Method for subdividing multilayer optical film cleanly and rapidly

• US 20060191630A1
• Filed: 01/30/2006
• Published: 08/31/2006
• Est. Priority Date: 05/21/2002
• Status: Abandoned Application

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Wheatley, John A., Dobrzynski, Steven J., Mortenson, David K., Tait, Bruce E.
• Application Number:
  US11/342,962
• Publication Number:
  US 20060191630A1
• Time in Patent Office: Days
• US Class Current: 156/272.8
• CPC Class Codes: B23K 2101/16 Bands or sheets of indefinite length
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• CPC Class Codes: B23K 2103/172 wherein at least one of the layers is non-metallic
• CPC Class Codes: B23K 2103/40 Paper
• CPC Class Codes: B23K 2103/42 Plastics B23K2103/16 takes precedence
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/0006 taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/009 using a non-absorbing, e.g. transparent, reflective or refractive, layer on the workpiece using a mask on the workpiece B23K26/066
• CPC Class Codes: B23K 26/0846 for moving elongated workpieces longitudinally, e.g. wire or strip material
• CPC Class Codes: B23K 26/142 for the removal of by-products
• CPC Class Codes: B23K 26/18 using absorbing layers on the workpiece, e.g. for marking or protecting purposes
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B32B 2310/0843 using laser
• CPC Class Codes: B32B 2457/20 Displays, e.g. liquid crystal displays, plasma displays
• CPC Class Codes: B32B 2551/00 Optical elements
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/025 Transfer laminating
• CPC Class Codes: B32B 37/203 One or more of the layers being plastic
• CPC Class Codes: B32B 37/26 with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: B32B 38/0004 : Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: G02B 5/287 : comprising at least one layer of organic material
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1059 : Splitting sheet lamina in plane intermediate of faces
• CPC Class Codes: Y10T 156/1077 : Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1082 : Partial cutting bonded sandwich [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1085 : One web only

Abstract

Polymeric multilayer optical films, and laminate bodies that include such films, are cut or subdivided into one or more discrete pieces by removably applying a first and second liner to opposed major surfaces of the multilayer optical film. Laser radiation is then directed at the multilayer optical film through the first liner in such a way as to produce cut lines that define a plurality of pieces of the first liner and of the multilayer optical film. Thereafter, the plurality of pieces of the first liner are removed from the plurality of pieces of the multilayer optical film while the pieces of multilayer optical film are supported by the second liner. Application of the first liner to the multilayer optical film can be accomplished with electrostatics.

Claims

1. A method of subdividing a multilayer optical film body, comprising:

providing a multilayer optical film body comprising at least one multilayer optical film by unwinding a roll of the multilayer optical film body;

applying a first and second liner to opposed major surfaces of the multilayer optical film body;

directing laser radiation at the multilayer optical film body through the first liner, the laser radiation being adapted to produce cut lines that define a plurality of pieces of the first liner and of the multilayer optical film body; and

removing the plurality of pieces of the first liner from the plurality of pieces of the multilayer optical film body while the pieces of multilayer optical film body are supported by the second liner; and

winding up the multilayer optical film body and the second liner into a roll after the directing and removing steps.

2. The method of claim 1, wherein at least some of the cut lines extend completely through the multilayer optical film body but not completely through the second liner.

5. The method of claim 1, wherein the first liner is applied to the multilayer optical film body electrostatically.

8. The method of claim 1, wherein the providing step comprises continuously unwinding a roll of the multilayer optical film body.

9. The method of claim 1, wherein the applying step comprises continuously unwinding a roll of the first liner.

11. The method of claim 1, wherein the removing step comprises unwinding a roll of tape, contacting the pieces of the first liner with the tape, and winding up the tape with the pieces of the first liner adhered thereto.

12. The method of claim 1, wherein the multilayer optical film body comprises polymeric microlayers.

13. The method of claim 1, wherein the first liner comprises a paper layer.

14. The method of claim 13, wherein the first liner consist essentially of a paper layer.

15. The method of claim 13, wherein the first liner is applied to the multilayer optical film body electrostatically.

16. The method of claim 1, wherein the second liner comprises a paper layer and a polymer layer.

17. The method of claim 1, wherein the laser radiation is controlled such that at least some of the cut lines do not extend through the second liner.

18. The method of claim 1, wherein the directing step is performed at a laser cutting station, and the directing step further comprises:

providing an air flow in a first direction across the laser station.

20. The method of claim 18, wherein the laser radiation moves with respect to the multilayer optical film body in directions that have substantially no component parallel to the first direction.

3-4. -4. (canceled)

6-7. -7. (canceled)

10. (canceled)

19. (canceled)