed in this phase
of the program.
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1. INTRODUCTION
The objective of phase 1 of this program was the design and
construction of a preliminary (breadboard) model of a Processor based on
the results of studies applying the L Iprinciple to the processing
of 9-1/2 inch wide photographic film.
The breadboard model was built to enable a sensitometric program
to be undertaken to determine the necessary design and functional param-
eters for the manufacture of a prototype 9-1/2 inch
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Processor. STAT
The breadboard processor is now available and fully operational
for the sensitometric evaluation program.
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2.1 The principle, to date, has been successfully applied
to the processing of 16, 35, and 70 m/m width film only. On the basis of
experience gained from these narrower width films, the application of the
Sepratron principle to wider films was not expected to create serious basic
problems. Certain problems were however, anticipated, and on these a
large percentage of the program effort was expended.
2.2 Problem Areas and Solutions Obtained
Three major problem areas were anticipated as requiring primary
attention. These were as follows:
1) The strong curl action of the wider 9-1/2 in film about its
long axis.
2) The obtaining of uniform action of the air and liquid cushions
on which the film is transported.
3) Chemical reaction in relation to turbulation in elevated
temperatures.
Parallel with the problems outlined above, other problems of a
secondary nature but vital to the production of hardware, such as the
selection of basic construction materials were also given early considera-
tion in the program.
2.3 Film Curl
Photographic film is not an homogeneous material, it consists of
a silver halide carrying gelatin emulsion, coated on a transport flexible
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base, such as cellulose estar. This structure may vary between film types
by changes to the composition of the gelatin, or t4 e base, or by the
coating of another layer of gelatin on the opposite side of the base, as a
method of controlling curl. Curl of photographic film occurs as a result
of the difference in moisture capacity of the components. Gelatin is very
hygroscopic and the base material relatively the opposite, or non-hygroscopic
For this reason various types of film, exhibit different characteristics of
curl, and as a result, feeding of such curled film through process STAT
modules was expected to result in mechanical damage, if the impingement
action taking place on both sides of the film, failed to apply sufficient
flattening action to the curl. The film in this case would show scratches
down the middle, since both outside edges and the highest point of the
curl, in the middle of the film would contact the module. In other words
the air and liquid cushion action on which the film rides, would not be
effective. Two solutions were investigated:
1) To adapt the shape of the film passage in the module to
suit the shape of the curled film.
2) To design the air and liquid passages so that the pressure
would force the film into a flat condition.
The first approach was considered and after a thorough investiga-
tion, discarded for the following reasons:
1) A curved surface shape to the film passage would produce
differential pressure and turbulation across the width of the film, which
would be difficult to control, and would furthermore create additional
problems in the use of different film widths.
2) Due to the tendency towards very thin film bases, and the
increasing use of non-curl backing, a situation would be created where
non-curling films were processed in curved process channels.
2-2
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3) Complication in the construction of the modules. An exten-
sive series of testing and evaluation was carried out parallel with the
curved passage investigation to determine the requirements of a straight
non-curved passage that would cope with curled film.
Early tests with experimental clear lucite models employing
smoke, showed that if the air passing between the channel walls and the
film, maintained a certain velocity at a constant pressure a non-collapsible
air cushion was formed having the required properties. Many model air
and liquid passages very similar in shape and form, incorporating small
changes between air and liquid passages to compensate for density changes
in the air and liquid mediums were built, and tested to provide the data for
the final design selected.
2.4 UNIFORM AIR AND LIQUID CUSHIONS IN
MODULES
The determination of the right air and liquid channel parameters
to combat the film curl, was also correlated to the problem of providing a
uniform air and liquid cushion to maintain a proper film transport condition.
By considering this requirement and conducting parallel tests on the
experimental air and liquid channels, the final shapes determined,
satisfied both requirements.
It should be stressed that in problems of this nature, theoretical
solutions can only be proved by extensive experimental work, in which
minor changes produce large differences in results.
2.5 CHEMICAL REACTION IN RELATION TO TURBULATION IN
ELEVATED TEMPERATURES
A test program with photographic film in 35 and 70 m/rn modules
was conducted to determine the effectiveness and the correlation between
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high liquid turbulation and elevated temperatures, in terms of the increase
in density obtained.
These tests were important in establishing the parameters of the
The numerous tests conducted, crystallized very clearly an optimum
relationship between turbulation and elevated process temperatures .
High agitation becomes most effective between normal conventional pro-
cess temperatures of 68?F up to 100?F.
The cross over point between the two occurs between 100?F and
110?F where further increases in turbulation have decreasing effectiveness,
but elevated temperatures continue to be effective.
The establishment of these parameters greatly influenced the
design and construction of the final module.
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The information resulting from test programs previously described
considerably affected the original general design of the process chamber.
The determination of the relationship between turbulation and elevated
process temperatures in the area of 100?F to 110?F, established that it
would not be necessary to continually increase the rate of turbulation to
gain higher processing speeds, specially in the developer module. The
replacement of a high turbulation zone in the-film channel with a normal
turbulation rate zone permitted a simplification of the method of joining the
two sections of a processing module. The practice on the 16/35 mm
modules necessitated that the joining channels between modules be mounted
with better than .002 inches accuracy. Now, since the two process areat
are joined together in one mechanical component, less attentionto the
accuracy factor, is required, resulting in an improvement in the reliability
and simplicity.of the overall design.
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2.7 CONSTRUCTION MATERIALS
Evaluation tests were conducted with various materials to
determine the most suitable material from which to manufacture the pro-
cess modules. The increase from 16 mm and 35 mm process modules to
9-1/2 inch modules, especially in conjunction with elevated temperatures,
was a matter of considerable concern.
In early tests, Polyurethane was used with good results con-
cerning castability, absolute temperature stability and resistance to
chemical corrosion. In other respects, however this material did not prove
satisfactory. Machining proved to be very difficult due to flexibility of
the material, and additionally the cementing of joints provided to be
possible only under certain conditions which could not always be fulfilled.
Further tests made between P.V.C. and Acrylic plastics, resulted in the
selection of the latter material as being the most suitable for overall
handling, construction and performance capabilities.
2.8 PUMPS AND BLOWERS
The selection of suitable pumps was given careful consideration
to ensure that all the working conditions would be satisfied. These
included operation and sealing of the impellar shaft at elevated tempera-
tures, a low tendency to cavitate over the range of working conditions,
and a careful appraisal of materials used in the pump casing itself.
To activate the air bearing and separation zones a reliable
turbo-blower was selected.
2.9 TEMPERATURE CONTROL
The use of elevated process temperatures to permit an increase
in processing speeds necessitates the holding of solution temperatures
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to a greater accuracy than is required at lower temperatures. The volume
of flow required from the pumps for the transport cushion provided con-
siderable assistance in preventing temperature differentials in each
module system. With the rate of flow established, and the heaters selected,
the design of the tanks best suited for the design concept were carefully
considered, to ensure accurate temperature control, and to keep the
volume of solutions required to an absolute minimum.
2.10 FINAL BREADBOARD
The breadboard constructed to embody the results of the foregoing
test and evaluation programs consists of a six module system, which is
completely light sealed to permit processing tests to be conducted under
normal daylight conditions . A light tight adapter is provided to permit use
of a standard A9 magazine.
Electrical control systems are provided for solution heating
temperature control and recirculation for each module.
Front and rear elevations of this breadboard model are included
at the back of this report.
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3.1 CONCLUSIONS AND RECOMMENDATIONS
In the design concept and selection of equipment and materials
for the wide filmy (breadboard, continuous consideration was
given to the requirements of the prototype processor.
The objective of this consideration was that too far a departure
from the design concept of the breadboard in the design of the prototype
could very well introduce functional variations that might
produce different sensitometric results. As a consequence, only minor
changes are anticipated between the two.
From this program, a clear picture can now be visualized of the
prototype machine, incorporating the breadboard experiences combined
with the dryer stage, into a compact mobile processor.
We are confident that the results of phase 1 of this program, as
demonstrated in the breadboard model, fully justify the continuation of
this contract into phase II.
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