METHOD FOR MANUFACTURING AN OPTICAL FILM

• US 20110117331A1
• Filed: 04/03/2008
• Published: 05/19/2011
• Est. Priority Date: 04/03/2008
• Status: Abandoned Application

• Current Assignee: Dki Plast A/S (KB Components AB)
• Original Assignee: Dki Plast A/S (KB Components AB)
• Inventors: Mikkelsen, Henrik Bang
• Application Number:
  US12/936,007
• Publication Number:
  US 20110117331A1
• Time in Patent Office: Days
• US Class Current: 428/195.1
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

A method for manufacturing an optical film (1) is disclosed. The method comprises the step of providing a continuous sheet of transparent plastic material (2). One side of said sheet of transparent plastic material (2) is coated with a layer of curable transparent resin. The coating of curable transparent resin coating is embossed using an embossing roller (5) having a surface, with a predetermined surface structure, so as to provide a desired optical structure in said curable transparent resin. The curable transparent resin is cured, while the curable transparent resin is in contact with said embossing roller (5), so as to harden said desired optical structure.

Claims

1. Method for manufacturing an optical film, said method comprising the steps of

providing a continuous sheet of transparent plastic material,

coating one side of said sheet of transparent plastic material with a coating comprising a layer of curable transparent resin,

embossing said coating of curable transparent resin using an embossing roller having a surface, with a predetermined surface structure, so as to provide a desired optical structure in said curable transparent resin

curing said curable transparent resin, so as to harden said desired optical structure,

wherein said curable transparent resin is cured while in contact with said embossing roller.

2. Method according to claim 1, wherein said curable transparent resin is an UV curable resin.

3. Method according to claim 1, wherein said coating is subjected to a heat treatment prior to the embossing on the roller.

4. Method according to claim 3, wherein said heat treatment comprises infrared irradiation.

5. Method according to claim 1, wherein said continuous sheet comprises PET.

6. Method according to claim 1, wherein said curable transparent resin comprises unsaturated aliphatic urethane acrylate as a main constituent.

7. Method according to claim 2 or claim 3 wherein said curable transparent resin comprises a photo initiator selected from the group of α

-ketones.

8. Method according to claim 2 or claim 3 wherein said curable transparent resin comprises a silicone surface additive.

9. Method according to claim 1 wherein said continuous sheet of transparent material has a thickness in the interval between 100 and 1000 microns, preferably 100 microns and 300 microns, and most preferred between 150 and 250 microns.

10. Method according to claim 1, wherein said curable transparent resin coating has a thickness in the interval between 100 and 1000 microns, preferably between 200 and 500 microns prior to embossment.

11. Optical film manufactured using a method according to claim 1.