US20060191630A1 - Method for subdividing multilayer optical film cleanly and rapidly - Google Patents

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.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application is a continuation of U.S. application Ser. No. 10/268,118, filed Oct. 10, 2002, which is a continuation-in-part of U.S. application Ser. No. 10/152,412, filed May 21, 2002, now abandoned and claims priority thereto.
FIELD OF THE INVENTION
• The present invention relates to methods of cutting or subdividing an optical body comprising a multilayer optical film into a plurality of smaller pieces.
BACKGROUND
• Multilayer optical films, i.e., films that provide desirable transmission and/or reflection properties at least partially by an arrangement of microlayers of differing refractive index, are known. It has long been known to make such multilayer optical films by depositing a sequence of inorganic materials in optically thin layers (“microlayers”) on a substrate in a vacuum chamber. Typically, the substrate is a relatively thick piece of glass, limited in size due to constraints on the vacuum chamber volume and/or the degree of uniformity possible by the deposition process.
• More recently, multilayer optical films have been demonstrated by coextrusion of alternating polymer layers, See, e.g., U.S. Pat. No. 3,610,729 (Rogers), U.S. Pat. No. 4,446,305 (Rogers et al.), U.S. Pat. No. 4,540,623 (Im et al.), U.S. Pat. No. 5,448,404 (Schrenk et al.), and U.S. Pat. No. 5,882,774 (Jonza et al.), the disclosures of which are incorporated herein by reference in their entireties. In these polymeric multilayer optical films, polymer materials are used predominantly or exclusively in the makeup of the individual layers. Such films are compatible with high volume manufacturing processes, and can be made in large sheets and roll goods.
• Many product applications, however, require relatively small and numerous pieces of film. Filters for individual photodiode detectors is one such application. Windows, reflectors, and/or filters for fiber optic devices and other small-scale photonics devices are additional applications. For these applications, small pieces of multilayer optical film can be obtained from a larger sheet of such film by subdividing the sheet by mechanical means, such as by cutting the sheet with a shearing device (e.g., a scissors), or slitting the sheet with a blade. However, the forces exerted on the film by the cutting mechanism can produce layer delamination in a region along the cut line or edge of the film. This is particularly true for many polymeric multilayer optical films. The delamination region is often discernable by a discoloration relative to intact areas of the film. Because the multilayer optical film relies on intimate contact of the individual layers to produce the desired reflection/transmission characteristics, the delamination region fails to provide those desired characteristics.
• In some product applications, the delamination may not be problematic or even noticeable. In others—particularly where it is important for substantially the entire piece of film from edge to edge to exhibit the desired reflection or transmission characteristics, or where the film can be subjected to mechanical stresses and/or wide temperature variations that could cause the delamination to propagate in the film over time—the delamination can be highly detrimental.
• There exists, therefore, a need for an improved method for subdividing multilayer optical film and articles comprising such film. Preferably, the method would not produce delamination at the cut lines or film edges, would cut the film cleanly without substantial debris accumulation on the film, and would be compatible with automated and/or continuous manufacturing processes.
BRIEF SUMMARY
• The present application discloses methods of subdividing or cutting a multilayer optical film body comprising a multilayer optical film into one or more discrete pieces. In a simple case, the multilayer optical film body consists essentially of a multilayer optical film. In other cases the multilayer optical film body can also comprise one or more additional layers laminated to the multilayer optical film. A first and second liner are removably applied to opposed major surfaces of the multilayer optical film body. Preferably, laser radiation is then directed at the film body through one of the liners (arbitrarily designated 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 film body. Typically, the laser radiation produces a plume of smoke and debris that deposits on the workpiece—in this case, on the first liner. Thereafter, the plurality of pieces of the first liner (with accompanying debris) are removed 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. The removal can be accomplished by contacting the first liner with an adhesive tape and pulling the tape away from the multilayer optical film body.
• Preferably, at least the first liner is applied to the film body using electrostatics. After the cut lines are formed with the laser radiation and before removal of the pieces of the first liner from the pieces of multilayer optical film body, a neutralizer member can be used to reduce the electrostatic attraction between the first liner and the multilayer optical film body.
• Although laser radiation is a preferred technique for cutting the film body, alternative approaches such as rotary die cutting and ultrasonic cutting may also be suitable in some cases.
BRIEF DESCRIPTION OF THE DRAWINGS
• Throughout the specification reference is made to the appended drawings, where like reference numerals designate like elements, and wherein:
• FIG. 1 is a greatly magnified perspective view of a multilayer optical film body;
• FIG. 2 is a plan view of a sheet of multilayer optical film body, with broken cut lines indicating how it is to be subdivided;
• FIG. 3 is a sectional view of a multilayer optical film body disposed between an upper and lower liner, the figure further depicting electromagnetic radiation forming gaps at cut lines that define discrete pieces of the multilayer optical film body and of the upper liner;
• FIG. 4 is a sectional view similar toFIG. 3, but where an adhesive film has been applied to the upper liner so that it can remove the pieces of upper liner from the pieces of multilayer optical film body;
• FIGS. 3aand4aare similar toFIGS. 3 and 4 respectively except that the former figures include cut lines that extend completely through the microlayers of the multilayer optical film(s) in the film body but do not extend completely through an optically thick tearable outer layer the film body;
• FIG. 5 is a plan view of a piece of multilayer optical film body cut from a larger sheet;
• FIG. 6 is a sectional view through the piece of multilayer optical film body ofFIG. 5 with a plurality of filter frames attached thereto;
• FIG. 7 depicts a continuous process for subdividing a multilayer optical film body; and
• FIG. 8 shows a plan view of multilayer optical film body as it is being cut.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
• As used herein, “film” refers to an extended optical body whose thickness is generally no more than about 0.25 mm (10 thousandths of an inch, or “mils”). In some instances a film can be attached or applied to another optical body such as a rigid substrate or another film having suitable reflection or transmission properties. The film can also be in a physically flexible form, whether it is free-standing or attached to other flexible layer(s). The term “film body” as used herein shall mean a film whether by itself or in combination with other components, such as in a laminate construction.
• FIG. 1 depicts a multilayeroptical film body20. The film body comprisesindividual microlayers22,24. The microlayers have different refractive index characteristics so that some light is reflected at interfaces between adjacent microlayers. The microlayers are sufficiently thin so that light reflected at a plurality of the interfaces undergoes constructive or destructive interference in order to give the film body the desired reflective or transmissive properties. For optical films designed to reflect light at ultraviolet, visible, or near-infrared wavelengths, each microlayer generally has an optical thickness (i.e., a physical thickness multiplied by refractive index) of less than about 1 μm. However, thicker layers can also be included, such as skin layers at the outer surfaces of the film, or protective boundary layers disposed within the film that separate packets of microlayers. Multilayeroptical film body20 can also comprise one or more thick adhesive layers to bond two or more sheets of multilayer optical film in a laminate.
• The reflective and transmissive properties of multilayeroptical film body20 are a function of the refractive indices of the respective microlayers. Each microlayer can be characterized at least at localized positions in the film by in-plane refractive indices n_x, n_y, and a refractive index nz associated with a thickness axis of the film. These indices represent the refractive index of the subject material for light polarized along mutually orthogonal x-, y-, and z-axes, respectively (seeFIG. 1). In practice, the refractive indices are controlled by judicious materials selection and processing conditions.Film body20 can be made by co-extrusion of typically tens or hundreds of layers of two alternating polymers A, B, followed by optionally passing the multilayer extrudate through one or more multiplication die, and then stretching or otherwise orienting the extrudate to form a final film. The resulting film is composed of typically tens or hundreds of individual microlayers whose thicknesses and refractive indices are tailored to provide one or more reflection bands in desired region(s) of the spectrum, such as in the visible or near infrared. In order to achieve high reflectivities with a reasonable number of layers, adjacent microlayers preferably exhibit a difference in refractive index (Δn_x) for light polarized along the x-axis of at least 0.05. If the high reflectivity is desired for two orthogonal polarizations, then the adjacent microlayers also preferably exhibit a difference in refractive index (Δn_y) for light polarized along the y-axis of at least 0.05. Otherwise, the refractive index difference Δn_ycan be less than 0.05 and preferably about 0 to produce a multilayer stack that reflects normally incident light of one polarization state and transmits normally incident light of an orthogonal polarization state.
• If desired, the refractive index difference (Δn_z) between adjacent microlayers for light polarized along the z-axis can also be tailored to achieve desirable reflectivity properties for the p-polarization component of obliquely incident light. For ease of explanation in what follows, at any point of interest on an interference film the x-axis will be considered to be oriented within the plane of the film such that the magnitude of Δn_x, is a maximum. Hence, the magnitude of Δn_ycan be equal to or less than (but not greater than) the magnitude of Δn_x. Furthermore, the selection of which material layer to begin within calculating the differences Δn_x, Δn_y, Δn_zis dictated by requiring that Δn_xbe non-negative. In other words, the refractive index differences between two layers forming an interface are Δn_j=n_1j−n_2j, where j=x, y, or z and where the layer designations1,2 are chosen so that n_1x≧n_2x, i.e., Δn_x≧0.
• To maintain high reflectivity of p-polarized light at oblique angles, the z-index mismatch Δn_zbetween microlayers can be controlled to be substantially less than the maximum in-plane refractive index difference Δn_x, such that Δn_z≦0.5*Δn_x. More preferably, Δn_z≦0.25*Δn_x. A zero or near zero magnitude z-index mismatch yields interfaces between microlayers whose reflectivity for p-polarized light is constant or near constant as a function of incidence angle. Furthermore, the z-index mismatch Δn_zcan be controlled to have the opposite polarity compared to the in-plane index difference Δn_x, i.e. Δn_z<0. This condition yields interfaces whose reflectivity for p-polarized light increases with increasing angles of incidence, as is the case for s-polarized light.
• Exemplary materials that can be used in the fabrication of polymeric multilayer optical film can be found in PCT Publication WO 99/36248 (Neavin et al.), incorporated herein by reference. Desirably, at least one of the materials is a polymer with a stress optical coefficient having a large absolute value. In other word, the polymer preferably develops a large birefringence (at least about 0.05, more preferably at least about 0.1 or even 0.2) when stretched. Depending on the application of the multilayer film, the birefringence can be developed between two orthogonal directions in the plane of the film, between one or more in-plane directions and the direction perpendicular to the film plane, or a combination of these. In special cases where isotropic refractive indices between unstretched polymer layers are widely separated, the preference for large birefringence in at least one of the polymers can be relaxed, although birefringence is still often desirable. Such special cases may arise in the selection of polymers for mirror films and for polarizer films formed using a biaxial process, which draws the film in two orthogonal in-plane directions. Further, the polymer desirably is capable of maintaining birefringence after stretching, so that the desired optical properties are imparted to the finished film. A second polymer ran be chosen for other layers of the multilayer film so that in the finished film the refractive index of the second polymer, in at least one direction, differs significantly from the index of refraction of the first polymer in the same direction. For convenience, the films can be fabricated using only two distinct polymer materials, and interleaving those materials during the extrusion process to produce alternating layers A, B, A, B, . . . , as shown inFIG. 1. Interleaving only two distinct polymer materials is not required, however. Instead, each layer of a multilayer optical film can be composed of a unique material or blend not found elsewhere in the film. Preferably, polymers being coextruded have the same or similar melt temperatures.
• Exemplary two-polymer combinations that provide both adequate refractive index differences and adequate inter-layer adhesion include: (1) for polarizing multilayer optical film made using a process with predominantly uniaxial stretching, PEN/coPEN, PET/coPET, PEN/sPS, PET/sPS, PEN/Eastar,™ and PET/Eastar,™ where “PEN” refers to polyethylene naphthalate, “coPEN” refers to a copolymer or blend based upon naphthalene dicarboxylic acid, “PET” refers to polyethylene terephthalate, “coPET” refers to a copolymer or blend based upon terephthalic acid, “sPS” refers to syndiotactic polystyrene and its derivatives, and Eastar™ is a polyester or copolyester (believed to comprise cyclohexanedimethylene diol units and terephthalate units) commercially available from Eastman Chemical Co.; (2) for polarizing multilayer optical film made by manipulating the process conditions of a biaxial stretching process, PEN/coPEN, PEN/PET, PEN/PET, PEN/PETS and PEN/PETcoPET, where “PET” refers to polybutylene terephthalate, “PETG” refers to a copolymer of PET employing a second glycol (usually cyclohexanedimethanol), and “PETcoPBT” refers to a copolyester of terephthalic acid or an ester thereof with a mixture of ethylene glycol and 1,4-butanediol; (3) for mirror films (including colored mirror films), PEN/PMMA, coPEN/PMMA, PET/PMMA, PEN/Ecdel,™ PET/Ecdel,™ PEN/sPS, PET/sPS, PEN/coPET, PEN/PETG, and PEN/THV,™ “PMMA” refers to polymethyl methacrylate, Ecdel™ is a thermoplastic polyester or copolyester (believed to comprise cyclohexanedicarboxylate units, polytetramethylene ether glycol units, and cyclohexanedimethanol units) commercially available from Eastman Chemical Co., and THV™ is a fluoropolymer commercially available from 3M Company.
• Further details of suitable multilayer optical films and related constructions can be found in U.S. Pat. No. 5,882,774 (Jonza et al.), and PCT Publications WO 95/17303 (Ouderkirk et al.) and WO 99/39224 (Ouderkirk et al.), all of which are incorporated herein by reference. Polymeric multilayer optical films and film bodies can comprise additional layers and coatings selected for their optical, mechanical, and/or chemical properties. See U.S. Pat. No. 6,368,699 (Gilbert et al.). The polymeric films and film bodies can also comprise inorganic layers, such as metal or metal oxide coatings or layers.
• In a simple embodiment, the microlayers can have thicknesses corresponding to a ¼-wave stack, i.e., arranged in optical repeat units or unit cells each consisting essentially of two adjacent microlayers of equal optical thickness (f-ratio=50%), such optical repeat unit being effective to reflect by constructive interference light whose wavelength λ is twice the overall optical thickness of the optical repeat unit. Such an arrangement is shown inFIG. 1, wheremicrolayer22 of polymer A adjacent to microlayer24 of polymer13 forms a unit cell oroptical repeat unit26 that repeats throughout the stack. Thickness gradients along a thickness axis of the film (e.g., the z-axis) can be used to provide a widened reflection band. Thickness gradients tailored to sharpen such band edges can also be used, as discussed in U.S. Pat. No. 6,157,490 (Wheatley et al.), also incorporated herein by reference.
• Other layer arrangements, such as multilayer optical films having 2-microlayer optical repeat units whose f-ratio is different from 50%, or films whose optical repeat units consist essentially of more than two microlayers, are also contemplated. These alternative optical repeat unit designs can reduce or eliminate certain higher-order reflections. See, e.g., U.S. Pat. No. 5,360,659 (Arends et al) and U.S. Pat. No. 5,103,337 (Schrenk et al.).
• FIG. 2 shows a portion of a sheet of a multilayeroptical film body30 in plan view.Film body30 is manufactured and sold or supplied in transverse dimensions that are larger than desired for a particular end-use application. Subdividing thefilm body30 into a smaller piece or pieces is therefore required to adapt the film to the application. The desired size and shape of the pieces can vary widely. For simplicity,FIG. 2 shows pieces defined by two intersecting sets of parallel cut lines, labeled32 and34. If both sets of cut lines are used,film body30 is converted into discrete rectangular (including square) or parallelogram-shaped pieces that extend in two directions, i.e., the length and width offilm30. If only one of the sets is used, the pieces become elongated rectangular strips. Of course, the cut lines need not be straight, and can include curves, bends, angles, and straight sections in any combination. Often, however, simple shapes such as circles, rectangles, parallelograms, or other polygons are all that is required.
• Applicants have found laser radiation to be useful in cutting and subdividing polymeric multilayer optical film bodies without any substantial delamination at the cut lines. The laser radiation is selected to have a wavelength at which at least some of the materials of the optical film have substantial absorption so that the absorbed electromagnetic radiation can vaporize the film body along the cut line. Otherwise, the laser radiation would be transmitted or reflected by the film just as other incident light, whose wavelength is within an intended operating range of the film. The laser radiation is also shaped with suitable focusing optics and controlled to suitable power levels to accomplish the vaporization along a narrow cut line. Preferably, the laser radiation can also be rapidly scanned across the workpiece according to preprogrammed instructions, and switched on and off rapidly so that cut lines of arbitrary shape can be followed. Commercially available systems found to be useful in this regard are being marketed as the LaserSharp brand of laser processing modules, sold by LasX Industries Inc., St. Paul, Minn. These modules use a CO₂laser source operating at a wavelength of about 10.6 μm (from about 9.2-11.2 μm) to cut the workpiece.
• Applicants have also found that vaporized material created during the laser radiation cutting process can accumulate as debris on the workpiece. Such debris can accumulate to an extent that makes the piece of film unacceptable for the intended application. To avoid this problem, a first liner can be applied to the multilayer optical film body before the laser cutting operation. If intimate contact is maintained between the first liner and the multilayer optical film body, any debris created during the cutting step accumulates on the first liner rather than on the multilayer optical film body. The first liner, however, is also preferably applied in a way that permits it to be readily removed so that a clean piece of multilayer optical film body can be obtained. In one approach, the first liner can be applied to the multilayer optical film body electrostatically prior to laser cutting. The electrostatic charge can later be at least partially neutralized to reduce the attraction of the liner to the film body and thus permit the separation thereof. Alternatively, a thin layer of low tack adhesive can be used, such as the type used for repositionable office notes.
• During cutting, the laser radiation is preferably directed at the multilayer optical film body through the first liner. Therefore, unless the first liner is non-absorbing at the laser wavelength, the first liner will be cut into pieces substantially identical to the pieces of the multilayer optical film body since the two layers are in intimate contact. That is, as the laser radiation is controlled to cut distinct pieces of the multilayer optical film body, it simultaneously cuts substantially identical pieces of the first liner. A preferred first liner is paper. Paper vaporizes but does not melt upon exposure to the laser radiation, and thus the pieces of paper do not become bonded to the adjacent pieces of multilayer optical film body. The paper can be treated with a very thin (well under 1 mil) layer of silicone and still retain these desirable properties. In such case the silicone-treated side of the paper preferably contacts the multilayers optical film body. Other materials that exhibit minimal or no melting upon exposure to the laser radiation can also be used.
• For convenience in handling, a second liner can be applied to the multilayer optical film body on a side thereof opposed to the first liner. Moreover, by appropriate selection of liners and appropriate control of laser radiation, a so-called “kiss-cut” can be achieved along at least some of the cut lines, whereby the first liner and the multilayer optical film body are completely vaporized at the cut line, but the second liner is not completely vaporized but instead is at least partially intact, and preferably substantially fully intact. In this way, the distinct pieces of the multilayer optical film body can be formed but can still be carried in an ordered arrangement and handled as a web or sheet for rapid processing. The second liner serves as a substrate for supporting and carrying the individual pieces after they have been cut Note that the second liner can support and carry the individual pieces whether it is oriented above or below such pieces.
• FIG. 3 is illustrative in this regard. In the sectional view of that figure, a polymeric multilayeroptical film body40 is depicted as a single layer for simplicity. Afirst liner42 and asecond liner44 have been applied to be in intimate contact with opposed major surfaces of thefilm body40.Liner44 is shown as comprising twolayers44a,44b, for reasons discussed below.Laser radiation46a,46b,46cis directed atfilm body40 throughliner42 atcut lines48a,48b,48crespectively. Suitable beam shaping optics mid power control (not shown) are provided so that narrow gaps are formed as shown by vaporization ofliner42 andfilm body40, whileliner44 remains substantially intact. Some of the vaporized material accumulates asdebris50 onfirst liner42. The cut lines and gaps definedistinct pieces40a,40b,40cofmultilayer film body40 and correspondingpieces42a,42b,42cofliner42. InFIG. 3 the pieces ofliner42 remain in intimate contact with the pieces ofmultilayer film body40 such as by electrostatic attraction or other reversible attachment mechanism.
• Cut lines48a-ccan be formed simultaneously or sequentially. The LaserSharp laser processing modules mentioned above scan a single beam of laser radiation, whereby radiation46a-crepresent sequential scans of the beam. As mentioned above, other cutting techniques such as rotary die cutting and ultrasonic cutting may be acceptable alternatives to laser radiation.
• FIG. 4 depicts a technique for conveniently removing the debris-coatedliner pieces42a-cfrom the multilayer opticalfilm body pieces40a-c. A pressure sensitiveadhesive tape52 is placed in contact with the construction ofFIG. 3 such that the pressure sensitive adhesive contacts thefirst liner42. Iffilm42 is held to filmbody40 electrostatically during laser cutting, the electrostatic forces are preferably substantially neutralized or at least reduced such that the attractive force betweenliner42 andfilm body40 is substantially less than the attractive force betweenliner42 andtape52. Then,liner pieces42a-ccan be rapidly separated fromfilm body pieces40a-cby simply pullingtape52 away fromfilm body40, or vice versa. Tens, hundreds, or thousands of discrete liner pieces can be readily and rapidly removed in this way.Tape52 preferably extends the width of the multilayeroptical film body40 so as to simultaneously contact a row of the plurality of pieces to be cut.
• After removal ofliner pieces42a-c, the multilayer opticalfilm body pieces40a-care also desirably separated fromsecond liner44. Preferably, this is done by providing a relatively weak bond betweenfilm body40 andsecond liner44. Such bond can be achieved electrostatically or by use of a small amount of low-tack pressure sensitive adhesive. The bond is weak enough to permit easy separation ofpieces40a-cby passing theliner44 around a sharp corner or bend and gently removingpieces40a-ctherefrom.
• Liner44 preferably comprises at least twolayers44a,44bselected to facilitate kiss-cutting.Layer44a, disposed adjacent the multilayeroptical film body40, is preferably composed of a material having a substantially lower absorption of the laser radiation than that offilm body40. Having lower absorption,layer44acan experience little or no vaporization during the laser cutting procedure with appropriate control of the laser. A polyethylene material with a thickness of about 0.001 inch (25 μm) or more has been found to be adequtate for a CO₂laser cutting system operating at about 10.6 μm. Such material however can stretch or deform from the heat generated by the laser at the cut lines. If theliner44 is held in tension and used to move the multilayeroptical film body40 through the laser cutting area, stretching or deformation ofliner layer44acan causepieces40a-cto move out of alignment with each other and thus cause mispositioned laser cuts. For thisreason layer44bis preferably composed of a relatively high modulus material such as a high modulus adhesive-coated paper to keep thefilm body40 andfilm pieces40a-cdimensionally stable.
• Multilayer opticalfilm body pieces40a-chave edges substantially devoid of delamination by use of the laser cutting procedure, and also have clean major surfaces free of debris by use of first andsecond liners42,44. The heat generated by the laser radiation deforms the microlayers at the edges to produce a kind of seat of the multilayer optical film.
• FIG. 5 shows a plan view of a piece of polymeric multilayeroptical film body60 that has been subdivided from a larger sheet of a polymeric multilayer optical film body.Piece60 has laser-cut peripheral edges62a-ddefining an elongated strip, preferably by kiss-cutting as depicted inFIG. 3. Additional laser cuts are provided to enable further subdivision of the multilayer optical film body into individual filter packages.Edges64a,64bdefine alignment holes for mounting the strip in an injection molding apparatus. These edges are also preferably kiss-cut.Points66 define linear arrays of holes serving the function of perforation lines to permit tearing or shearing along such lines. During laser cutting, the laser radiation is preferably controlled to make a complete through-cut (not simply a kiss cut) through the multilayer optical film body and through both first and second liners at points66. Preferably, one hole intersectsperipheral edge62aand another hole intersectsperipheral edge62cso that a fractional hole or notch is provided along each edge for ease of tearing.
• Melt zones68 are formed by reducing the laser radiation to levels that do not vaporize completely throughmultilayer film body60. This can be accomplished by defocusing the laser beam, reducing the laser power, and/or scanning the laser more rapidly across the workpiece. Although some of the multilayer optical film body can be vaporized atmelt zones68, at least a portion of the multilayer optical film body thickness remains intact atmelt zones68, though distorted by the localized heating. This distortion can be exemplified by localized rippling or undulation of the microlayers as well as co-mixing and a resulting loss of distinct individual microlayers. Themelt zones68 are provided to prevent the spread of delamination that can occur when thepiece60 is later cut into even smaller pieces by shear or tensile mechanical means along the perforation lines. Reference is made to U.S. Publication No. 2003/0217806 (Attorney Docket No. 57742US003), entitled “Multilayer Optical Film With Melt Zone To Control Delamination”, filed on Oct. 10, 2002 and incorporated herein by reference.
• As shown inFIG. 5, meltzones68 extend across the width of the ship and are arranged in pairs that alternately defineactive window areas67 andmechanical separation areas69. Perforation holes such as those defined atpoints66 can be provided in themechanical separation areas69, or they can be omitted. Whether perforation holes are provided or not, meltzones68 that border theseparation area69 are preferably spaced far enough apart so that a continuous band of multilayer optical film, undistorted by the laser cutting process and extending across the width of the strip, borders each melt zone. These bands of undistorted multilayer optical film act as buffer zones that help prevent the spread of delamination whenwindow areas67 are separated from each other by mechanical action (such as application of tensile force if perforation holes are present, or by shearing means) acrossseparation areas69.
• The multilayer optical film body can also comprise one or more multilayer optical films permanently attached to an optically thick outer layer whose composition and thickness are selected to make such outer layer tearable with the application of moderate tensile forces. The outer layer is made from an optically clear polymer, preferably a polyester such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN), a polycarbonate, or copolymers thereof, although the layer can include colorants, absorbers, or diffusing materials as desired. An adhesive layer can be used to bond the multilayer optical film to such an outer layer. A multilayer optical film body so constructed can be sandwiched between the first and second removable liners and cut lines can then be formed with laser radiation directed through the first liner. During the laser cutting, the multilayer optical film body is oriented such that the tearable outer layer is adjacent the second liner, i.e., farthest away from the laser radiation. Further, the laser radiation can be controlled at at least some of the cut lines to cut (vaporize) only partially through the multilayer optical film body, vaporizing completely through the multilayer optical film(s) but leaving the tearable outer layer intact. After the laser cutting procedure and after removal of the first and second liners, the multilayer optical film body, still in the form of a continuous sheet due to the intact ouster layer, can then be easily separated into distinct pieces as defined by the cut lines by simply pulling the pieces apart by hand along the cut lines or by applying such moderate forces with simple machinery. The tensile forces during separation are concentrated exclusively on the tearable outer layer. The multilayer optical film(s) included in such construction experience virtually no tensile forces during separation, and have sealed edges at the periphery of the defined pieces. The likelihood of delamination of the multilayer optical film(s) during separation is thus essentially zero. Cut lines as described herein are identified withminerals49a,49b,49cinFIGS. 3aand4a, which figures are similar toFIGS. 3 and 4 except that multilayeroptical film body40 is shown having a tearableouter layer40dadjacent thesecond liner44. Such cut lines can replace each pair ofmelt zones68 and line of perforation holes atpoints66 as shown inFIG. 5 to permit easy separation ofwindow areas67 into separate pieces. The peripheral edges62a-d(seeFIG. 5) can also use such cut lines, or the laser radiation can if desired cut through the entire multilayer optical film body (including the tearable outer layer) in those places as shown inFIGS. 3-4.
• One or more multilayer opticalfilm body pieces60 can be placed in an injection molding machine using alignment holes defined byedges64a,64b. Molten polymer material can then be formed in a series of boxes or frames114 around thepiece60 as shown best in the sectional view ofFIG. 6. After cooling, individual filter assemblies can be made by mechanically cutting themultilayer film body60 along the perforation lines defined by points66. Such individual filter assemblies and applications thereof are discussed in more detail in U.S. application Ser. No. 10/152,546, entitled “Photopic Detector System and Filter Therefor”, filed on May 21, 2002 and incorporated herein by reference. The filter frames can include an aperture adapted to receive a photodetector. The photodetector/filter assembly combination provides a modified detection system with spectral properties resulting in part from the photodetector's spectral properties and in part from the spectral transmission of the multilayer optical film.
• The utility of the described method of subdividing a sheet of multilayer optical film body into pieces thereof is in no way limited to forming strips of such material for use in box filters. The method is useful anywhere a piece or pieces (particularly a large number of pieces, e.g., at least 10, at least 50, or at least 100) of a multilayer optical film body are to be obtained from a larger sheet or roll of such material, and particularly where delamination along the edges of the multilayer optical film can be problematic and where a clean surface over the entire piece of multilayer optical film body is desired.
• FIG. 7 depicts a roll-to-roll process200 for converting a sheet of multilayer optical film body into pieces of multilayer optical film body cleanly and rapidly.Roll202 is unwound to provide alaminate film204 that can consist essentially of a polymeric multilayer optical film body (e.g.,element40 inFIG. 3) and a second liner (e.g.,liner44 inFIG. 3) adhered to one major surface (designated arbitrarily as the second major surface) of the multilayer optical film body. In a previous step not shown, the second liner was applied to the second major surface of the multilayer optical film body such as by electrostatic attraction or by use of a small amount of low tack adhesive. Thelaminate film204 passes around anidler roller206 such that the multilayer optical film body contacts theroller206.Laminate film204 then passes through torque-driven niprollers208,210. A first liner212 (e.g.,element42 inFIG. 3) is unwound from aroll214, brought into close proximity withlaminate film204 byidler roller216, and applied to the multilayer optical film body component oflaminate film204 by passing the films proximate a conventionalstatic bar218. The electrostatic forces imparted bystatic bar218 produce an intimate contact betweenfirst liner212 and a first major surface of the multilayer optical film. Thefilm combination204/212 (“web”) then passes through alaser radiation station220, where laser radiation from alaser control module222 is directed at the web to producediscrete pieces224 of the multilayer optical film body and of the first liner, as shown inFIG. 3. A flat table226 is provided with a honeycomb array of holes connected to avacuum source228 to keep the web uniformly flat across its width (cross-web direction) and along a substantial portion of its length (down-web direction) during laser cutting.Laser module222 includes beam shaping and steering optics and controls that can cut a programmed pattern of cut lines, each at predetermined power settings, while the web moves at a constant speed. Alternatively, the motion of the web can be stopped while thelaser module222 cuts a first pattern of cut lines, then advances forward and stops again to permit the laser module to cut a second pattern of cut lines, and so on in a step-and-repeat fashion. Preferably,laser radiation station220 includes anexhaust hood230 configured to provide a strong air flow across the web in a given direction. The air flow helps reduce optical distortion from the plume of smoke and debris that is generated at the point of laser cutting. Preferably, during cutting, the beam steering optics in thelaser module222 moves the laser cutting point on the web in directions that have substantially no component parallel to the direction of airflow to further avoid distortion from the plume.
• Immediately after the web exitslaser radiation station220, now partially cut to definepieces224, it passes proximate aconventional neutralizer bar232. The neutralizer bar eliminates or at least reduces the electrostatic attraction between the pieces of multilayer optical film body oflaminate film204 and the pieces offirst liner212. With the bond between the corresponding pieces thus weakened, andadhesive tape234 is unwound from aroll236 and passed through a pair of niprollers233,235 where the adhesive-coated side oftape234 is pressed againstdiscontinuous pieces224aof the first liner. As one take-up roll238 pullstape234 in one direction and another take-up roll240 pulls the web in a different direction,tape234 separates and carries away debris-coatedfirst liner pieces224afrom the nowpristine pieces224bof multilayer optical film body. The web is then wound up loosely with a silicone-coatedPET liner242 for temporary protection during storage and handling. In a later step, the second liner can be guided over a sharp bend or radius to completely separate the loosely held multilayer opticalfilm body pieces224bfrom the second liner as well.
• Nip rollers233,235 can be driven at a constant speed to act as the speed loop for roll-to-roll system200. Depending on the number, density, orientation, and type of cut lines to be made by thelaser module222, the web (i.e., thefilm combination204/212) can be greatly weakened at thelaser radiation station220. To prevent web breakage, it may be desirable to provide additional strength to the web by leaving at least one strip of the web, and preferably one strip on each side of the web, continuous and uncut. Such continuous strips, referred to herein as “weed”, can be discarded immediately after niprollers233,235 as shown withreference numeral244.
• FIG. 8 shows a top view of aweb250—comprising a polymeric multilayer optical film body sandwiched between a first and second liner—at the laser radiation station220 (seeFIG. 7).Web250 moves along adirection252. An air current is set up byexhaust hood230 to provide air current in adirection254 transverse to the web. Theweb250 is segregated into a central workingportion250aand weedportions250b, which portions are separated from the workingportion250abycut lines256. Some strengthening of the web can be achieved if cut lines256 are through-cut lines, but additional strengthening can be achieved if they are kiss-cut-lines since thelower liner44 would in that case be intact between the workingportion250aand theweed portions250b. Additional cut lines—preferably kiss-cut lines—definerepresentative shapes258,260 for pieces to be cut. To help reduce distortion due to the plume of smoke and vaporized material,laser module222 can be programmed to scan the laser cutting point inpreferred directions258a,260a-bas shown, which are or which have components that are antiparallel toair flow direction254.
• Optionally, theweb250 can have two distinct weed portions on each side of the web, i.e., a left outer weed portion along the left side ofFIG. 8 and a right outer weed portion along the right side ofFIG. 8. An additional through-out made by thelaser module222 separates such outer weed portions fromweed portions250b, the latter of which can be described as inner weed portions, and which would then utilize kiss-cut lines at256. If present, the outer weed portions can be separated from the inner weed portions and collected immediately after thelaser cutting station220. Such outer weed portions help provide a clean uniform edge for the final roll product. Meanwhile, the inner weed portions travel with the remainder of the web through niprollers233,235 as described above.
EXAMPLE
• A polymeric multilayer interference film was manufactured by coextruding alternating layers of a low melt coPEN made from a 90/10 copolymer of polyethylene naphthalate (PEN)/polyethylene terephthalate (PET) and polymethylmethacrylate (PMMA) at about 277° C. to form an extrudate having 224 individual layers sandwiched between two outer skin layers composed of the low melt coPEN. These layers defined an optical packet consisting essentially of 112 unit cells with an approximately linear thickness gradient along an axis perpendicular to the stack. The thickest unit cell, located at one side of the packet, was approximately 1.3 times thicker than the thinnest unit cell, located at the other side of the packet. The optical packet was asymmetrically multiplied to give a multilayer optical film construction having 448 individual layers with outer skin layers and an interior polymer boundary layer (PBL) between packets. The layer multiplication was carried out so that one of the optical packets had an overall thickness about 1.3 times that of the other packet. The extrudate was quenched on a chill roller to form a cast multilayer film. The cast film was sequentially stretched in the machine direction (MD) and the transverse direction (TD) using stretch ratios 3.4:1 and 3.4:1 respectively, producing a finished film having in-plane refractive indices (n_1x, n_1y) and an out-of-plane refractive index (n_1x) of about 1.744, 1.720, and 1.508 respectively in the coPEN layers, and in-plane refractive indices (n_2x, n_2y) and an out-of-plane refractive index (n_1z) of about 1.495, 1.495, and 1.495 respectively in the PMMA layers. All indices were measured with a Metricon surface wave characterization device at 550 nm. The finished from comprised two optical packets each of ¼-wave design, and each with an approximately linear thickness gradient along an axis perpendicular to the plane of the film to give a range of reflected wavelengths within each optical packet. The thickest twit cell in the furnished film had a thickness about 1.8 times that of the thinnest unit cell in the finished film, corresponding to a range of reflected wavelengths from approximately 665 nm to 1220 nm. Skin layers on the outsides of the optical structure were low melt coPEN, with an approximate thickness of 11 μm (0.43 mils). The overall film thickness was about 90 sun (3.7 mils).
• Two substantially identical rolls of multilayer film made as described above were selected on basis of their optical properties, and were corona treated to improve adhesion. One of the corona-treated films was coated with a UV-initiated adhesive at approximately 122 mini (5 mils) and irradiated with UV light to activate the curing process of the adhesive. The adhesive, made by a hot melt extrusion process, was a homogeneous mixture of a thermoplastics component (ethylene vinyl acetate), a curable resins component (mixture of epoxy and polyol), and a photoinitiator component (a triaryl sulfonium hexafluoroantimonate salt). The two multilayer films were then laminated together and curing of the laminate adhesive was accelerated with a heat soak at 25° C. (80° F.) for 10 minutes. The resulting film body consisted of two multilayer optical films with a clear adhesive layer in between. The element was in the form of a roll and had a thickness of approximately 12.4 mils (300 μm), a width of about 4 inches (100 mm), and a length of at least about 50 feet (well over 10 meters).
• The film body, or interference element, thus constructed exhibited a reflection band in the near infrared wavelength region and a pass band in the visible region for normally incident light. Percent transmission was about 70% or more from about 450-640 nm; and was less than 1% from about 700-1140 nm, and less than 5% from 680-700 nm and from 1140-1160 nm.
• The second liner was a high modulus paper with a thin layer of polyethylene adhered thereto with a strong pressure sensitive adhesive. The paper thickness was about 2 mils (50 μm), the polyethylene layer thickness was about 1 mil (25 μm), and the overall thickness of the second liner was about 3 mils (75 μm). The adhesive coated paper was obtained under part number CT 1007 from TLC Industrial Tape, Harwood Heights, Ill. The polyethylene layer was laminated to one major surface of the multilayer optical film body in a continuous process using a nip roll. In a separate step, the adhesive-coated paper was laminated to the polyethylene layer. (Alternatively, the polyethylene layer can comprise a low tack adhesive on the side that contacts the multilayer optical film body and the same procedure followed.) This was rolled up and stored for days.
• The first liner was a high modulus paper with a thickness of about 2 mils (50 μm), and one side was silicone-treated. The paper was purchased from Litin Paper Company, Minneapolis, Minn.
• These elements were processed in a manner substantially as depicted inFIG. 7 to produce a plurality of strips substantially as shown inFIG. 5, except more cut lines and melt zones were provided to define eightactive windows67 rather than four, and except as noted below. The strips were about 4.5 mm wide and about 69 mm long, with the length being aligned with the downweb direction and the melt zones being aligned with the crossweb direction. (Alternatively, the strips can be aligned with the crossweb direction.) The melt zones that bounded perforation lines were spaced apart by about 1.5 mm, and melt zones that bounded window areas were spaced apart by about 5.5 mm. The silicone-treated side of the paper liner (first liner212) was made to contact thelaminate film204. A constant web speed of about 2 to 3 ft/min (0.01-0.015 nm/sec) was used. The web passed within about one-half inch (10 mm) ofstatic bars218, which were controlled to a setting just below the are point. The web also passed within a similar distance of neutralizer bars232. Atlaser radiation station220, a LaserSharp brand laser processing module, model LPM300, was used. The CO₂laser had a spot size of about 8 mils (0.2 mm), and this produced kiss-cut and through-cut lines about 13-14 mils (0.35 mm) in width. The following settings were used for the following types of cut lines:

  	Cut line/feature	Process Speed	Frequency

  	Kiss-cut (CW)	1100 mm/sec	20	kHz
  	Kiss-cut (DW)	875 mm/sec	20	kHz
  	Perforation cut (CW)	950 mm/sec	2.2	kHz
  	Through-cut (DW)	600 mm/sec	20	kIIz
  	Melt Zone (CW)	1800 mm/sec	20	kHz

  
  In this table, “CW” refers to a cut line that extends in the cross web direction, and “DW”refers to a cut line that extends in the down web direction. In addition, power was set to 100%, duty cycle was set to 50%, and jump speed was set to 5000 mm/sec for each of the features. The CW kiss-cut setting was used to cutminor edges62b,62dof the strips (seeFIG. 5), the DW kiss-cut setting was used to cutmajor edges62a,62cof the strips andcircular edges64a,64b, the CW perforation setting was used forperforations66, the DW throughout was used for the cut-lines separating the working portion from the weed portions (seelines256 inFIG. 8), and the CW melt zone setting was used formelt zones68. The melt zone setting produced melt zones in which the upper multilayer optical film (i.e., the multilayer optical film adjacent the first liner) was completely vaporized along with the first liner, whereas the lower multilayer optical film (the multilayer optical film adjacent the second liner) was intact but exhibited substantial deformation/undulation of its constituent layers.
• Continuous bands on either side of the web were used for weed, as depicted inFIG. 8, except that an inner and outer weed portion were formed on each side of the working portion as described previously. Each inner weed portion had a width of about one-eighth of an inch (about 3 mm). This can be compared to the central working portion of the web (see againFIG. 8), which had a width of about 3-3.5 inches (about 75 to 90 mm). The outer weed portions were roughly one-half inch wide (roughly 10 mm). The outer weed portions were separated from the remainder of the web and collected between thelaser radiation station220 and theneutralizer bar232. Down web of thelaser radiation station220, a roll of single-sided adhesive tape having a width about equal to the central working portion of the web was used fortape234, in a continuous fashion. The tape was a conventional 3M™ painter's masking tape. The inner weed portions were separated from the second liner immediately alter the niprollers233,235 and rolled up onroll238 along with the tape and pieces of first liner. Individual pieces (strips) of the multilayer optical film body were easily removed by hand from the second liner. Upon inspection, the pieces exhibited substantially no delamination along the laser-cut edges. Still smaller pieces were obtained by exerting a moderate amount of tensile force by hand to create breaks along the perforation lines. Examination of the edges so cut revealed delamination along the edges, but the delamination did not extend across themelt zones68.
• Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not limited to the illustrative embodiments set forth herein.

Claims (18)

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

3-4. (canceled)

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

6-7. (canceled)

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

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

10. (canceled)

11. The method ofclaim 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 ofclaim 1, wherein the multilayer optical film body comprises polymeric microlayers.

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

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

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

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

17. The method ofclaim 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 ofclaim 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.

19. (canceled)

20. The method ofclaim 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.

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