Method for making multilayer optical films having thin optical layers
First Claim
Patent Images
1. A method for making a multilayer optical film, comprising the steps of:
- providing a first and second resin;
extruding the first and second resins into a resin stream comprising a plurality of layers and having first and second major surfaces, wherein at least some of the plurality of layers comprise the first resin and at least some of the plurality of layers comprise the second resin, wherein the number of layers having a layer thickness of less than k microns and disposed within 400 microns of the first surface is greater than the number of layers having a layer thickness of less than k microns and disposed within 400 microns of the second surface, and wherein k≦
10; and
casting the resin stream against a casting surface such that the first major surface is in contact with the casting surface.
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Abstract
A method for making multilayer optical films is provided in which the degradation of the optical extinction of the thinnest optical layers is avoided by casting these layers close to the casting wheel.
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Citations
34 Claims
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1. A method for making a multilayer optical film, comprising the steps of:
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providing a first and second resin; extruding the first and second resins into a resin stream comprising a plurality of layers and having first and second major surfaces, wherein at least some of the plurality of layers comprise the first resin and at least some of the plurality of layers comprise the second resin, wherein the number of layers having a layer thickness of less than k microns and disposed within 400 microns of the first surface is greater than the number of layers having a layer thickness of less than k microns and disposed within 400 microns of the second surface, and wherein k≦
10; andcasting the resin stream against a casting surface such that the first major surface is in contact with the casting surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method for making a multilayer optical film, comprising the steps of:
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providing first and second resins; extruding the first and second resins into a resin stream having a plurality of layers and having first and second major surfaces, wherein at least some of the plurality of layers comprise the first resin and at least some of the plurality of layers comprise the second resin, wherein at least some of the plurality of layers are of a first layer type having a layer thickness of less than k microns, where k≦
10, and wherein at least some of the layers of the first layer type are disposed within 400 microns of the first surface and at least some of the layers of the first layer type are disposed within 400 microns of the second surface; andcasting the resin stream such that the first major surface of the resin stream is in contact with a first casting surface and the second major surface is in contact with a second casting surface. - View Dependent Claims (18, 19, 20, 21)
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22. A method for making a multilayer optical film, comprising the steps of:
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providing first and second resins; extruding the first and second resins into a resin stream having a plurality of layers and having first and second major surfaces, wherein at least some of the plurality of layers comprise a first resin and at least some of the plurality of layers comprise a second resin, wherein a first set having at least one member and consisting of the layers having layer thicknesses of less than k microns and disposed within 400 microns of the first surface has at least as many members as a second set consisting of the layers having layer thicknesses of less than k microns and disposed within 400 microns of the second surface, wherein k≦
10, and wherein the median layer thickness of the first set is not greater than the median layer thickness of the second set; andcasting the resin stream against a casting surface such that the first surface is in contact with the casting surface. - View Dependent Claims (23, 24, 25)
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26. A method for making a multilayer optical film, comprising the steps of:
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providing a first and second resin; extruding the first and second resin into a resin stream having first and second major surfaces and comprising a plurality of layers, wherein at least some of said plurality of layers are of a first layer type having a layer thickness of less than k microns, wherein k≦
10, and wherein substantially all of said of layers of said first layer type are disposed within 400 microns of the first surface; andcasting the first major surface of the resin stream against a casting surface. - View Dependent Claims (27, 28, 29)
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30. A method for making a multilayer optical film, comprising the steps of:
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providing a first and second resin; extruding the first and second resins into a resin stream comprising a plurality of layers and having first and second major surfaces, wherein at least some of the plurality of layers comprise the first resin and at least some of the plurality of layers comprise the second resin, and wherein at least some of the plurality of layers are of a first layer type having a layer thickness of less than k microns, wherein k≦
10; andbringing the resin stream into contact with at least one casting surface, such that substantially all of the layers of the first layer type are disposed within about 400 microns of at least one casting surface. - View Dependent Claims (31, 32, 33)
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34. A method for making a multilayer optical film, comprising the steps of:
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providing a first and second resin; extruding the first and second resin into a resin stream comprising a plurality of layers and having first and second major surfaces, wherein at least some of the plurality of layers comprise the first resin and at least some of the plurality of layers comprise the second resin, wherein at least some of the plurality of layers are of a first layer type having a layer thickness of less than 1 micron, and wherein the portion of the resin stream within 400 microns of the second major surface is substantially devoid of layers of the first layer type; and casting the resin stream such that the first major surface of the resin stream is in contact with a casting surface.
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Specification