Specification
LIGHT COLLIMATING AND DIFFUSING FILM AND SYSTEM FOR MAKING
THE FILM
BACKGROUND OF THE INVENTION
A light diffusive film has been developed for receiving light and diffusing the light.
The light diffusive film is manufactured using multiple manufacturing steps. First, a
plurality of polystyrene beads are disposed in an aery late solution. The acrylate
solution is then applied to a surface of a plastic film. Thereafter, the plastic film is
heated to cure the acrylate and to bond the polystyrene beads to the plastic film. A
significant drawback with the manufacturing process of the light diffusive film is that
it requires several relatively complex steps to coat the film with the acrylate 'solution
and polystyrene beads. Further, the manufacturing process is relatively expensive to
perform.
Accordingly, there is a need for a light diffusive film that can be manufactured using a
simplified process without utilizing polystryene beads or an acrylate solution.
BRIEF DESCRIPTION OF THE INVENTION
A light collimating and diffusing film in accordance with an exemplary embodiment
is provided. The film includes a plastic layer having a first side and a -second side
opposite the first side and at least a first peripheral edge. The first side has a first
textured surface, wherein between 7 to 20 percent of slope angles on the first textured
surface proximate a first axis has a value between zero and five degrees. The first
axis is substantially parallel to the first peripheral edge. The plastic layer collimales
light propagating therethrough.
A method for manufacturing a light collimating and diffusing film in accordance with
another exemplary embodiment is provided. The method includes extruding heated
plastic through a die to form a plastic layer. The plastic layer has a first 'side and a
second side opposite the first side and at least a first peripheral edge. The plastic
layer extends along both a first axis and a second axis. The first axis is substantially
parallel to the first peripheral edge. The second axis is substantially perpendicular to
the first axis. The method further includes cooling at least one of first and second
rotating cylindrical rollers below a predetermined temperature. The method further
includes moving the plastic layer between first and second rotating cylindrical rollers.
The first cylindrical roller contacts the first side of the plastic layer and the second
cylindrical roller contacts the second side. The first cylindrical roller forms a first
textured surface on the first side of the plastic layer, wherein between 7 to 20 percent
of slope angles on the first textured surface proximate the first axis have a value
between zero and five degrees.
A system for manufacturing a light collimating and diffusing film in accordance with
another exemplary embodiment is provided. The system includes an extruder device
operably coupled to a die. The extruder device urges heated plastic through the die to
form a plastic layer. The plastic layer has a first side and a second side opposite the
first side and at least a first peripheral edge. The plastic layer extends along both a
first axis and a second axis. The first axis is substantially parallel to the first
peripheral edge. The second axis is substantially perpendicular to the first axis. The
system further includes first and second cylindrical rollers disposed proximate one
another for receiving the plastic layer. The system further includes a cooling device
configured to cool at least one of the first and second cylindrical rollers below a
predetermined temperature. The first cylindrical roller contacts the first side of the
plastic layer and forms a first textured surface on the first side of the plastic layer.
The second cylindrical roller contacts the second side of the plastic layer, wherein
between 1 to 20 percent of slope angles on the first textured surface proximate the
first axis have a value between zero and five degrees.
A method for manufacturing a light collimating and diffusing film in accordance with
another exemplary embodiment is provided. The method includes heating a plastic
layer having a first side and a second side. The plastic layer has a first side and a
second side opposite the first side and at least a first peripheral edge. The plastic
layer extends along both a first axis and a second axis. The first axis is substantially
parallel to the first peripheral edge. The second axis is substantially perpendicular to
the first axis. The method further includes heating at least one of the first and second
cylindrical rollers above a predetermined temperature. The method further includes
moving the plastic layer between first and second rotating cylindrical rollers wherein
the first cylindrical roller contacts the first side of the plastic layer and the second
cylindrical roller contacts the second side. The first cylindrical roller forms a first
textured surface on the first side proximate the first axis of the plastic layer, wherein
between 7 to 20 percent of slope angles on the first textured surface proximate the
first axis have a value between zero and five degrees.
A system for manufacturing a light collimating and diffusing film in accordance with
another exemplary embodiment is provided. The system includes a first heating
device configured to heat a plastic layer. The plastic layer has a first side and a
second side opposite the first side and at least a first peripheral edge. The plastic
layer extends along both a first axis and a second axis. The first axis is substantially
parallel to the first peripheral edge. The second axis is substantially perpendicular to
the first axis. The system further includes first and second cylindrical rollers being
disposed proximate one another for receiving the plastic layer. The system further
includes a second heating device configured to heat at least one of first and second
cylindrical rollers. The first cylindrical roller contacts the first side of the plastic layer
and forms a first textured surface on the first side and the second cylindrical roller
contacts the second side of the plastic layer, wherein between 7 to 20 percent of slope
angles on the first textured surface proximate the first axis have a value between zero
and five degrees.
A tool for forming a textured surface on a light collimating and diffusing film in
accordance with another exemplary embodiment is provided. The tool includes a
cylindrical portion disposed about a first axis and having an external textured surface
and first and second ends. The cylindrical portion further includes a first line
disposed proximate the external textured surface extending substantially across the
cylindrical portion substantially perpendicular to the first end. The cylindrical portion
further includes a second line extending around a periphery of the cylindrical portion
substantially a predetermined distance from the first end. The external textured
surface has a plurality of projecting portions and a plurality of trough portions,
wherein each projecting portion extends outwardly from at least one adjacent trough
portion. The plurality of projecting portions and the plurality of trough portions
define a plurality of slope angles, wherein between 7 to 20 percent of the slope angles
on the external textured surface proximate the first line or the second line have a value
between zero and five degrees.
A method for forming a textured surface on a cylindrical roller in accordance with
another exemplary embodiment is provided. The cylindrical roller is disposed about a
first axis and has an external textured surface and first and second ends. The
cylindrical roller further includes a first line disposed proximate.the external textured
surface extending substantially across the cylindrical roller substantially perpendicular
to the first end. The cylindrical roller further includes a second line extending around
a periphery of the cylindrical portion substantially a predetermined distance from the
first end. The method includes rotating the cylindrical roller at a predetermined
rotational speed about the first axis. The method further includes emitting a pulsating
energy beam that contacts the outer surface of the cylindrical roller at a predetermined
intensity and moving the energy beam from the first end to the second end of the
cylindrical roller during the rotation of the cylindrical roller. The energy beam
removes portions of the outer surface to obtain the textured surface, wherein between
7 to 20 percent of slope angles on the textured surface proximate the first line or the
second line have a value between zero and five degrees.
A method for forming a textured surface on a cylindrical roller in accordance with
another exemplary embodiment is provided. The cylindrical roller is disposed about a
first axis and has an external textured surface and first and second ends. The
cylindrical roller further includes a first line disposed proximate the external textured
surface. The first line extends substantially across the cylindrical roller substantially
perpendicular to the first end. The cylindrical roller further includes a second line
extending around a periphery of the cylindrical portion substantially a predetermined
distance from the first end. The method includes rotating the cylindrical roller at a
predetermined rotational speed about the first axis in an electrolyte fluid. The
cylindrical roller is electrically grounded. The method further includes applying a
predetermined current density to the electrolyte fluid wherein metal ions in the fluid
bond to the outer surface of the cylindrical roller to fbtm the textured surface, wherein
between 7 to 20 percent of slope angles on the textured surface proximate the first line
or the second line have a value between zero and five degrees.
A method for forming a textured surface on a cylindrical roller in accordance with
another exemplary embodiment is provided. The cylindrical roller is disposed about a
first axis and has an external textured surface and first and "second ends. The
cylindrical roller further includes a first line disposed proximate the external textured
surface. The first line extends substantially across the cylindrical roller substantially
perpendicular to the first end. The cylindrical roller further includes a second line
extending around a periphery of the cylindrical portion substantially a predetermined
distance from the first end. The method further includes rotating the cylindrical roller
at a predetermined rotational speed about the first axis in a fluid containing metal ions
and non-metal particles. The method further includes chemically bonding the metal
ions and the non-metal particles to the outer surface of the cylindrical roller to form
the textured surface, wherein between 7 to 20 percent of slope angles on the textured
surface proximate the first line or the second line have a value between zero and five
degrees.
A method for forming a textured surface on a cylindrical roller in accordance with
another exemplary embodiment is provided. The cylindrical roller is disposed about a
first axis and having an external textured surface and first and second ends. The
cylindrical roller further includes a first line disposed proximate the external textured
surface. The first line extends substantially across the cylindrical roller substantially
perpendicular to the first end. The cylindrical roller further includes a second line
extending around a periphery of the cylindrical portion substantially a predetermined
distance from the first end. The method includes rotating the cylindrical roller at a
predetermined rotational speed about the first axis. The method further includes
applying a dielectric fluid on the cylindrical roller. The method further includes
iteratively discharging an electric spark from one or more electrodes disposed
proximate the cylindrical roller. The electric spark contacts the outer surface of the
cylindrical roller that heats and melts a predetermined amount of metal on the
cylindrical" roller to form the textured surface. The electric spark is moved from the
first end to the second end of the cylindrical roller during the rotation of the
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cylindrical roller, wherein between 7 to 20 percent of slope angles on the textured
surface proximate the first line or the second line have a value between zero and five
degrees.
A method for forming a textured surface on a cylindrical roller in accordance with
another exemplary embodiment is provided. The cylindrical roller is disposed about a
first axis and has an external textured surface and first and second ends. The
cylindrical roller further includes a first line disposed proximate,the external textured
surface. The first line extends substantially across the cylindrical roller substantially
perpendicular to the first end. The cylindrical roller further includes a second line
extending around a periphery of the cylindrical portion substantially a predetermined
distance from the first end. The method includes rotating the cylindrical roller at a
predetermined rotational speed about the first axis. The method further includes
iteratively contacting the outer surface of the cylindrical roller using a cutting tool at a
predetermined frequency. The cutting tool moves from the first end to the second end
of the cylindrical roller during the rotation of the cylindrical roller. The cutting tool
removes portions of the outer surface to obtain the textured surface, wherein between
7 to 20 percent of slope angles on the textured surface proximate the first line or the
second line have a value between zero and five degrees.
A method for forming a textured surface on a cylindrical roller in accordance with
another exemplary embodiment is provided. The cylindrical roller is disposed about a
first axis and has an external textured surface and first and second ends. The
cylindrical roller further includes a first line disposed proximate the external textured
surface. The first line extends substantially across the cylindrical roller substantially
perpendicular to the first end. The cylindrical roller further includes a second line
extending around a periphery of the cylindrical portion substantially a predetermined
distance from the first end. The method includes coating the cylindrical roller with a
chemically resistant layer, wherein the chemically resistant layer is removed at
predetermined locations to expose the underlying cylindrical roller surface at the
predetermined locations. The method further includes rotating the cylindrical roller at
a predetermined rotational speed about the first axis in a container containing an
etching solution. The etching solution removes portions of the cylindrical roller at the
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predetermined locations to obtain the textured surface, wherein between 7 to 20
percent of slope angles on the textured surface proximate the first line or the second
line have a value between zero and five degrees.
A back lighted device in accordance with another exemplary embodiment is provided.
The back lighted device includes a light source. The back lighted device further
includes a light guide disposed proximate the light source for receiving light from the
light source. The back lighted device further includes at least one plastic layer having
a first side and a second side opposite the first side and at least a first peripheral edge.
The first side has.a first textured surface, wherein between 7 to 20 percent of slope
angles on the first textured surface proximate a first axis have a value between zero
and five degrees, the first axis being substantially parallel to the first peripheral edge,
wherein the plastic layer collimates light propagating therethrough.
A light collimating and diffusing film in accordance with another exemplary
embodiment is provided. The film includes a unitary layer wherein greater than or
equal to 80 percent of a total mass of the unitary layer comprises a polycarbonate
compound. The unitary layer has a first side and a second side opposite the first side
and at least a first peripheral edge. The first side has a first textured surface, wherein
between 7 to 20 percent of slope angles on the first textured surface proximate a first
axis have a value between zero and five degrees. The first axis is substantially
parallel to the first peripheral edge. The plastic layer collimates light propagating
therethrough.
Other systems and/or methods according to the embodiments will become or are
apparent to one with skill in the art upon review of the following drawings and
detailed description. It is intended that all such additional systems and methods be
within the scope of the present invention, and be protected by the accompanying
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is an exploded view of a back lighted device in accordance with an
exemplary embodiment;
Figure 2 is a schematic of a portion of the back lighted device of Figure 1;
Figure 3 is a cross-sectional schematic of a light collimating and diffusing film
utilized in the back lighted device of Figure 1 in accordance with another exemplary
embodiment;
Figure 4 is a graph indicating a slope distribution on a front surface of the light
collimating and diffusing film;
r"'
Figure 5 is a top view of a cylindrical roller illustrating exemplary trajectories for
determining a slope angle distribution;
Figure 6 is a top view of a light collimating and diffusing film illustrating exemplary
trajectories for determining a slope angle distribution;
Figure 7 is a top view of a cylindrical roller illustrating exemplary trajectories for
determining a slope angle distribution;
Figure 8 is a top view of a light collimating and diffusing film illustrating exemplary
trajectories for determining a slope angle distribution;
Figure 9 is a schematic of a melt calendaring system for manufacturing a light
collimating and diffusing film in accordance with another exemplary embodiment;
Figure 10 is a schematic of an embossing system for manufacturing a light
collimating and diffusing film in accordance with another exemplary embodiment;
Figure II is a schematic of an energy beam engraving system for obtaining a textured
surface on a cylindrical roller in accordance with another exemplary embodiment;
Figure 12 is a schematic of a textured surface on a cylindrical roller obtained using
the energy beam engraving system of Figure 11;
Figure 13 is a schematic of a textured surface on a light collimating and diffusing film
obtained using the cylindrical roller of Figure 12;
Figure 14 is a schematic of a particle and metal ion co-deposition system for obtaining
a textured surface on a cylindrical roller in accordance with another exemplary
embodiment;
Figure 15 is a schematic of a textured surface on a cylindrical roller obtained using
the particle and metal ion co-deposition system of Figure 14;
Figure 16 is a schematic of a textured surface on a light collimating and diffusing film
obtained using the cylindrical roller of Figure 15;
Figure 17 is a schematic of a metal ion deposition system for obtaining a textured
surface on a cylindrical roller in accordance with another exemplary embodiment;
Figure 18 is a schematic of a micro-machining engraving system for obtaining a
textured surface on a cylindrical roller in accordance with another exemplary
embodiment;
Figure 19 is an enlarged front view of a cutting cool utilized in the system of Figure
18;
Figure 20 is an enlarged side view of the cutting coo) utilized in the system of Figure
18;
Figure 21 is a schematic of chemical etching engraving system for obtaining a
textured surface on a cylindrical roller in accordance with another exemplary
embodiment;
Figure 22 is an enlarged cross-sectional view of a portion of the cylindrical roller
utilized by the system of Figure 21; and
Figure 23 is a schematic of an electric discharge engraving system for obtaining a
textured surface on a cylindrical roller in accordance with another exemplary
embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Referring to Figures 1 and 2, a back lighted device 20 for illuminating a liquid crystal
display device (not shown) is illustrated. The back lighted device 20 includes a light
source 22, a reflector film 24, a light guide 26, a light collimating and diffusing film
28, a light collimating film 30, a light collimating film 32, and a light diffuser film 34.
As shown, the light source 22 is disposed at a first end of the light guide 26. Further,
the reflector film 24 is disposed, proximate a first side of the light guide 26. A first
side of the light collimating and diffusing film 28 is disposed proximate a second side
of the light guide 26* and is spaced apart from the light guide 26 utilizing posts 36, 38.
The posts 36, 38 form an air gap 40 between the light guide 26 and the film 28. The
light collimating film 30 is disposed proximate a second side of the film 28. Finally,
the light collimating film 32 is disposed proximate the light collimating film 30 and
the light diffusing film 34 is disposed proximate the light collimating film 32.
The path of an exemplary light beam propagating through both the light guide 26 and
the light collimating and diffusing film 28 will now be explained. The light source 22
emits a light beam 42 that propagates through the light guide 26 and is refracted
therein toward an axis 44 that is substantially perpendicular to a top surface of the
light guide 26. When the light beam 42 exits the light guide 26 and the air gap 40, the
light beam 42 is refracted away from the axis 44 at approximately 45 degrees. When
the light beam 42 enters the light collimating and diffusing film 28, the film 28
refracts the light beam 42 toward the axis 44. Thereafter, when the light beam 42
exits the film 28 to light beam is refracted away from the axis 44 at approximately 31
degrees. Thereafter, the light beam 42 enters the bottom side of the light collimating
film 30 at a 31 degree angle relative of the axis 44 and propagates through the film 30.
The film 30 refracts the light beam at a top surface thereof to a zero degree angle
relative to the axis 44. Because the light beam enters film 32 at a zero degree angle
relative to the axis 44, the film 32 provides a relatively high luminance along axis 44.
Referring to Figures 2 and 3, the light collimating and diffusing film 28 will now be
explained in greater detail. The film 28 is utilized to refract lighj .beams toward the
axis 44. The film 28 is constructed from a unitary plastic layer having a thickness in a
10
range of 0.025-10 millimeters. Of course, the film 28 can be constructed with a
thickness less than 0.025 millimeters or greater than 10 millimeters. The film 28 has
an optical brightener compound disposed in the plastic layer wherein a mass of the
optical brightener compound is in a range of 0.001-1.0 percent of a total mass of the
plastic layer. The film 28 further includes an antistatic compound, such as fluorinated
phosphonium sulfonate, disposed in the plastic layer. Fluorinated phosphonium
sulfonate has a general formula: {CF3(CF2)n(SO3)}e {P(R|)(R2)(R3)(R4)} wherein F
is fluorine; n is an integer of from 1-12, S is sulfur; R|, Rj and R3 are the same
element, each having an aliphatic hydrocarbon radical of 1-8 carbon atoms or an
aromatic hydrocarbon radical of 6-12 carbon atoms; and R4 is a hydrocarbon radical
of 1-18 carbon atoms. The film 28 further includes an ultraviolet (UV) absorber
compound disposed in the plastic layer wherein a mass of the UV absorber compound
is in a range of 0.01-1.0 percent of a total mass of the plastic layer. The film 28
includes a textured top surface 46 having a plurality of projecting portions 52 and a
plurality of trough portions 54. The average height of the plurality of projecting
portions 52 is within a range of 25-75 percent of an average width of the plurality of
projecting portions. Further, the average width of the plurality of projecting portions
52 is within a range of 0.5-100 microns. The projecting portions 52 and the trough
portions 54 are distributed on the top surface 46 to obtain a desired slope angle
distribution.
The slope angle distribution is a distribution of a plurality of slope angles along at
least one predetermined trajectory on the light collimating and diffusing film 28.
Further, each slope angle () is calculated using the following equation:
Slope Angle 4> = arc tan |A/» / Aw| where:
(Aw) represents a predetermined width along the textured surface 46, such as 0.5
microns for example;
(Ah) represents a height difference between (i) a lowest position on the textured
surface 46 along the width (Aw), and (ii) a highest position on the surface 46 along
the width (Aw).
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The slope angles reported in this patent application for a plastic film can be calculated
from filtered two dimensional surface profile data generated using a Surfcoder ET
4000 instrument manufactured by Kosaka Laboratory Limited, Tokyo, Japan. The
operational settings of the Surfcoder ET 4000 instrument are as follows: Cutoff =
0.25mm, Sample Length and Evaluation Length both set at 10mm. The speed being
set at 0.1 mm/second with profile data being obtained at 8000 equally spaced points.
The slope angles reported in this patent application for a cylindrical roller can be
calculated from filtered two dimensional surface profile data generated using a
Surfcoder SE 1700a instrument also manufactured by Kosaka Laboratory Limited.
The operational settings of the Surfcoder SE 1700a instrument are as follows:
Evaluation Length = 7.2mrn, Cutoff Lc = 0.800mm. The speed being set at 0.500
mm/second with profile data being obtained at 14400 points.
The slope angle distribution can be determined along a predetermined reference
trajectory or line on the plastic layer. Alternately, a slope angle distribution can be
determined on an entire surface of the plastic layer using multiple reference
trajectories or lines.
For example, referring to Figures 6 and 8, a plurality of slope angles () can be calculated along a
line 80 or a line 82. In one or more of the foregoing trajectories, the desired slope
angle distribution comprises between 7 to 20 percent of slope angles having a value
between zero and five degrees.
Referring to Figure 4, a graph illustrating a slope angle distribution on a textured
surface 46 on a first side of the film 28 in accordance with an exemplary embodiment
is illustrated. The inventors herein have recognized that when 20 percent or less of
slope angles on the textured surface 46, and preferably between 7 to 20 percent of
slope angles on the surface 46, have a value between zero and five degrees, adjacent
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brightness enhancing films (e.g., films 30 and 32) have increased luminance with
respect to the axis 44.
Referring to Figures 1 and 2, the percentage of slope angles between zero and five
degrees on the textured top surface 46 controls the angle of the light that exits the film
28 and enters the light collimating film 30. When the percentage of slope angles on
the surface 46 is about 16 percent, the light exits the film 28 at a 31 degree angle
relative to axis 44 as shown. In an alternate embodiment, if it is desirable for the light
to exit the film 28 at an angle greater than 31 degrees relative to the axis 44, then the
film 28 could be constructed with greater than 16 percent of the slope angles having a
value between zero and five degrees. In another alternate embodiment, if it is
desirable for the light to exit the film 28 at an angle less than 31 degrees relative to the
axis 44, then the film 28 could be constructed with less than 16 percent of the slope
angles having a value between zero and five degrees.
Referring to Figure 3, the film 28 also has a textured surface 48 on a second side of
the film 28. The textured surface 48 has a slope angle distribution wherein greater
than or equal to or 70 percent of the slope angles on the textured surface 48 have a
value between zero and five degrees.
Referring to Figure 9, a melt calendaring system 100 for manufacturing a textured
plastic layer 106 that can be subsequently cut into a predetermined shape to form light
collimating and diffusing film 28 is illustrated. The melt calendaring system 100
includes an extruder device 102, a die 104, cylindrical rollers 64, 108, 110, 112, 114,
116, a cylindrical spool 118, a roller cooling system 120, a film thickness scanner
122, motors 124, 126,128, and a control computer 130.
The extruder device 102 is provided to heat plastic above a predetermined
temperature to induce the plastic to have a liquid state. The extruder device 102 is
operably coupled to the die 104 and to the control computer 130. In response to a
control signal (E) from the control computer 130, the extruder device 102 heats plastic
therein above a predetermined temperature and urges the plastic through the die 104
to form the plastic layer 106.
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The cylindrical rollers 64. 108 are provided to receive the plastic layer 106
therebetween from the die 104 and to form a textured surface on a least one side of
the plastic layer 106. The cylindrical rollers 64, 108 are preferably constructed from
steel and are operably coupled to the roller cooling system 120. Of course, in an
alternate embodiment, the cylindrical rollers 64, 108 may be constructed from other
metallic or non-metallic materials known to those skilled in the art. The roller cooling
system 120 maintains a temperature of the rollers 64, 108 below a predetermined
temperature to solidify the plastic layer 106 as it passes between the rollers 64, 108.
The cylindrical roller 64 has a textured surface 107 wherein between 7 to 20 percent
of slope angles on the textured surface 107 or along at least one trajectory on the
textured surface 107 have a value between zero and five degrees. Thus, when the.
cylindrical roller 64 contacts a first side of the plastic layer 106, the cylindrical roller
64 forms a textured surface on the plastic layer 106, wherein between 7 to 20 percent
of slope angles on the surface 46 of the layer 106 or along at least one trajectory on
the textured surface 46 have a value between zero and five degrees.
Referring to Figures 5 and 7, the slope angles (<}>) of the cylindrical roller 64 can be
;
determined along a predetermined trajectory across the outer surface 107, such as a
line 68 extending substantially across the roller 64 substantially perpendicular to the
end 211 or a line 62 extending substantially around a periphery of the roller 64 a
predetermined distance from the end 211. Alternately, the slope angles () of the
cylindrical roller 64 can be determined along a line 84 or a line 86.
The cylindrical rollers 110, 112 are configured to receive the plastic layer 106 after
the layer 106 has passed between the rollers 64, 108. The position of the cylindrical
roller 116 can be adjusted to vary an amount of surface area of the plastic layer 106
that contacts the cylindrical roller 108. The cylindrical roller 110 is operably coupled
to the roller cooling system 120 that maintains the temperature of the roller 110 below
a predetermined temperature for solidifying the plastic layer 106. The cylindrical
roller 112 receives a portion of the plastic layer 106 downstream of the roller 110 and
directs the plastic layer 106 toward the cylindrical rollers 114, 116.
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The cylindrical rollers 114. 116 are provided to receive the plastic layer 106
therebetween and to move the plastic layer 106 toward the cylindrical spool 118, The
cylindrical rollers 114, 116 are operably coupled to the motors 126, 124, respectively.
The control computer 130 generates control signals (Ml), (M2) which induce motors
124, 126, respectively, to rotate the rollers 116, 114 in predetermined directions for
urging the plastic layer 106 towards the spool 118.
The cylindrical spool 118 is provided to receive the textured plastic layer 106 and to
form a roll of plastic layer 106. The cylindrical spool 118 is operably coupled to the
motor 128. The control computer 130 generates a control signal (M3) that induces the
motor 128 to rotate the spool 118 in predetermined direction for forming a roll of the
plastic layer 106.
The film thickness scanner 122 is provided to measure a thickness of the plastic layer
106 prior to the layer 106 being received by the cylindrical rollers 114, 116. The film
thickness scanner 122 generates a signal (Tl) indicative of the thickness of the plastic
layer 106 that is transmitted to the control computer 130.
Referring to Figure 10, an embossing system 150 for manufacturing a plastic layer
154 that can be subsequently cut into a predetermined shape to form the film 28 is
illustrated. The embossing system 150 includes a cylindrical spool 152, a filmheating
device 156, cylindrical rollers 64, 160, 162, 164, 166, 168, a cylindrical spool
170, a roller heating system 172, a film thickness scanner 174, motors 176, 178, 180,
and a control computer 182.
The cylindrical spool 152 is provided to hold the plastic layer 150 thereon. When the
cylindrical spool 152 rotates, a portion of the plastic layer 150 is unwound from the
spool 152 and moves toward the cylindrical rollers 64, 160.
The film-heating device 156 is provided to heat the plastic layer 150 as it moves from
the cylindrical spool 152 towards the cylindrical rollers 64. 160. The control
computer 182 generates a signal (HI) that is transmitted to the film-heating device
156 that induces the device 156 to heat the plastic layer 150 above a predetermined
temperature.
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The cylindrical rollers 64, 160 are provided to receive the plastic layer 154
therebetween from the cylindrical spool 152 and to form a textured surface on a least
one side of the plastic layer 154. The cylindrical rollers 64, 160 are preferably
constructed from steel and are operably coupled to the roller heating system 172. Of
course, in an alternate embodiment, the cylindrical rollers 64, 160 may be constructed
from other metallic or non-metallic materials known to those skilled in the art. The
roller heating system 172 maintains a temperature of the rollers 64, 160 above a
predetermined temperature to at least partially melt the plastic layer 154 as it passes
between the rollers 64, 160. The cylindrical roller 64 has an outer textured surface
107 wherein between 7 to 20 percent of slope angles on the textured surface 107 have
a value between zero and five degrees. Thus, when the cylindrical roller 64 contacts a
first side of the plastic layer 154, the cylindrical roller 64 forms a textured surface, on
the plastic layer 154, wherein between 7 to 20 percent of slope angles on the top
surface of the layer 154 have a value between zero and five degrees.
The cylindrical rollers 162, 164 are configured to receive the plastic layer 154 after
the layer 154 has passed between the rollers 64, 160. The position of the cylindrical
roller 162 can be adjusted to vary an amount of surface area of the plastic layer 154
that contacts the cylindrical roller 160. The cylindrical roller 164 receives a portion
of the plastic layer 154 downstream of the roller 162 and directs the plastic layer 154
toward the cylindrical rollers 166,168.
The cylindrical rollers 166, 168 are provided to receive the plastic layer 154 and to
move the plastic layer 154 toward the cylindrical spool 170. The cylindrical rollers
166, 168 are operably coupled to the motors 178, 176, respectively. The control
computer 182 generates control signals (M4), (M5) which induce motors 176, 178,
respectively, to rotate the rollers 168, 166 in predetermined directions for urging the
plastic layer 154 towards the spool 170.
The cylindrical spool 170 is provided to receive the plastic layer 154 and to form a
roll of plastic layer 154. The cylindrical spool 170 is operably coupled to the motor
180. The control computer 182 generates a control signal (M6) that induces the motor
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180 to rotate the spool 170 in predetermined direction for forming a roll of the plastic
layer 1'54.
The filrn thickness scanner 174 is provided to measure a thickness of the plastic layer
154 prior to the layer 154 being received by the cylindrical rollers 114, 116. The film
thickness scanner 174 generates a signal (T2) indicative of the thickness of the plastic
layer 154 that is transmitted to the control computer 182.
f-
Referring to Figure J 1 , a system 200 for forming a textured surface on the cylindrical
roller 64 in accordance with an exemplary embodiment is illustrated. The cylindrical
roller 64 has a textured surface can be utilized in the melt calendaring system 100 or
the embossing system 150 to form a textured plastic layer used to obtain the film 28.
The system 200 includes a laser 202, a linear actuator 204, a motor 206, and a control
computer 208.
The laser 202 is provided to emit a pulsating laser beam that contacts an outer surface
at a predetermined intensity to remove portions of the outer surface 209 to obtain a
textured surface thereon. The laser beam emitted by the laser 202 has a focal
diameter at the outer surface 209 of the cylindrical roller 64 in a range of 0.005-0.5
millimeters. Further, the laser beam has an energy level in a range of 0.05-1.0 Joules
delivered over a time period in a range of 0.1-100 microseconds for a predetermined
area of the cylindrical roller 64. The laser 202 is operably coupled to the control
computer 208 and generates the laser beam in response to a control signal (Cl) being
received from the control computer 208. The laser 102 comprises a neodymium
(Nd):yttrium, aluminum, garnet (YAG) laser configured to emit a laser beam having a
wavelength of 1.06 microns. It should be understood, however, that any laser source
capable-o-f forming the desired textured surface on a cylindrical roller can be utilized.
In an alternate embodiment, the laser 202 can be replaced with an electron beam
emission device configured to form the desired textured surface on a cylindrical
roller. In still another alternate embodiment, the laser 202 can be replaced with an < ion
beam emission device configured to form the desired textured surface on a cylindrical
»•
roller.
17
The linear actuator 204 is operably coupled to the laser 202 for moving the laser 202
along an axis 203. The axis 203 is substantially parallel to the outer surface 209 of
the cylindrical roller 64. The linear actuator 204 moves the laser 202 relative to the
cylindrical roller 64 at a speed within a range of 0.001-0.1 millimeters per secondO..
In an alternate embodiment, linear actuator 204 could be coupled to cylindrical roller
64 to move the roller 64 in an axial direction relative to a stationary laser.
The motor 206 is operably coupled to the cylindrical roller 64 to rotate the roller 64
while the linear actuator 204 is moving the laser 202 along the axis 203 from an end
211 to an end 213 of the roller 64. The control computer 200 generates a signal
Documents
Application Documents
| # |
Name |
Date |
| 1 |
592-DELNP-2007-GPA-(10-11-2008).pdf |
2008-11-10 |
| 1 |
592-DELNP-2007_EXAMREPORT.pdf |
2016-06-30 |
| 2 |
592-delnp-2007-abstract.pdf |
2011-08-21 |
| 2 |
592-delnp-2007-form-6-(10-11-2008).pdf |
2008-11-10 |
| 3 |
592-DELNP-2007-Form-2-(10-11-2008).pdf |
2008-11-10 |
| 3 |
592-delnp-2007-assignment.pdf |
2011-08-21 |
| 4 |
592-DELNP-2007-Form-1-(10-11-2008).pdf |
2008-11-10 |
| 4 |
592-delnp-2007-claims.pdf |
2011-08-21 |
| 5 |
592-DELNP-2007-Correspondence-Others.pdf |
2011-08-21 |
| 5 |
592-DELNP-2007-Correspondence-Others-(10-11-2008).pdf |
2008-11-10 |
| 6 |
592-delnp-2007-description (complete).pdf |
2011-08-21 |
| 6 |
592-DELNP-2007-Assignment-(10-11-2008).pdf |
2008-11-10 |
| 7 |
592-delnp-2007-pct-237.pdf |
2011-08-21 |
| 7 |
592-delnp-2007-drawings.pdf |
2011-08-21 |
| 8 |
592-delnp-2007-pct-220.pdf |
2011-08-21 |
| 8 |
592-delnp-2007-form-1.pdf |
2011-08-21 |
| 9 |
592-delnp-2007-form-2.pdf |
2011-08-21 |
| 9 |
592-delnp-2007-pct-210.pdf |
2011-08-21 |
| 10 |
592-DELNP-2007-Form-3.pdf |
2011-08-21 |
| 10 |
592-delnp-2007-pct-101.pdf |
2011-08-21 |
| 11 |
592-delnp-2007-form-5.pdf |
2011-08-21 |
| 12 |
592-DELNP-2007-Form-3.pdf |
2011-08-21 |
| 12 |
592-delnp-2007-pct-101.pdf |
2011-08-21 |
| 13 |
592-delnp-2007-form-2.pdf |
2011-08-21 |
| 13 |
592-delnp-2007-pct-210.pdf |
2011-08-21 |
| 14 |
592-delnp-2007-form-1.pdf |
2011-08-21 |
| 14 |
592-delnp-2007-pct-220.pdf |
2011-08-21 |
| 15 |
592-delnp-2007-drawings.pdf |
2011-08-21 |
| 15 |
592-delnp-2007-pct-237.pdf |
2011-08-21 |
| 16 |
592-DELNP-2007-Assignment-(10-11-2008).pdf |
2008-11-10 |
| 16 |
592-delnp-2007-description (complete).pdf |
2011-08-21 |
| 17 |
592-DELNP-2007-Correspondence-Others-(10-11-2008).pdf |
2008-11-10 |
| 17 |
592-DELNP-2007-Correspondence-Others.pdf |
2011-08-21 |
| 18 |
592-delnp-2007-claims.pdf |
2011-08-21 |
| 18 |
592-DELNP-2007-Form-1-(10-11-2008).pdf |
2008-11-10 |
| 19 |
592-DELNP-2007-Form-2-(10-11-2008).pdf |
2008-11-10 |
| 19 |
592-delnp-2007-assignment.pdf |
2011-08-21 |
| 20 |
592-delnp-2007-form-6-(10-11-2008).pdf |
2008-11-10 |
| 20 |
592-delnp-2007-abstract.pdf |
2011-08-21 |
| 21 |
592-DELNP-2007_EXAMREPORT.pdf |
2016-06-30 |
| 21 |
592-DELNP-2007-GPA-(10-11-2008).pdf |
2008-11-10 |