Embossed Layer Release for Microstructured Thin Film Flakes

Solution Overview

Problem

The existing process for manufacturing thin film flakes with microstructures requires a thin release layer that can be harmful to the coating layers and adds extra production steps and materials, particularly when using soluble release layers like NaCl or borax.

Innovation Solution

A two-layer structure is used where the embossed layer, with a lower softening temperature than the substrate, serves as the release layer and is dissolvable in a solvent without affecting the thin film coating, eliminating the need for a separate release layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a thin release layer is applied to the substrate to enable removal of the thin film optical coating, then the thin film coating can be released from the substrate, but the release layer adds extra production steps and materials and may be harmful to the coating layers

Engineering Contradiction:

Improverelease processVSAvoidproduction steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The substrate itself is made soluble so that it serves as the release layer, eliminating the need for a separate release layer. The substrate material (e.g., PET) is dissolved in a solvent (e.g., acetone) to release the thin film optical coating, combining the substrate function with the release function into a single material system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The release function is extracted from a separate release layer and integrated into the substrate material itself. The substrate is designed to be soluble in a specific solvent, allowing it to dissolve and release the coating without requiring an additional release layer coating step.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If a separate release layer is used to allow removal of the thin film coating, then the coating can be released, but residue from the release layer may contaminate the coating

Engineering Contradiction:

Improvecoating removalVSAvoidresidue contamination

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The release function is extracted from a separate release layer and integrated into the substrate material itself. The substrate is designed to be soluble in a specific solvent, allowing it to dissolve and release the coating without requiring an additional release layer coating step.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The substrate and release function are made homogeneous by using the same material for both purposes. The soluble substrate dissolves uniformly in the solvent, ensuring complete removal without leaving behind separate release layer residues that could contaminate the coating.

Inventive Principle:

Principle #33Homogeneity

3Quantity of substance

If the release layer is made thinner to reduce solvent requirement, then less solvent and material are needed, but the release layer becomes more difficult to apply and control

Engineering Contradiction:

Improvesolvent amountVSAvoidrelease layer thickness control

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The release function is extracted from a separate release layer and integrated into the substrate material itself. The substrate is designed to be soluble in a specific solvent, allowing it to dissolve and release the coating without requiring an additional release layer coating step.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The substrate serves multiple functions: it provides mechanical support during coating deposition and serves as the release layer for coating removal. This multi-functionality eliminates the need for a separate release layer and its associated thickness control challenges.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces processing steps and materials, prevents residue issues from release layers, and produces high-quality thin film flakes with microstructures, such as color-shifting flakes, by directly coating the embossed layer and dissolving it to release the flakes without damaging the optical coating.

Implementation Method 1

the embossed layer is capable of being dissolved in a dissolving agent and wherein the thin film coating is not dissolvable by said dissolving agent

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

coating a surface of the second layer directly with a thin film coating so that at least a layer of the thin film coating conforms to the microstructure formed in the second layer

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS10329429B2Microstructured device with embossed layer

Publication Date: 2019.06.25 VIAVI SOLUTIONS INC(US)

AI summary

A security device has a support substrate of a first material having a softening temperature t1 and an embossed layer of a second different material supported by the support substrate having a softening temperature t2, wherein t2<t1.A thin film coating deposited directly upon the embossed layer, wherein the embossed layer is capable of being dissolved in a dissolving agent and wherein the thin film coating is not dissolvable by said dissolving agent. There is not need for an additional release layer as the second different material is dissolvable and allows flakes to be formed by dissolving the second layer.