Solvent-free method for manufacturing thin film device

Abstract

The invention relates to a solvent-free method for manufacturing a thin film device. A method of forming a thin film device includes: coating a web with a plurality of layers of thin film; and applying a mechanical force to release the multilayer film from the web. Additional methods of forming thin film devices are disclosed.

Description

[0001] This application is a divisional application of an application with a filing date of March 14, 2019, application number 201910194741.0, and invention name “Solvent-free method for manufacturing a thin film device”. Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 62 / 643,038, filed on March 14, 2018, the disclosure of which is hereby incorporated by reference. Field of the Invention

[0003] The present disclosure generally relates to a method of forming a thin film device, the method comprising: coating a web with a multi-layer thin film; and applying a mechanical force to release the multi-layer thin film from the web. Background of the Invention

[0004] The film device is usually manufactured on a net with a release layer, which is between the multilayer structure and the net. In some cases, the release layer is a sodium chloride release layer, which is evaporated before coating the film device. In other cases, the release layer is an acetone soluble polymer release layer provided by a polyethylene terephthalate net. In both cases, the film is stripped off in a wet process, which uses acetone / water or 100% acetone to dissolve the release layer. The use of dangerous and flammable acetone (solvent) requires special process equipment for stripping, rinsing, filtering and drying of the film to be stripped.

[0005] There is a need for a method of removing a multilayer structure from a web having a release layer without using caustic solvents, for example using a simpler and less expensive dry process instead of the current wet process. Additionally, or alternatively, there is a need for a method of removing a multilayer structure from a web without a release layer. Such a method would be a simpler process and would be more cost effective due to the elimination of additional materials. SUMMARY OF THE INVENTION

[0006] In one aspect, a method of forming a thin film device is disclosed, the method comprising: coating a mesh with a multi-layer thin film; and applying a mechanical force to release the multi-layer thin film from the mesh.

[0007] In another aspect, a method of forming a thin film device is disclosed, the method comprising coating a web with a first layer; coating the first layer with a reflector layer; coating the reflector layer with a second layer to form a multilayer film; and releasing the multilayer film from the web by a drying technique.

[0008] In yet another aspect, a method of forming a thin film device is disclosed, the method comprising: providing a web having a release layer; coating the release layer with a multi-layer film; and applying a mechanical force to release the multi-layer film from the web.

[0009] This application provides the following: 1) A method for forming a thin film device, the method comprising: Covering the mesh with multiple layers of film; and A mechanical force is applied to release the multilayer film from the web.

[0010] 2) The method as described in 1), wherein the multilayer film comprises 3 layers.

[0011] 3) The method as described in 1), wherein the multilayer film comprises a Fabry-Perot structure.

[0012] 4) A method for forming a thin film device, the method comprising: Cover the net with the first layer; covering the first layer with a reflective layer; encapsulating the reflector layer with a second layer to form a multilayer film; and The multilayer film is released from the web by a drying technique.

[0013] 5) The method as described in 4), further comprising collecting the released multilayer film; and further comprising grinding the released multilayer film.

[0014] 6) The method as described in 4), wherein the drying technique is to apply a mechanical force to generate local tension to break the multilayer film, followed by applying high-speed gas, air or steam.

[0015] 7) The method as described in 4), wherein the drying technique is a mechanical force applied by local ultrasound.

[0016] 8) The method as described in 4), wherein the drying technique is an applied mechanical force that pulls the multilayer film directly from the web.

[0017] 9) The method as described in 4), wherein the drying technique is an applied mechanical force that stretches the multilayer film while applying a vibration force.

[0018] 10) The method as described in 4), wherein the drying technique is a mechanical force applied by drawing a vacuum through closely placed vacuum blades to peel the multilayer film off the web.

[0019] The other features and advantages of each embodiment will be explained in part in the following description, and in part will be obvious from the description or can be known by practicing each embodiment. The purpose and other advantages of each embodiment will be realized and obtained by means of the elements and combinations particularly pointed out in the description of this article. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present disclosure in its several aspects and embodiments may be more fully understood from the detailed description and accompanying drawings, in which: Figure 1 A transfer method for performing aspects of the method according to an embodiment of the present disclosure is shown; Figure 2 is a cross-sectional view of a thin film device according to an embodiment of the present disclosure; Figure 3 is a cross-sectional view of a thin film device according to an embodiment of the present disclosure; Figure 4 is a cross-sectional view of a thin film device according to an embodiment of the present disclosure; and Figure 5 is a cross-sectional view of a thin film device according to an embodiment of the present disclosure.

[0021] Like reference numerals denote like elements throughout the specification and drawings. DETAILED DESCRIPTION OF THE INVENTION

[0022] It should be understood that the foregoing general description and the following detailed description are both exemplary and explanatory only, and are intended to provide an explanation of the various embodiments of the present teaching. The layers / components shown in each figure may be described with respect to a specific figure, but it should be understood that the description of a specific layer / component will apply to equivalent layers / components in other figures.

[0023] In its broad and varied embodiments, a method for forming a thin film device 10 is disclosed, the method comprising: coating a web 40 with a multilayer thin film 20; and applying a mechanical force to release the multilayer thin film 20 from the web 40. In one aspect, the web 40 does not include a release layer 30, and the multilayer thin film 20 is deposited directly onto the web 40. The multilayer thin film 20 may include two or more layers, such as 3, 4, 5, or 6 or more layers, such as 7 layers. In one aspect, the multilayer thin film 20 may include 3 layers. In another aspect, the multilayer thin film 20 may include 5 layers. The multilayer thin film 20 may include a Fabry-Perot structure. The Fabry-Perot structure may have 5 or more layers to provide a thin film interference effect. The number of layers present in the Fabry-Perot structure may vary, depending not only on the desired optical properties, but also on other properties, such as magnetic properties. The method may be used to manufacture thin film devices 10, such as special effect pigments. The layers comprising the multilayer thin film 20 are discussed more fully below.

[0024] In one aspect, a method of forming a thin film device 10 may include coating a web 40 with a first layer; coating the first layer with a reflector layer; coating the reflector layer with a second layer to form a multilayer film 20; and releasing the multilayer film 20 from the web 40 by a drying technique. In one aspect, the web 40 does not include a release layer 30, and the multilayer film 20, such as the first layer, is deposited directly onto the web 40. The method may also include collecting the released multilayer film 20. The method may also include grinding the released multilayer film 20. The first layer, the reflector layer, and the second layer are discussed more fully below.

[0025] In another aspect, a method of forming a thin film device 10 is disclosed, the method comprising: providing a web 40 having a release layer 30; coating the release layer 30 with a multilayer thin film 20; and applying a mechanical force to release the multilayer thin film 20 from the web 40. In one aspect, the multilayer thin film 20 may include 3 layers. In another aspect, the multilayer thin film 20 may include 5 layers. The multilayer thin film 20 may include a Fabry-Perot structure. The Fabry-Perot structure may have 5 or more layers to provide a thin film interference effect. The number of layers present in the Fabry-Perot structure may vary, depending not only on the desired optical properties, but also on other properties such as magnetic properties. The method may be used to manufacture thin film devices 10, such as special effect pigments. The layers comprising the multilayer thin film 20 are discussed more fully below. In one aspect, the multilayer thin film 20 coated on the release layer 30 may include a first layer coated on the release layer 30; the first layer is coated with a reflector layer; and the reflector layer is coated with a second layer to form the multilayer thin film 20. The first layer, the reflector layer, and the second layer are discussed more fully below.

[0026] The web 40 used in the methods disclosed herein can be any material that can accommodate at least one of the release layer 30 and the multilayer film 20. In one aspect, the web 40 can be a microstructured web 40, such as polyethylene terephthalate (PET). The web 40 can be flexible. In some aspects, the web 40 can include the release layer 30. In other aspects, the web 40 can be free of the release layer 30, so that the multilayer film 20, such as the first layer, can be directly coated onto the web 40.

[0027] The release layer 30 used in some of the methods disclosed herein can be disposed on the surface of the web 40 with low adhesion to the web 40. In one aspect, the release layer 30 can be present with a lower adhesion to the first layer of the multilayer film 20 than the low adhesion to the web 40. In this way, the release layer 30 can be more easily removed from the web 40 than the first layer of the multilayer film 20. In one aspect, the release layer 30 can be water-soluble. The release layer 30 can be removed from the multilayer film 20 after the grinding process and before the passivation / functionalization wet process, for example, as used with a pigment containing a metal layer such as an aluminum layer. Drying techniques, such as dry stripping processes, can be performed in the absence of the release layer 30, or can be performed with the release layer 30 having low adhesion to the web 40. The release layer 30 does not necessarily need to be present between the web 40 and the multilayer film 20.

[0028] The release layer 30 can be selected from polyvinyl alcohol preparations, polysaccharide preparations (dextran), polyacrylic acid preparations, polyvinyl acetate preparations, polyvinyl pyrrolidone preparations, carboxymethyl cellulose preparations and combinations thereof. The release layer 30 can be water-soluble, but insoluble in the solvent used to coat the multilayer film 20, which includes a first layer, a reflector layer and a second layer. In addition, the molecular weight of the release layer 30 can be changed to improve solubility in water. For example, if the first layer has a water-based preparation, the release layer 30 should have a low solubility in water. The release layer 30 should maintain its integrity for a period of time required for coating and drying of at least the first layer of the multilayer film 20.

[0029] In one aspect, release layer 30 can be a polyvinyl alcohol (PVA) preparation. This preparation is nontoxic, clear and inert. It is a water-soluble polymer with excellent film-forming properties. The coating of PVA has low adhesion to the surface of hydrophobic polymers such as polyethylene phthalate (PET), and is insoluble in most organic solvents. When one or more solvent-borne layers are coated on the PVA layer pre-coated on the hydrophobic polymer sheet (net), the PVA layer not only remains intact during the coating process, but also can be easily separated from the polymer sheet (net) by applying mechanical force, such as from the impact of compressed air or water flow. In this way, the PVA layer can play the role of release layer 30.

[0030] The PVA layer can be formed by coating the PVA aqueous solution onto the net 40. Both fully hydrolyzed PVA and partially hydrolyzed (e.g., 86%-88% hydrolyzed) PVA can be used to form the release layer 30. In addition, PVA with a molecular weight in the range of from Mw 10,000 to 200,000 can be suitable for the release layer 30. Partially hydrolyzed PVA can produce a clear coating and high solubility in cold water, while fully hydrolyzed PVA can produce a harder coating due to its strong intramolecular hydrogen bond interaction. Low molecular weight can achieve rapid water dissolution and low solution viscosity. On the contrary, high molecular weight can cause slow water dissolution and high solution viscosity.

[0031] A formulation having 0.01% to 30% PVA can be used to coat the web 40 and form the release layer 30. In addition to PVA, additives such as surfactants, deforming agents, organic solvents, antifouling agents, etc. can also be included in the formulation forming the release layer 30 to enhance the coating properties. Depending on the properties of the web 40, an effective PVA release layer can have a layer thickness in the range from about 1 nm to about 10 microns, for example, in the range from about 50 nm to about 1100 nm.

[0032] PVA can be cross-linked at room temperature or elevated temperature by a cross-linking agent. Suitable cross-linking agents include, but are not limited to, dialdehydes such as glyoxal and glutaraldehyde; dicarboxylic acids such as malonic acid, succinic acid, glutaric acid, adipic acid, etc.; boric acid; and certain polyvalent metal ions such as Al 3+ Crosslinking of the PVA layer can render it insoluble in water and able to function as a release material for water-borne coatings.

[0033] In one aspect, a polyacrylic acid (PAA)-PVA blend can be used as the release layer 30. The adhesion of the blend to the web 40 can be adjusted by adding a base such as sodium hydroxide to control the content of neutralized carboxylic acid groups. When PAA reacts with sodium hydroxide, it forms a sodium carboxylate salt. It has been found that the adhesion of the PAA-PVA release layer 30 to the web 40 can decrease as the content of the carboxylate content increases. In this way, it is possible to adjust the release of the multilayer film 20 by controlling the amount of carboxylate in the release layer 30.

[0034] The release layer 30 may include an inorganic salt and / or an organic salt. Non-limiting examples of suitable salts for the release layer 30 include sodium chloride, sodium sulfate, potassium chloride, sodium acetate, and combinations thereof. The salt may change the properties of the release layer 30 and may reduce the adhesion between the release layer 30 and the web 40.

[0035] The multilayer film 20 may include a first layer, a reflector layer, a second layer, and at least one of an additional layer such as an absorber layer and / or a magnetic layer. The additional layer may be located at multiple locations in the multilayer film 20. For example, the multilayer film 20 may include a Fabry-Perot structure, such as an absorber layer / dielectric layer / reflector layer / dielectric layer / absorber layer.

[0036] In the disclosed method, the first layer and the second layer can each independently be an organic layer or a composite organic layer / inorganic layer. The first layer and the second layer can each independently include at least one of the following: colorless particles, organic colorant pigments, organic colorant dyes, inorganic colored particles, organic absorbent particles, inorganic absorbent particles, organic high refractive index dielectric particles, inorganic high refractive index dielectric particles, organic low refractive index dielectric particles, inorganic low refractive index dielectric particles, inorganic metal particles, inorganic composite materials, and inorganic alloys. The molecules and / or particles of the first layer and the second layer can have a size that does not produce Mie scattering. When the molecular size or particle size is larger than the wavelength of the incident light, Mie scattering can be produced. This is in contrast to Rayleigh scattering, which is the case when the wavelength of the incident light is larger than the particle size.

[0037] Non-limiting examples of inorganic high refractive index dielectric particles and inorganic low refractive index particles include SiO 2 、TiO2 、Al 2 O 3 、ZrO 2 , WO 3 , VO 5 、ITO、Ta 2 O 5 、CeO 2 , Y 2 O 3 、ZnS、ZnO、In 2 O 3 ,La 2 O 3 、MgO、Nd 2 O 3 , Pr 6 O 11 , Fe 2 O 3 , Fe 3 O 4 、SiO、SnO 2 、FeOx、MgF 2 , AlF 3 , CeF 3 、LaF 3 、LiF、CaF 2 , TiC, TiN, cermet, diamond-like carbon, metal carbide, metal nitride, metal boride, metal carbonitride, metal oxycarbide, metal oxynitride, metal oxycarbonitride, boron carbide, and combinations thereof.

[0038] Non-limiting examples of organic absorbent particles and inorganic absorbent particles include carbon, graphite, silicon, germanium, cermets, metals mixed in dielectric matrices, and other materials that can act as uniform or selective absorbents in the visible spectrum. Cermets and different alloys, such as Inconel, stainless steel, Hastelloy, etc., can also be used for their optical and physical properties. Certain metal carbides, metal nitrides, metal borides, metal carbonitrides, metal oxycarbides, metal oxynitrides, metal oxycarbonitrides can also be used for their absorption properties when embedded in an organic matrix.

[0039] The first layer and / or the second layer may include organic monomers and polymers that may be used, acrylates (e.g., methacrylates), epoxies, perfluoroolefins, polytetrafluoroethylene (Teflon), fluorinated ethylene propylene (FEP), polyesters, polyethylenes, polyamides, polyimides, polyurethanes, polyacrylates, polymethacrylates, polycarbonates, polyureas, cellulose acetate butyrate, cellulose acetate propionate, cellulose nitrate, and combinations thereof.

[0040] The first layer and / or the second layer may include inorganic dielectric particles to change not only the visual appearance of the final thin film pigment flake, but also its other functions. Functional properties created by the addition of inorganic particles include, but are not limited to, electrical and / or magnetic properties, fluorescent properties, up-converting properties (e.g., converting a near infrared laser beam into visible light or converting a low energy color of light, such as red, into a higher energy color, such as blue or green), flame retardants, and static dissipation.

[0041] Non-limiting examples of organic colorant pigments and organic colorant dyes include perylene, perinone, quinacridone, quinacridonequinone, anthrapyrimidine, anthraquinone, anthranthrone, benzimidazolone, disazo condensation, azo, quinolone, xanthene, azomethine, quinophthalone, indanthrone, phthalocyanine, triarylcarbonium ion, dioxazine, aminoanthraquinone, isoindoline, diketopyrrolopyrrole, thioindigo, thiazineindigo, isoindoline, isoindolinone, pyranthrone, isoviolanthrone, miyoshimethane, triarylmethane, vat dyes, sulfur dyes, and mixtures thereof.

[0042] The multilayer film 20 may include a first layer of epoxy, acrylate, or epoxy-acrylate hybrid coated on PVA-PET. The first layer may be coated using a solvent-containing formulation using a slot diecoater or a drawdown coater. In one aspect, this first layer may be successfully stripped from the PET web 40 by an applied mechanical force such as an air stripping process.

[0043] In yet another aspect, the multilayer film 20 may include all of the following: n 、(LH) n , (HL) n H, (LH) nL and combinations thereof, wherein n is an integer from about 1 to about 100, such as an integer from about 2 to 4. The L layer and the H layer are each QWOT at a selected design wavelength. Other suitable designs can also be obtained by combining high dielectric coatings and low dielectric coatings with different optical thicknesses, and in some designs, some layers may not have the same wavelength QWOT. Similarly, some optical designs can be symmetrical.

[0044] The multilayer film 20 including the first layer, the second layer, the reflector layer and the additional layer can be deposited using a deposition process. In one aspect, each layer can be independently applied as a coating using a process selected from the following: slot molding, gravure printing, micro-gravure printing, spraying, curtain coating, metering rod, Meyer bar coating, flexographic printing and offset printing. In another aspect, each layer can be independently applied as a coating using a process selected from physical vapor deposition and chemical vapor deposition under vacuum. In yet another aspect, the first layer and the second layer can be applied using a process selected from the following: slot molding, gravure printing, micro-gravure printing, spraying, curtain coating, metering rod, Meyer bar coating, flexographic printing and offset printing; and the reflector layer is applied using a process selected from physical vapor deposition and chemical vapor deposition under vacuum.

[0045] The reflector layer of the multilayer film 20 can be deposited under vacuum. The reflector layer can include any material with reflective properties, such as metal. Non-limiting examples of materials with reflective properties include aluminum, silver, copper, gold, platinum, tin, titanium, palladium, nickel, cobalt, rhodium, niobium, chromium, and compounds, combinations or alloys thereof. Non-limiting examples of other suitable reflective alloys and compounds include bronze, brass, titanium nitride and the like, and alloys of the metals listed above, such as silver-palladium. The reflector layer can have an intrinsic color, such as copper, gold, silver-copper alloy, brass, bronze, titanium nitride, and compounds, combinations or alloys thereof.

[0046] The reflector layer may also include particles with reflective properties incorporated into an organic matrix. The same materials described for the reflector layer deposited under vacuum may be used as additive particles into a suitable organic matrix. In addition, a variation of the Brashear silver process may be used to deposit the silver reflector layer.

[0047] Special effect pigments based on a reflector layer comprising aluminum can be further processed using a passivation treatment in order to avoid oxidation of the aluminum layer.

[0048] The multilayer film 20 can independently include cohesion and adhesion promoter materials in each of the first layer, reflector layer, second layer and / or additional layers. These materials can be added directly to each layer or interface of the multilayer film 20. Suitable adhesion promoters include, but are not limited to, molecules and resins containing hydroxyl groups, thiol groups, amine groups, carboxylic acid groups, phosphoric acid groups or siloxane groups.

[0049] The methods disclosed herein may include using drying techniques, such as applying mechanical force to release the multilayer film 20 from the web 40 and / or the web 40 with the release layer 30 (if present). In one aspect, the application of mechanical force can cause the multilayer film 20 to form a sheet that can be released and further processed. In another aspect, the application of mechanical force does not form a sheet, but forms a self-supporting film device 10 with a specific optical and functional design.

[0050] The applied mechanical force may include local tension to cause the multilayer film 20 to break to form a thin sheet. In one aspect, the local tension may be assisted by a sharp knife in contact with the back of the web 40. The applied local tension may be followed by the application of a high velocity gas, air or steam. In particular, the air stripping process may include: (1) applying tension to the web 40 to induce cracks in the multilayer film 20 to form a thin film device, such as a thin sheet, and (2) applying a compressed air stream to the multilayer film 20 to blow the thin sheet of the multilayer film 20 from the web 40.

[0051] In another aspect, the applied mechanical force may include localized application of ultrasound. In another aspect, the applied mechanical force may include pulling the multilayer film 20 directly from the web 40. The applied mechanical force may also include stretching the multilayer film 20 while applying a vibration force. The applied mechanical force may also include peeling the multilayer film 20 from the web 40 by placing a vacuum blade in close proximity to the multilayer film 20 to draw a vacuum to suck the multilayer film 20 from the web 40 into a collection chamber. The collection of the film device, such as a sheet, may be performed, for example, in Figure 1 The thin film device transfer method shown in FIG. 2 is implemented by the thin film device transfer method (thin film device transfer method) shown in FIG.

[0052] The multilayer film 20 of release can be further processed, for example collected and / or ground. In one aspect, the multilayer film 20 of release is in the form of a thin slice that can be collected, for example, collected in a cyclone separator by a suitable airflow ventilation system. The thin slice collected can be ground. Grinding can be selected from the following process: jet milling, cryogenic grinding, ultrasonic grinding based on liquid medium, pulverizing and high shear wet grinding. Then, the thin slice can be rinsed and / or dried. In one aspect, the drying step is unnecessary because some aluminum passivation processes require water, for example sodium laurylphosphonate, octylphosphonic acid, octadecylphosphonic acid, potassium lauryl phosphate, and the sol-gel encapsulation process with the material such as silicon dioxide, titanium dioxide, zirconium oxide, ceria, aluminum oxide or their combination.

[0053] In yet another aspect, the thin film device 10 may include a multilayer thin film 20 and a release layer 30. The release layer 30 may change the optical properties and may incorporate functionality into the thin film device 10. The release layer 30 may be present on one side of the multilayer thin film 20, or may be present on both sides of the multilayer thin film 20, such as Figure 2 and Figure 3 If release layers 30 are present on both sides of the multilayer film 20, each release layer 30 may be the same or different. For example, one release layer 30 may function as the release layer 30 that is originally in contact with the web 40, and a second release layer 30 may provide additional functionality to the film.

[0054] In one aspect, the release layer 30 can be coated on both sides of the web 40 to reduce manufacturing costs, such as Figure 4 The first proposed manufacturing structure would be similar to: multilayer film / release layer / web / release layer / multilayer film.

[0055] In yet another aspect, a stack of release layer 30 and multilayer film 20 can be formed on web 40 to reduce manufacturing costs. A second proposed manufacturing structure would be similar to: web / release layer / multilayer film / release layer / multilayer film 20, such as Figure 5 This can provide twice the amount of flakes from the same surface of the web 40. In addition, the first proposed manufacturing structure ( Figure 4 ) and the second proposed manufacturing structure ( Figure 5 ) can be combined to further reduce costs and increase production.

[0056] Example 1 The multilayer film 20 comprising three layers is deposited directly onto a web 40 of PET, i.e., there is no release layer. The multilayer film 20 comprises a first organic layer of a composite hybrid acrylate-epoxy resin with an organic red colorant deposited using a slot die process. A reflector layer of aluminum is coated onto the first layer using vacuum deposition. A second layer is coated onto the reflector layer using a slot die process and comprising a composite hybrid acrylate-epoxy resin with an organic red colorant.

[0057] A mechanical force is applied to the multilayer film 20 to release the multilayer film 20 from the net 40. By applying tension to the net 40 with the help of a sharp knife in contact with the back of the net 40, the mechanical force includes the breaking of the multilayer film 20. The knife does not directly contact the multilayer film 20 to avoid damage to the multilayer film 20. Then, the multilayer film 20 coated on the net 40 is exposed to a high flow / high speed air flow to blow off the broken coating. The application (breaking) of the knife and the application of air are almost simultaneous. In this way, the multilayer film 20 is released from the net 40 and forms a film device, such as a thin sheet. The thin sheet is collected in a cyclone separator through an appropriate air flow ventilation system. The thin sheet, i.e. the released multilayer film 20, is ground using a jet mill grinding technique.

[0058] Example 2 A multilayer film 20 comprising three layers is deposited directly onto a web 40 of PET having a release layer 30 made of a water-soluble polymer formulation (PVA). The multilayer film 20 comprises a first organic layer of a composite hybrid acrylate-epoxy resin with an organic red colorant deposited using a slot die process. A reflector layer of aluminum is coated onto the first layer using vacuum deposition. A second layer is coated onto the reflector layer using a slot die process and comprising a composite hybrid acrylate-epoxy resin with an organic red colorant.

[0059] A mechanical force is applied to the multilayer film 20 to release the multilayer film 20 from the net 40. By applying tension to the net 40 with the help of a sharp knife in contact with the back of the net 40, the mechanical force includes the breaking of the multilayer film 20. The knife does not directly contact the multilayer film 20 to avoid damage to the multilayer film 20. Then, the multilayer film 20 coated on the net 40 is exposed to a high flow / high speed air flow to blow off the broken coating. The application (breaking) of the knife and the application of air are almost simultaneous. In this way, the multilayer film 20 is released from the net 40 and forms a film device, such as a thin sheet. The thin sheet is collected in a cyclone separator through an appropriate air flow ventilation system. The thin sheet, i.e. the released multilayer film 20, is ground using a jet mill grinding technique.

[0060] Example 3 A five-layer film is formed based on a third layer of chromium, a first layer of zinc sulfide, a reflector layer of aluminum, a second layer of zinc sulfide, and a fourth layer of chromium. The multilayer film 20 has an optical thickness of the zinc sulfide dielectric layers (first and second layers) to produce a non-green or slow green color shifting design. The first and second layers are vacuum physically vapor deposited on a PET web 40 using a boxcoater. The PET web 40 includes a release layer 30 of PVA (60 nm to 200 nm). The PVA release layer 30 is air-strippable and water-soluble. The green multilayer film 20 has the following structure: 8 nm Cr / 368 nm ZnS / 80 nm Al / 368 nm ZnS / 8 nm Cr.

[0061] Example 4 A five-layer thin film interference is formed based on a third layer of chromium, a first layer of magnesium fluoride, a reflector layer of aluminum, a second layer of magnesium fluoride, and a fourth layer of chromium. The multilayer film 20 has an optical thickness of a magnesium fluoride dielectric layer (first layer and second layer) to produce a red / gold conversion design. The first layer and the second layer are roll-to-roll vacuum physical vapor deposited on a PET web 40. The PET web 40 includes a release layer 30 of PVA with different thicknesses (60 nm to 200 nm). The PVA layer is coated using a K101 Control K-Hand Coater using K-Bars number 0, 2, and 5 corresponding to 4 microns, 12 microns, and 50 microns, respectively. In all cases, the PVA coating formulation has 2.2% solids, and the dry physical thickness of the PVA layer is 88 nm, 264 nm, and 1100 nm, respectively. The multilayer with three PVA release layers 30 is air-strippable and water-soluble. Thicker PVA layers tend to make the air stripping process more efficient. The red / gold multilayer film 20 has the following structure: 10 nm Cr / 250 nm MgF 2 / 80 nm Al / 250 nm MgF 2 / 10 nm Cr.

[0062] A method for forming a thin film device, comprising: providing a web having a water-soluble release layer; coating the water-soluble release layer with a multilayer film; and applying a mechanical force to release the multilayer film from the web. In the method, the multilayer film comprises a Fabry-Perot structure. In the method, the multilayer film comprises a first layer coated on the water-soluble release layer; coating the first layer with a reflector layer; and coating the reflector layer with a second layer to form the multilayer film. In the method, the release layer is selected from a polyvinyl alcohol preparation, a polysaccharide preparation, a polyacrylic acid preparation, a polyvinyl acetate preparation, a polyvinyl pyrrolidone preparation, a carboxymethyl cellulose preparation, and a combination thereof.

[0063] From the foregoing description, it will be appreciated by those skilled in the art that this teaching can be implemented in various forms. Therefore, although these teachings have been described in conjunction with their specific embodiments and examples, the true scope of this teaching should not be so limited. Various changes and modifications can be made without departing from the scope of this paper's teaching.

[0064] This scope disclosure will be interpreted broadly. It is intended that the disclosure discloses equivalents, devices (means), systems and methods for realizing the devices, activities and mechanical actions disclosed herein. For each device, article, method, equipment, mechanical element or mechanism disclosed, it is intended that the disclosure is also encompassed in its disclosure, and teaches equivalents, devices, systems and methods for practicing many aspects, mechanisms and devices disclosed herein. In addition, the disclosure relates to coatings and many aspects, features and elements thereof. Such a device can be dynamic in its use and operation, and the disclosure is intended to cover equivalents, devices, systems and methods of articles using the device and / or manufacture, and many aspects consistent with the description and spirit of the operation and function disclosed herein. The claims of the present application are equally interpreted broadly.

[0065] The description of the invention herein in its many embodiments is merely exemplary in nature, and thus variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations should not be regarded as departing from the spirit and scope of the invention.

Claims

1. A method for forming a thin film device, the method comprising: providing a web having a water soluble release layer; coating the water-soluble release layer with a multi-layer film; coating the multilayer film with another water-soluble release layer; as well as A mechanical force is applied to release the multilayer film from the web.

2. The method of claim 1, wherein the multilayer thin film comprises a Fabry-Perot structure.

3. The method of claim 1, wherein the multilayer film comprises a first layer coated on the water-soluble release layer; coating the first layer with a reflector layer; and The reflector layer is overcoated with a second layer to form the multilayer film.

4. The method according to claim 1, wherein the release layer is selected from the group consisting of polyvinyl alcohol preparations, polysaccharide preparations, polyacrylic acid preparations, polyvinyl acetate preparations, polyvinyl pyrrolidone preparations, carboxymethyl cellulose preparations, and combinations thereof.

5. The method of claim 1, wherein the web is microstructured.

6. The method according to claim 1, further comprising: After applying the mechanical force, a step of grinding the multilayer film.

7. The method according to claim 6, further comprising: After grinding the multi-layer film, a passivation step is performed.

8. The method of claim 1, wherein the water-soluble release layer is a fully hydrolyzed polyvinyl alcohol formulation.

9. The method of claim 1, wherein the water soluble release layer is a partially hydrolyzed polyvinyl alcohol formulation.

10. The method of claim 1, wherein the water soluble release layer has a molecular weight ranging from 10,000 to 200,000.

11. The method of claim 1, wherein the water soluble release layer is a formulation having 0.01% to 30% polyvinyl alcohol.

12. The method according to claim 11, wherein the preparation further has an additive, the additive comprising at least one of a surfactant, a deforming agent, an organic solvent and an antifouling agent.

13. The method of claim 1, wherein the water-soluble release layer has a thickness of from 1 nm to 10 microns.

14. The method according to claim 1, further comprising: Before covering with the multi-layer film, a step of cross-linking the release layer with a cross-linking agent.

15. The method of claim 1, wherein the water soluble release layer is a mixture of polyacrylic acid and polyvinyl alcohol.

16. The method according to claim 15, further comprising: The step of combining sodium hydroxide with the mixture of polyacrylic acid and polyvinyl alcohol before coating with the multi-layer film.

17. The method of claim 1, wherein the water soluble release layer has a salt comprising sodium chloride, sodium sulfate, potassium chloride, sodium acetate, and combinations thereof.

18. The method of claim 1, wherein the water soluble release layer is coated on both sides of the web.

19. The method of claim 1, further comprising: Prior to the step of applying the mechanical force, a step of covering the other water-soluble release layer with another multi-layer film.

20. The method of claim 3, wherein the first layer and the second layer can each independently be an organic layer or a composite organic layer / inorganic layer.

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