Method for subdividing multilayer optical film cleanly and rapidly

• US 6,991,695 B2
• Filed: 10/10/2002
• Issued: 01/31/2006
• Est. Priority Date: 05/21/2002
• Status: Expired due to Term

• 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.
• Primary Examiner(s): Osele, Mark A.
• Application Number:
  US10/268,118
• Publication Number:
  US 20030217806A1
• Time in Patent Office: 1,209 Days
• Field of Search: 156/248, 156/268, 156/270, 264/400
• US Class Current: 156/248
• 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 wherein the first liner is applied to the multilayer optical film body electrostatically;

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;

reducing the electrostatic attraction of the first liner to the multilayer optical film body;

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.

2. The method of claim 1, wherein the reducing step comprises passing the first liner and the multilayer optical film body proximate a neutralizer bar.

3. 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, wherein the applying step comprises passing the first liner and the multilayer optical film body proximate a static bar;

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;

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.

4. 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;

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;

wherein the multilayer optical film body comprises a tearable outer layer, and wherein at least some of the cut lines are formed through the at least one multilayer optical film but not through the tearable outer layer.

5. A method of cutting a multilayer optical film body into a plurality of discrete pieces, comprising:

providing a multilayer optical film body comprising at least one multilayer optical film;

applying a first liner to the multilayer optical film body;

forming cut lines through the first liner and at least partially through the multilayer optical film body, the cut lines defining a plurality of discrete pieces;

removing the plurality of pieces of the first liner from the plurality of pieces of the multilayer optical film body;

supporting the multilayer optical film body with a second liner during at least the forming and removing steps; and

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

wherein the multilayer optical film body comprises a tearable outer layer, and wherein at least some of the cut lines are formed through the at least one multilayer optical film but not through the tearable outer layer.

6. A method of cutting a multilayer optical film body into a plurality of discrete pieces, comprising:

providing a multilayer optical film body comprising at least one multilayer optical film;

applying a first liner to the multilayer optical film body wherein the first liner is applied to the multilayer optical film body electrostatically;

forming cut lines through the first liner and at least partially through the multilayer optical film body, the cut lines defining a plurality of discrete pieces;

reducing the electrostatic attraction of the first liner to the multilayer optical film body before the removing step

removing the plurality of pieces of the first liner from the plurality of pieces of the multilayer optical film body;

supporting the multilayer optical film body with a second liner during at least the forming and removing steps; and

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

7. The method of claim 6, wherein the reducing step comprises passing the first liner and the multilayer optical film body proximate a neutralizer bar.

8. A method of cutting a multilayer optical film body into a plurality of discrete pieces, comprising:

providing a multilayer optical film body comprising at least one multilayer optical film wherein the providing step comprises continuously unwinding a roll of the multilayer optical film body;

applying a first liner to the multilayer optical film body wherein the applying step comprises passing the first liner and the multilayer optical film body proximate a static bar;

forming cut lines through the first liner and at least partially through the multilayer optical film body, the cut lines defining a plurality of discrete pieces;

removing the plurality of pieces of the first liner from the plurality of pieces of the multilayer optical film body;

supporting the multilayer optical film body with a second liner during at least the forming and removing steps; and

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