CN1653387A - 干净、快速细分多层光学膜的方法 - Google Patents
干净、快速细分多层光学膜的方法 Download PDFInfo
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Abstract
聚合物多层光学膜和包含这种膜的层合体,可通过在多层光学膜的两个相对主表面上贴合可去除的第一和第二衬垫将这些膜切割或细分成一个或多个分立的片。然后通过第一衬垫在多层光学膜上辐射激光,从而产生切割线,这些切割线使第一衬垫和多层光学膜形成许多小片。随后,从多层光学膜片上去除第一衬垫片,而用第二衬垫支撑多层光学膜。在多层光学膜上贴合第一衬垫的步骤可通过静电作用完成。
Description
发明领域
本发明涉及将含多层光学膜的光学实体切割或细分成许多小片的方法。
发明背景
多层光学膜是众所周知的,通过适当排列折射指数不同的微层,这种膜至少可部分获得所需透射和/或反射性质。在真空室中,在基底上按顺序依次沉积多个无机材料光学薄层(“微层”),由此制备上述多层光学膜,这个方法早就为人所知。一般地,基底是较厚的玻璃片,可能是沉积过程对真空室体积和/或均匀程度有限制,基底尺寸也受到限制。
最近,多层光学膜已通过交替共挤出聚合物层得到说明。例如,可参见美国专利3610724(Rogers)、4446305(Rogers等)、4540623(Im等)、5448404(Schrenk等)和5882774(Jonza等)。在这些聚合物多层光学膜中,形成各层的时候主要或全部使用聚合物材料。这些膜适应大体积生产过程,可制成大块片材和成卷的商品。
但是,许多产品在应用中需要大量小片膜,例如单个光二极管探测器。其他应用包括光纤器件和其他小型光子器件中的窗体、反射器和/或过滤器。对于这些应用,通过机械方法细分片材,例如用剪切装置(例如剪刀)切割片材,或者用刀片切开片材,可从这种大片膜得到小片多层光学膜。但是,切割工具施加在膜上的力可能会使层沿着膜上切割线或切割边缘区域剥离。对于众多的聚合物多层光学膜尤其如此。由于相对于完好无损的区域而言颜色发生变化,膜上的脱层区常常看得见。因为多层光学膜依靠与各层的密切接触而产生所需的反射/透射特性,所以脱层区无法提供这些特性。
在某些产品的应用中,脱层可能不成问题,甚至可忽略不计。而在其他应用中,特别是当包括边缘在内的几乎整片膜对于形成所需反射或透射特性非常重要时,或者当膜要受到机械应力作用且/或要经历较大的温度变化而可能使脱层现象随时间在膜中扩散时,脱层将是致命的缺陷。
因此,需要改进细分多层光学膜和包含这种膜的制品的方法。该方法最好不要在切割线或膜边缘产生脱层现象,在切割膜时比较干净,不会在膜上积聚太多碎屑,而且适应于自动和/或连续生产过程。
发明简述
本发明介绍了将包含多层光学膜的多层光学膜体细分或切割成一个或多个分立的片。在简单情况下,多层光学膜体主要由多层光学膜构成。在其他情况下,多层光学膜体也可包含层压到多层光学膜上的一个或多个别的层。在多层光学膜体的两个相对主表面上安装了第一和第二活动衬垫。接着,可通过一个衬垫(姑且称为第一衬垫)对膜体进行激光辐射,激光辐射是用来形成切割线的,即将第一衬垫和膜体切割成许多片。激光辐射通常会产生一缕烟,还有碎屑沉积在工件上——在这里是沉积在第一衬垫上。随后可从多层光学膜体上拿走第一衬垫(以及碎屑),多层光学膜体由第二衬垫支撑。可使胶带与第一衬垫接触,然后从多层光学膜体上拉开胶带,以此带走第一衬垫和碎屑。
至少第一衬垫是通过静电固定在膜体上的。用激光辐射形成切割线之后,而在从多层光学膜体片取下第一衬垫片之前,可用中和器件减少第一衬垫和多层光学膜体之间的静电引力。
虽然激光辐射是切割膜体的优选技术,但其他方法如旋转模切割法和超声切割法在某些情况下也是适用的。
附图简述
以下整个说明过程都是在参考附图的情况下进行的,其中相同的指示数字代表相同的部件。
图1是多层光学膜体的高倍放大透视图;
图2是多层光学膜体片的俯视图,虚线表示细分的路径;
图3是位于上下衬垫之间的多层光学膜体的剖面图,该图还显示了电磁辐射在切割线上形成的间隙,是这些间隙将多层光学膜体和上衬垫分成了一个个分立的片;
图4是类似于图3的剖面图,但上衬垫上粘有黏性膜,该黏性膜能将各片上衬垫从各片多层光学膜体上拉下来;
图3a和4a分别类似于图3和4,不同之处在于前面两幅图中的切割线完全穿透膜体中多层光学膜微层,但没有完全穿过膜体外层的可撕裂厚度;
图5是从一大片多层光学膜体上切下来的一片光学膜的俯视图;
图6是图5所示多层光学膜体片的透视图,它上面装有许多过滤器框架;
图7是细分多层光学膜体的连续过程;
图8是切割完成后的多层光学膜体的俯视图。
实施方式示例详述
这里所用“膜”是指延展性光学体,其厚度一般不超过约0.25mm(1/10000英寸,或“mil”)。某些情况下,膜可以附着或粘贴到具有合适的反射或透射性质的另一个光学体如硬质基底上,或者另一块膜上。膜的形式也可以是物理弹性膜,可以独立支撑,也可以附着在其他弹性层上。这里所用术语“膜体”是指完全由膜构成的实体,或者与其他组分联合构成的实体,如在层合结构中那样。
图1描述了多层光学膜体20。膜体包含独立的微层22、24。微层具有不同的折射指数,因而某些光将在毗邻微层间的界面上发生反射。微层足够薄,因而在许多界面上发生的反射光将发生相长干涉或相消干涉,以便赋予膜体所需反射或透射性质。对于意在反射紫外线、可见光或近红外光的光学膜,每个微层的光学厚度(即物理厚度乘以折射指数)一般小于约1μm。但是,较厚的层也可以包括在内,如位于膜外表面上的表层,或者在膜内分开各组微层的保护性界层。多层光学膜体20也可以包含一个或多个厚黏性层,在层合物内将两片或多片多层光学膜黏结在一起。
多层光学膜体20的反射和透射性是各微层折射指数的函数。每个微层的特征是,膜中至少局部位置的面内折射指数为nx、ny,膜的厚度方向的折射指数为nz。这些指数分别表示光分别沿互相正交的x-、y-和z-轴偏振时,组分材料的折射指数。在实践中,折射指数可通过严格挑选材料和加工条件来控制。膜体20的制备方法是,交替共挤出聚合物A、B,通常达数十或数百层,然后任选使多层挤出物通过一个或多个倍增模具,接着拉伸或挤出物或使挤出物定向,形成最终的膜。所得膜通常由数十个或数百个独立微层组成,它们的厚度和折射指数经过调整,可在所需光谱区内提供一个或多个反射段,如可见光或近红外光。为了用数量合理的层得到高反射性,对于在x-轴发生偏振的光,相邻微层的折射指数差(Δnx)宜至少为0.05。如果对两个正交的偏振光都要求有高反射性,则对于在y-轴发生偏振的光,相邻微层的折射指数差(Δny)也宜至少为0.05。另外,折射指数差Δny也可以小于0.05,宜约为0,以得到多层堆积结构,它能反射一种偏振态的正入射光,而透过正交偏振态的正入射光。
如果需要,对于沿z-轴偏振的光,也可以调整相邻微层之间的折射指数差(Δnz),以获得所需的反射斜入射光p-偏振组分的性质。下面为了便于解释,谈论到干涉膜上的任何点的时候,都把x-轴看成在膜平面之内,以使Δnx的值达到最大。这样,Δny的值可以等于或小于(但不能大于)Δnx的值。此外,在考虑选择何种材料层开始计算Δnx、Δny和Δnz时,主要受到Δnx为非负的要求的限制。换句话说,形成界面的两层的折射指数差是Δnj=Δn1j-Δn2j,其中j=x、y或z,在选择层标记时要使得Δn1x≥Δn2x,即Δnx≥0。
为了使斜角入射的p-偏振光保持高反射性,可控制微层之间的z-指数失配度Δnz,使之基本上小于最大面内折射指数差Δnx,从而Δnz≤0.5*Δnx。Δnz≤0.25*Δnx更好。z-指数失配度为0或接近0时,所得微层间的界面对p-偏振光的反射率相对于入射角为常数或近似为常数。此外,可控制z-指数失配度Δnz,使它与平面内指数差Δnx相比具有相反的偏光性,即Δnz<0。此条件下得到的界面对p-偏振光的反射率随着入射角的增加而增加,就像s-偏振光那样。
可用来制备聚合物多层光学膜的材料的例子见PCT专利公开WO99/36248(Neavin等)。其中至少一种材料宜为应力光学系数绝对值较大的聚合物。换句话说,聚合物拉伸后宜形成较大的双折射指数(至少约为0.05,更宜至少约为0.1,或者0.2)。根据多层膜的应用,双折射可发生在膜平面内的两个正交方向之间,在一个或多个面内方向与垂直于膜面的方向之间,或者这两种情况都有。在特殊情况下,即未拉伸聚合物层之间的各向同性折射指数相差较大的时候,可以放松对至少一种聚合物具有大双折射指数的要求,但一般仍然希望具有双折射性。这种特殊情况可能存在于为平面镜膜和偏振器膜选择聚合物的时候,这些膜用双轴向方法形成,即在平面内的两个正交方向上拉膜。此外,聚合物在被拉伸后宜保持双折射性,从而赋予最终的膜以所需的光学性质。可为多层膜中的其他层选择第二种聚合物,使这第二种聚合物在最终膜里至少一个方向上的折射指数明显不同于第一种聚合物在同一方向上的折射指数。为方便起见,一般只用两种不同的聚合物材料制备膜,在挤出过程中交替放置这些材料,得到交叠层A、B、A、B、……,如图1所示。但并不要求只交叠两种不同的聚合物材料。相反,多层光学膜中的每一层都可以由不同于膜中其他地方的独特材料或混合材料组成。共挤出的聚合物宜具有相同或相似的熔化温度。
既能提供足够大的折射指数,又能提供足够强的层间黏着力的双聚合物组合的例子包括:(1)对于主要用单轴向拉伸法制备的偏光多层光学膜,PEN/共PEN、PET/共PET、PEN/sPS、PET/sPS、PEN/EasterTM和PET/EasterTM,其中“PEN”指聚萘二甲酸乙二酯,“共PEN”指基于萘二酸的共聚物或混合物,“PET”指对苯二甲酸乙二酯,“共PET”指基于对苯二甲酸的共聚物或混合物,“sPS”指间同立构聚苯乙烯及其衍生物,EasterTM是可购于Eastman ChemicalCo.的聚酯或共聚酯(相信包含环己二醇单元和对苯二甲酸单元);(2)对于通过控制双轴向拉伸法工艺条件制备的偏光多层光学膜,PEN/coPEN、PEN/PET、PEN/PBT、PEN/PETG和PEN/PET共PBT,其中“PBT”指聚对苯二甲酸丁二酯,“PETG”指PET与第二种醇(通常为环己二醇)的共聚物,“PET共PBT”指对苯二甲酸或其酯与乙二醇和1,4-丁二醇混合物的共聚酯;(3)对于镜面膜(包括有色镜面膜),PEN/PMMA、共PEN/PMMA、PET/PMMA、PEN/EcdelTM、PET/EcdelTM、PEN/sPS、PET/sPS、PEN/共PET、PEN/PETG和PEN/THVTM,其中“PMMA”指聚甲基丙烯酸甲酯,EcdelTM是可购于EastmanChemical Co.热塑性聚酯或共聚酯(相信包含环己二酸单元、聚丁二醇单元和环己二醇单元),THVTM是可购于3M公司的氟聚物。
合适的多层光学膜和相关结构的其他详细信息见美国专利5882774(Jonza等)和PCT专利公开WO95/17303(Ouderkirk等)和WO99/39224(Ouderkirk等)。聚合物多层光学膜和膜体可包含其他层和为其光学、机械和/或化学性质而选择的涂层。见美国专利6368699(Gilbert等)。聚合物膜和膜体还可包含无机层,如金属层、金属氧化物涂层或层。
在一种简单实施方式中,微层可以是厚度为1/4波长的堆积结构,即形成光学重复单元或单胞,每个重复单元或单胞基本上由两个相邻的等光学厚度微层构成(f比=50%),这种光学重复单元能有效反射波长λ两倍于光学重复单元总光学厚度的相长干涉光。这种结构如图1所示,其中聚合物A的微层22毗邻聚合物B的微层24,形成单胞或光学重复单元26,该单胞或重复单元在整个堆积结构中重复出现。可利用膜在厚度轴方向(即z-轴方向)的厚度梯度增大反射范围。也可以通过调整厚度梯度使此范围变窄,如美国专利6157490(Wheatley等)所述。
其他层结构,如含有f比不是50%的双微层光学重复单元的多层光学膜,或光学重复单元主要由两个以上的微层组成的膜,也在考虑范围之内。这些光学重复单元结构可减少或消除某些高级反射。例如,可参见美国专利5360659(Arends等)和5103337(Schrenk等)。
图2所示为一片多层光学膜体30的局部俯视图。膜体30在生产和销售时,其横向尺寸比在最终的特定应用中所要求的尺寸大。因此,为使膜适应具体用途,需要将膜体30细分为较小的片。所需膜片的大小和形状可在很大范围内变化。为方便起见图2所示膜片用两组交叉的平行切割线表示,标记为32和34。如果两组切割线都使用,则膜体30将变成一个个独立的矩形(包括方形)或平行四边形片,它们均向两个方向延伸,即膜30的长度和宽度方向。如果只用一组切割线,则膜片将是矩形长条。当然,切割线不必笔直,当中可以杂以弧线、折线。但通常需要的都是简单形状,如圆形、矩形、平行四边形或其他多边形。
本发明申请者发现激光辐射可用于切割和细分聚合物多层光学膜体,并且在切割线上基本上不会引起脱层。所选激光辐射的波长至少为光学膜中的某些材料大量吸收,吸收的电磁辐射沿切割线使膜体蒸发。否则,激光辐射将如同其他波长在膜的目标作用范围内的入射光一样,透过膜或在膜上发生反射。激光辐射同样用合适的聚焦光学仪器整形,以控制在合适的功率水平,从而沿较窄的切割线完成蒸发作用。激光辐射也宜根据预编程指令,快速扫描工件,并快速开关,从而能够沿任意形状的切割线进行切割。可用于此目的的商业激光***在市场上有LaserSharp牌激光处理模块,由LasX Industries Inc.,St.Paul,MN生产。这些模块采用CO2激光源,切割工件的工作波长约为10.6μm(约9.2-11.2μm)。
申请者还发现在激光辐射切割过程中产生的蒸发物质会在工件上积聚成碎屑。这些碎屑积聚的程度可使膜片不适合目标应用。为避免这个问题,可在激光切割前,在多层光学膜体上装上第一衬垫。如果第一衬垫和多层光学膜体保持紧密接触,则在切割步骤产生的任何碎屑都将积聚在第一衬垫上,而不是在多层光学膜体上。但在安装第一衬垫时,也宜使它容易得到清除,这样才能得到一片片干净的多层光学膜体。一种方法是在激光切割前,通过静电将第一衬垫安装到多层光学膜体上。随后,可中和至少部分静电荷,以减小衬垫与膜体之间的吸引力,从而方便其分离。或者,也可以用一薄层低黏性黏合剂粘贴,如即时贴上所用的那种。
在切割期间,激光辐射宜通过第一衬垫照射在多层光学膜体上。因此,除非第一衬垫不吸收所用波长的激光,第一衬垫也将被切成片,而且其形状基本上与多层光学膜体片一样,因为这两层紧密接触。也就是说,在受控激光将多层光学膜体切割成片的同时,它也将第一衬垫切割成基本上相同的片。第一衬垫宜用纸。纸受到激光辐射时挥发而不熔化,因此纸片不会黏结到相邻的各片多层光学膜体上。可用一层极薄(小于1密耳)的硅酮处理纸,但纸仍保留所需的这些性质。在此情况下,纸宜以用硅酮处理过的那一面接触多层光学膜体。也可以采用其他材料,只要它们在受到激光辐射时极少熔化或不熔化。
为方便搬运,可在多层光学膜体上安有第一衬垫的反面安装第二衬垫。另外,可适当选择衬垫并适当控制激光辐射,以便在至少部分切割线上获得所谓的“吻-切”效果,即第一衬垫和多层光学膜体在切割线上完全蒸发,而第二衬垫没有完全蒸发,即至少有一部分保持不变,宜完全保持不变。这样,各片独立的多层光学膜体形成后,仍能以有序结构搬运,并以网络或片材的形式送去快速加工。第二衬垫就是在多层光学膜体切割成片后,起支撑和运送作用的。注意,不管第二衬垫位于各膜体片上面还是下面,都能支撑和运送这些片。
图3就是这种情况的示意图。在此剖面图中,为方便期间,只示出了一层聚合物多层光学膜体40。第一衬垫42和第二衬垫44紧密贴合在膜体40相对的两个主表面上。所示衬垫44包含两个层44a和44b,其原因如下。激光辐射46a、46b、46c分别通过衬垫42照射到膜体40的切割线48a、48b、48c上。提供了合适的光束整形光学仪器,并控制功率(未示出),以便衬垫42和膜体40蒸发时形成狭小的缝隙,同时衬垫44基本保持不变。切割线和缝隙将多层膜体40分成片40a、40b、40c,将衬垫42分成对应的片42a、42b、42c。在图3中,各片衬垫42与各片多层膜体40保持紧密接触,例如通过静电引力或其他可逆附着方法。
切割线48a-c可同时形成,也可依次形成。上面提到的LaserSharp激光处理模块以单束激光扫描,辐射46a-c表示依次扫描的激光束。如上所述,其他切割技术可替代激光辐射,如旋转模切割和超声切割。
图4所示为可从多层光学膜体片40a-c上方便地清除覆盖了碎屑的衬垫片42a-c的技术。压敏胶带52与图3所示结构接触,从而使压敏黏合剂与第一衬垫42接触。如果膜42在激光切割过程中与膜体40通过静电作用贴合在一起,宜基本上中和静电作用或至少减少静电作用,使衬垫42与膜体40之间的吸引力明显小于衬垫42与胶带52之间的吸引力。接着,简单地将胶带52从膜体40上拉开,或反过来拉,即可将衬垫片42a-c迅速从膜体片40a-c上分离开。通过这种方法,可迅速、方便地清除数十、成百、上千的衬垫片。胶带52宜覆盖多层光学膜体40的整个宽度,以便同时接触一排要切割的片。
清除衬垫片42a-c后,多层光学膜体片40a-c也宜从第二衬垫44上揭下来。这可通过在膜体40和第二衬垫44之间形成较小的黏合力来完成。这种黏合力可通过静电或用少量低黏性压敏黏合剂来形成。黏合力要足够小,以便使衬垫44通过一个尖角落或将它弯折时,就能容易地剥开片40a-c,并轻轻地揭掉。
衬垫44宜包含至少两个层44a、44b,以利于吻-切。靠近多层光学膜体40的层44a宜由对激光辐射的吸收性明显小于膜体40的材料组成。由于吸收性低,层44a在用经过适当控制的激光进行切割的过程中很少发生或不发生蒸发。研究发现,厚度约为0.001英寸(25μm)或更小的聚乙烯材料足以适用于工作波长约为10.6μm的CO2激光切割***。但这种材料在切割线处容易因激光产生的热而变长或变形。如果衬垫44存在张力,并用来剥离激光切割区的多层光学膜体40,则衬垫层44a的拉伸或变形会导致片40a-c彼此错开,从而得到错位激光切割体。为此,层44b宜由模量较高的材料组成,如高模量黏合剂涂层纸,以保持膜体40和膜片40a-c在尺寸上的稳定性。
利用激光切割方法,可使多层光学膜体片40a-c的边缘基本上不发生脱层;通过利用第一和第二衬垫42、44,它们还具有没有碎屑的清洁主表面。激光辐射产生的热使微层边缘发生变形,正好使多层光学膜形成密封。
图5所示为一片聚合物多层光学膜体60的俯视图,它是从较大的聚合物多层光学膜体上切割下来的。片60的激光切割周边62a-d围成了一个拉长的条,它宜用图3所示吻-切法形成。可用其他激光切割方式进一步将多层光学膜体细分成滤光片组。边缘64a、64b是对位孔,用来将膜条安装在注模装置中。这些边缘也宜吻-切而成。点66确定了线性排列的孔,形成打孔线,以便沿这些线撕裂或剪切。在激光切割过程中,宜控制激光辐射,以便沿点66对多层光学膜体和第一、第二衬垫进行完整的通切(而不是简单的吻-切)。一个孔横断边62a,另一个孔横断边62c,从而在每条边上形成部分孔或凹口,以方便撕裂。
降低激光辐射强度,使蒸发程度不致穿透多层膜体60,从而形成熔化区68。这可通过使激光束散焦、降低激光功率并/或使激光更快地扫描工件来实现。尽管某些多层光学膜体可在熔化区68蒸发,至少部分多层光学膜体在熔化区68的厚度不变,但会因局部受热而变形。这种变形情况的例子有微层局部起皱或发生起伏,以及各微层的共混和缺失。当随后用剪切或拉伸机械工具沿打孔线将片60切割成更小的片时,可利用熔化区68防止脱层的蔓延。可参考美国专利申请10/268354,题目为《以熔化区控制脱层的多层光学膜》,登记于2002年10月10日。
如图5所示,熔化区68平行于膜条的宽度方向,并成对存在,交替形成活动窗区67和机械分离区69。在机械分离区69,可在点66所确定的位置打孔,当然也可以不打孔。不管是否打孔,与分离区69相接的熔化区68宜离开足够远的距离,这样,多层光学膜的连续段与每个熔化区相接,此连续段在激光切割过程中不发生变形,其方向平行于膜条的宽度方向。这些未变形多层光学膜段起缓冲区的作用,在用机械方法(例如,如果打了孔,则利用张力;或者用剪切方法)将窗口区67沿分离区69彼此分离时不发生脱层。
多层光学膜体也可包含一块或多块多层光学膜,它们牢固地附着在光学厚度较厚的外层上,在选择外层组成和厚度时,可使外层能经受温和的张力。外层可用透明聚合物制备,宜为聚酯,如聚对苯二甲酸乙二酯(PET)或聚萘二甲酸乙二酯(PEN)、聚碳酸酯,或它们的共聚物,但如果需要,可在外层中加入着色剂、吸收剂或扩散材料。可用黏性层将多层光学膜黏合到这种外层上。这样得到的多层光学膜体可夹在第一和第二可去除衬垫之间,然后可用激光辐射透过第一衬垫形成切割线。在激光切割期间,多层光学膜体这样放置,使可撕裂外层靠近第二衬垫,即离激光辐射最远。此外,可在至少部分切割线上控制激光辐射强度,从而仅部分切穿(蒸发)多层光学膜体,完全穿透多层光学膜,但可撕裂外层不动。激光切割过程完成并清除第一和第二衬垫之后,多层光学膜体由于外层没动而仍为连续片的形式,然后可简单地用手或用简单机械以中等力量沿切割线拉开膜片,从而方便地将光学膜体分成片。分片过程中的张力全部集中在可撕裂外层上。这种结构中的多层光学膜在分片过程中几乎不受张力作用,并且膜片周围的边缘得到密封。因此,多层光学膜在分片过程中发生脱层的可能性几乎为零。这里所述切割线在图3a和4a中用数字49a、49b、49c表示,类似于图3和4,只是所示多层光学膜体40有一个靠近第二衬垫44的可撕裂外层40d。这些切割线可代替图5中每对熔化区68和点66上的打孔线,以方便将窗口区67分成独立的片。周边62a-d(见图5)也可用这种切割线,或者,如果需要,可用激光辐射在图3-4所示位置切穿整个多层光学膜体(包括可撕裂外层)。
可借助边64a、64b确定的对位孔将一个或多个多层光学膜体片60置于注模机中。如图6中剖面图所示,可在片60周围的一系列盒子或框架114中形成熔融聚合物材料。冷却后,沿点66所确定的打孔线用机械方法切割多层膜体60,制成一个个滤光器装置。这些滤光器装置及其应用的详细情况见美国专利申请10/152546,题目是《光探测器***及其滤光器》,登记于2002年5月21日。滤光框可含有一个孔,以安装光探测器。光探测器/滤光器组合装置构成了光谱性质得到改进的探测***,这部分得自光探测器的光谱性质,部分得自多层光学膜的光谱透射性。
用所述方法将多层光学膜体片材细分成块时,该方法不限于形成这种材料的条形产品,以用于箱式滤光器。在由较大的片材或卷材形成一个或多个多层光学膜体片(特别是很多片,例如至少10片,至少50片,或至少100片)时,特别是当多层光学膜体边缘的脱层会带来麻烦,需要整片多层光学膜体的表面清洁时,都可以采用这种方法。
图7所示为干净、快速地将多层光学膜体片材转化为多层光学膜体片的卷-卷工艺200。展开卷202,提供层合膜204,该膜基本上由聚合物多层光学膜体(例如图3中的元件40)和黏着在多层光学膜体的一个主表面(姑且称作第二主表面)上的第二衬垫(例如图3中的衬垫44)。在未示出的前一步骤中,将第二衬垫装在多层光学膜体的第二主表面上,例如通过静电引力或利用少量低黏性黏合剂。层合膜204绕过惰辊206,这样多层光学膜体就与辊206接触。层合膜204接着穿过扭力驱动啮合辊208、210。第一衬垫212(例如图3中的元件42)从辊214上展开,由惰辊216带动,与层合膜204靠近,使膜通过传统的静电棒218,这样衬垫就贴合在层合膜204的多层光学膜体组分上。静电棒218提供的静电引力使第一衬垫与多层光学膜的第一主表面紧密接触。膜组合204/212(“网”)接着通过激光辐射站220,来自激光控制模块222的激光辐射网,将多层光学膜体和第一衬垫切成分立片224,如图3所示。平台226上有一些呈蜂窝状排列的孔,这些孔与真空源228连接,使网在激光切割期间沿其宽度(横穿网的方向)和大部分长度(纵穿网的方向)区域的平整度均匀。激光模块222包含光束整形和控制器件,可按具有预定图案的切割线进行切割,每条切割线都以预定功率设置切割,而网以恒定速率移动。或者,在激光模块222按具有第一种图案的切割线切割时,可使网停止移动,然后前进一段距离再停下来,使激光模块按具有第二种图案的切割线切割,如此以分步-重复的方式进行下去。激光辐射站220宜包含排气罩230,其结构适合于沿指定方向为网提供强气流。气流有助于减少激光切割时产生的烟和碎屑引起的光学变形。在切割期间,激光模块222中的光束控制器件宜使激光切割点在网上沿这种方向移动,即基本上没有光线平行于气流的方向,从而进一步避免烟和碎屑引起变形。
网从激光辐射站220出来,部分切割成片224后,立即从传统中和棒232附近通过。中和棒可消除或至少减少层合膜204的多层光学膜体片和第一衬垫片212之间的静电引力。对应片之间的结合力受到削弱后,胶带234从卷236上展开,通过一对啮合辊233、235,胶带234上涂有黏合剂的一面压向第一衬垫的不连续片224a。收卷238沿一个方向拉胶带234,另一个收卷240沿另一个方向拉网,胶带234将粘有碎屑的第一衬垫片224a从原始多层光学膜体片224b上分开并带走。然后用涂有硅酮的PET衬垫242将网松散地卷起,在存储和搬运过程中起临时保护的作用。在后面的步骤中,可大幅度弯折第二衬垫,使松散地卷起的多层光学膜体片224b完全从第二衬垫上分开。
可以恒定速度驱动啮合辊233、235,作为卷-卷***200的速度环。根据激光模块222制备的切割线的数量、密度、方向和类型,网(即膜组合204/212)的强度在激光辐射站220受到很大削弱。为防止网破裂,宜在网上至少留下一条,更宜在网的每边留一条保持连续,不进行切割,以增加其强度。这种连续网条在这里称作“杂边”,可在通过啮合辊233、235之后立即扔掉,在图中用数字244表示。
图8为网250——包含夹在第一和第二衬垫之间的聚合物多层光学膜体——在激光辐射站220(见图7)上的顶视图。网250沿方向252移动。排气罩230形成气流,气流方向254垂直于网。将网250隔离成中央工作部分250a和杂边部分250b,这些部分是通过切割线256从工作部分250a上分离出来的。如果切割线256是通切线,则可对网起到一定的增强作用。如果它们是吻切线,则可进一步增加其强度,因为在这种情况下,下面的衬垫44在工作部分250a和杂边部分250b之间是完整的。其他切割线——宜为吻切线——确定了要切成片的代表性形状258、260。为减少烟和蒸发材料引起的变形,可安排激光模块222沿所示优选方向258a、260a-b扫描激光切割点,其中有些方向反平行于气流方向254。
任选地,网250在其每条边上有两个分开的杂边部分,即图8左边的左外侧杂边部分和图8右边的右外侧杂边部分。通过激光模块222形成的另一个贯通切口将这种外侧杂边部分从杂边部分250b上分开,后者可描述为内杂边部分,并利用吻切线256。如果存在,外侧杂边部分可从内侧杂边部分分开,通过激光切割站220后立即收集起来。这些外侧杂边部分有助于最终的成卷产品形成干净、均匀的边缘。同时,内侧杂边部分与剩余部分的网一起通过上述啮合辊233、235。
实施例
聚合物多层干涉膜通过如下方法制备:在约277℃共挤出低熔点共PEN和聚甲基丙烯酸甲酯(PMMA)交替层,形成的挤出物包含224个单层,这些单层夹在两个由低熔点共PEN组成的外表层之间,其中共PEN由90/10的聚萘二甲酸乙二酯(PEN)/聚对苯二甲酸乙二酯(PET)共聚物制成。这些层确定了基本上由112个单胞组成的光学组件,其沿垂直于堆积结构的轴存在大致呈线性变化的厚度梯度。位于组件一侧的最厚单胞比位于组件另一侧的最薄单胞约厚1.3倍。对光学组件进行不对称加倍,得到含有448个单层的多层光学膜结构,2外表层和内聚合物界层(PBL)位于组件之间。层加倍后,一个光学组件的总厚度约为另一个组件的1.3倍。挤出物在冷却辊上淬火,形成铸塑多层膜。随后沿纵向(MD)和横向(TD)拉伸铸塑膜,拉伸比均为3.4∶1,最终得到的膜在共PEN层的平面内折射指数(n1x、n1y)和平面外折射指数(n1z)分别约为1.744、1.720和1.508,PMMA层的平面内折射指数(n2x、n2y)和平面外折射指数(n2z)分别约为1.495、1.495和1.495。所有指数都用Metricon表面波表征仪器在550nm下测定。最终的膜包含两个光学组件,每个厚度为1/4波长,每个组件沿垂直于膜平面的轴向存在大致呈线性变化的厚度梯度,因而各自能够反射一定波长范围内的光。最终膜中最厚的单胞的厚度约为最薄单胞的1.8倍,对应的反射波长范围约在665-1220nm之间。光学结构外侧的表层是低熔点共PEN,厚度约为11μm(0.43密耳)。总膜厚约为90μm(3.7密耳)。
根据光学性质选择用上述方法制备的两卷基本相同的多层膜,用电晕处理,以提高黏着力。在其中一卷用电晕处理过的膜上涂敷可用UV引发的黏合剂,厚度约122μm(5密耳),然后用UV光照射,激发黏合剂的固化过程。用热熔挤出法制备的黏合剂是热塑性组分(乙烯-乙烯乙酸酯)、可固化树脂组分(环氧化物和多元醇的混合物)和光引发组分(三芳基锍六氟锑酸盐)的均相混合物。然后将两个多层膜层压在一起,在25℃(80°F)热浸泡10分钟,以加速层合黏合剂的固化。所得膜体由两个多层光学膜组成,中间夹有透明黏合剂层。该元件以成卷的形式存在,厚度约为12.4密耳(300μm),宽度约为4英寸(100mm),长度至少约为50英尺(超过10米)。
对于普通入射光,这样得到的膜体或干涉元件在近红外区有一个反射段,而在可见光区则表现为透射段。在约450-640nm范围内的透光率约为70%,在约700-1140nm范围内的透光率小于1%,在680-700nm和1140-1160nm范围内的透光率小于5%。
第二个衬垫是高模量纸,用强压敏黏合剂在它上面黏着了一薄层聚乙烯。纸的厚度约为2密耳(50μm),聚乙烯层的厚度约为1密耳(25μm),第二个衬垫的总厚度约为3密耳(75μm)。涂有黏合剂的纸购自TLC Industrial Tape,Hardwood Heights,Illinois,零件号为CT1007。用啮合辊通过连续工艺将聚乙烯层层压到多层光学膜体的一个主表面上。在另一个步骤中,涂有黏合剂的纸层压到聚乙烯层上。(或者,聚乙烯层在与多层光学膜体接触的面上可包含一个低黏性黏合剂,然后再进行同样的步骤。)将它卷起来,存放数天。
第一个衬垫是厚度约为2密耳(50μm)的高摸量纸,一面用硅酮处理。该纸购自Litin Paper Company,Minneapolis,Minnesota。
基本上按照图7所述方法加工这些元件,产生大致如图5所示的许多条状产物,不同之处是采用了更多的切割线和熔化区,划分了8个活性窗口67,而不是4个,其他不同点如下所述。这些膜条宽约4.5mm,长约69mm,长度方向平行于网的纵向,熔化区平行于网的横向。(或者膜条平行于网的横向。)限制穿孔线的熔化区彼此间隔约1.5mm,限制窗口区域的熔化区彼此间隔约5.5mm。纸衬垫上用硅酮处理过的一面与层合膜204接触。采用恒定的网速,约2-3ft/min(0.01-0.015m/s)。网穿过静电棒218约1/2英寸(10mm),将静电棒控制在刚好低于电弧点的条件下。网同样以类似距离通过中和棒232。在激光辐射站220,采用LaserSharp牌激光加工模块,型号为LPM300。CO2激光的光斑直径约为8密耳(0.2mm),这样制得的吻切和通切线宽约13-14密耳(0.35mm)。以下类型的切割线采用如下条件:
切割线/特征 | 加工速度(mm/s) | 频率(kHz) |
吻切(CW) | 1100 | 20 |
吻切(DW) | 875 | 20 |
穿孔切(CW) | 950 | 2.2 |
通切(DW) | 600 | 20 |
熔化区(CW) | 1800 | 20 |
在此表中,“CW”指横向切割线,“DW”指纵向切割线。此外,功率设为100%,负载循环设定为50%,每种特征下的跳跃速度设定为5000mm/s。CW吻切条件用于切割膜条的次边缘62b、62d(见图5),DW吻切条件用于切割膜条的主边缘62a、62c,以及圆形边缘64a、64b,CW穿孔条件用于打孔66,DW通切条件用于将工作部分从杂边部分分开的切割线(图8中的线256),CW熔化区条件用于熔化区68。在熔化区条件产生的熔化区中,上多层光学膜(即靠近第一衬垫的多层光学膜)沿第一衬垫完全蒸发,而下多层光学膜(靠近第二衬垫的多层光学膜)不发生变化,但其组成层发生明显的变形/起伏。
如图8所示,对于杂边部分,网的两边之一采用连续段,不同之处是在工作部分的每条边上形成内外杂边部分,如前所述。每个内杂边部分的宽度约为1/8英寸(约3mm)。可将此与网的中央工作部分做比较,该部分的宽度约为3-3.5英寸(约75-90mm)。外侧杂边部分大约宽1/2英寸(约10mm)。将外侧杂边部分同网的剩余部分分开,在激光辐射站220和中和棒232之间收集起来。在激光辐射站220的纵向,胶带234采用连续单边黏性胶带,其宽度约等于网的中央工作部分的宽度。胶带是常见的3MTM油漆遮蔽带。内侧杂边部分通过啮合辊233、235之后迅速与第二衬垫分离,然后连同胶带和第二衬垫一起卷在卷辊238上。各片(条)多层光学膜体很容易用手从第二衬垫上取下来。经检查,各膜片在激光切割边上几乎没有发生脱层现象。用手施加中等大小的张力,膜片可沿打孔线发生断裂,从而得到更小的膜片。这样切割的边缘经检查后,发现有脱层现象,但没有蔓延到熔化区68。
对于本领域的技术人员来说,在不背离本发明的范围和实质的情况下,很容易对本发明做出各种改进和变通。应当理解,本发明不受限于这里所述示例性实施方式。
Claims (22)
1.细分多层光学膜体的方法,它包括:
展开一卷多层光学膜体,提供至少包含一块多层光学膜的多层光学膜体;
在多层光学膜体相对的两个主表面上安装第一和第二衬垫;
透过第一衬垫在多层光学膜体上辐射激光,激光辐射可产生许多切割线,使第一衬垫和多层光学膜体形成许多小片;
从各片多层光学膜体上去除第一衬垫片,这时各片多层光学膜体由第二衬垫支撑;
在辐射和去除步骤之后,将多层光学膜体和第二衬垫卷成一卷。
2.权利要求1所述方法,其特征在于至少部分切割线完全穿过多层光学膜体,但没有完全穿过第二衬垫。
3.将多层光学膜体切割成许多分立小片的方法,它包括:
提供包含至少一块多层光学膜的多层光学膜体;
在多层光学膜体上安装第一衬垫;
通过第一衬垫且至少部分通过多层光学膜体形成切割线,这些切割线形成许多分立小片;
从各片多层光学膜体上去除第一衬垫片;
至少在形成切割线和去除第一衬垫片的过程中,以第二衬垫支撑多层光学膜体;
在形成和去除步骤之后,将多层光学膜体和第二衬垫卷成一卷。
4.权利要求3所述方法,其特征在于切割线通过激光辐射形成。
5.权利要求1或4所述方法,其特征在于第一衬垫通过静电作用安装在多层光学膜体上。
6.权利要求5所述方法,其特征在于它还包括在清除第一衬垫之前减小第一衬垫与多层光学膜体之间的静电引力。
7.权利要求6所述方法,其特征在于减小静电引力的步骤包括使第一衬垫和多层光学膜体近距离通过中和棒。
8.权利要求1或4所述方法,其特征在于提供多层光学膜体的步骤包括连续展开一卷多层光学膜体。
9.权利要求1或4所述方法,其特征在于安装衬垫的步骤包括连续展开一卷第一衬垫。
10.权利要求8所述方法,其特征在于安装衬垫的步骤包括使第一衬垫和多层光学膜体近距离通过静电棒。
11.权利要求1或4所述方法,其特征在于清除衬垫的步骤包括展开一卷胶带,使第一衬垫片与胶带接触,卷起黏着了第一衬垫片的胶带。
12.权利要求1或4所述方法,其特征在于多层光学膜体包含聚合物微层。
13.权利要求1或4所述方法,其特征在于第一衬垫包含纸层。
14.权利要求13所述方法,其特征在于第一衬垫基本上由纸层组成。
15.权利要求13所述方法,其特征在于通过静电作用将第一衬垫贴合到多层光学膜体上。
16.权利要求1或4所述方法,其特征在于第二衬垫包含纸层和聚合物层。
17.权利要求1或4所述方法,其特征在于控制激光辐射,使至少某些切割线不穿过第二衬垫。
18.权利要求1所述方法,其特征在于辐射步骤在激光切割站上进行,辐射步骤还包括:
沿穿过激光站的第一方向提供气流。
19.权利要求4所述方法,其特征在于形成切割线的步骤在激光切割站进行,形成切割线的步骤还包括:
沿穿过激光切割站的第一方向提供气流。
20.权利要求18或19所述方法,其特征在于激光辐射相对于多层光学膜体移动时,基本上没有辐射方向平行于第一方向。
21.权利要求1或4所述方法,其特征在于多层光学膜体包含可撕裂外层,至少有些切割线通过至少一块多层光学膜形成,但没有穿过可撕裂外层。
22.用权利要求1或4所述方法制备的多层光学膜体片。
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US10/152,412 US20030218278A1 (en) | 2002-05-21 | 2002-05-21 | Method for subdividing multilayer optical film cleanly and rapidly |
US10/268,118 | 2002-10-10 | ||
US10/268,118 US6991695B2 (en) | 2002-05-21 | 2002-10-10 | Method for subdividing multilayer optical film cleanly and rapidly |
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- 2003-04-30 KR KR10-2004-7018725A patent/KR20050006263A/ko not_active Application Discontinuation
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- 2003-04-30 AT AT03721949T patent/ATE347127T1/de not_active IP Right Cessation
- 2003-04-30 DE DE60310064T patent/DE60310064T2/de not_active Expired - Fee Related
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- 2003-05-14 TW TW092113070A patent/TWI278717B/zh not_active IP Right Cessation
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2006
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CN101809486B (zh) * | 2007-12-27 | 2011-11-30 | 日东电工株式会社 | 光学显示装置的制造***及制造方法 |
CN101462205B (zh) * | 2009-01-13 | 2011-12-07 | 包头高源激光科技发展有限公司 | 非晶态合金带材的激光切割方法 |
CN104520916A (zh) * | 2012-08-08 | 2015-04-15 | 住友化学株式会社 | 光学显示器件的生产***以及生产方法 |
CN104520916B (zh) * | 2012-08-08 | 2016-10-26 | 住友化学株式会社 | 光学显示器件的生产***以及生产方法 |
CN108145320A (zh) * | 2017-12-29 | 2018-06-12 | 南京联信自动化科技有限公司 | 一种数码产品装饰贴膜的切割方法 |
CN112201826A (zh) * | 2020-09-27 | 2021-01-08 | 无锡先导智能装备股份有限公司 | 浸泡池组件及膜材浸泡设备 |
Also Published As
Publication number | Publication date |
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EP1508069B1 (en) | 2006-11-29 |
ATE347127T1 (de) | 2006-12-15 |
US6991695B2 (en) | 2006-01-31 |
DE60310064D1 (de) | 2007-01-11 |
TWI278717B (en) | 2007-04-11 |
JP2005526997A (ja) | 2005-09-08 |
KR20050006263A (ko) | 2005-01-15 |
AU2003225231A1 (en) | 2003-12-12 |
TW200404674A (en) | 2004-04-01 |
US20030217806A1 (en) | 2003-11-27 |
DE60310064T2 (de) | 2007-06-21 |
EP1508069A1 (en) | 2005-02-23 |
WO2003100521A1 (en) | 2003-12-04 |
US20060191630A1 (en) | 2006-08-31 |
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