CN110271262A - 制造薄膜装置的无溶剂方法 - Google Patents

制造薄膜装置的无溶剂方法 Download PDF

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CN110271262A
CN110271262A CN201910194741.0A CN201910194741A CN110271262A CN 110271262 A CN110271262 A CN 110271262A CN 201910194741 A CN201910194741 A CN 201910194741A CN 110271262 A CN110271262 A CN 110271262A
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layer
plural layers
net
layers
mechanical force
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阿尔博特·阿革帝亚
梁康宁
约翰尼斯·P·赛德尔
雅罗斯拉夫·齐巴
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Only Yahweh Communication Technology Co Ltd
Viavi Solutions Inc
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Only Yahweh Communication Technology Co Ltd
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    • C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
    • C09C1/0015—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings
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    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
    • H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
    • H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
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    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
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    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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    • C09C1/0024—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating high and low refractive indices, wherein the first coating layer on the core surface has the high refractive index
    • C09C1/003—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating high and low refractive indices, wherein the first coating layer on the core surface has the high refractive index comprising at least one light-absorbing layer
    • C09C1/0033—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating high and low refractive indices, wherein the first coating layer on the core surface has the high refractive index comprising at least one light-absorbing layer consisting of a metal or an alloy
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    • C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
    • C09C1/0015—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings
    • C09C1/0024—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating high and low refractive indices, wherein the first coating layer on the core surface has the high refractive index
    • C09C1/0048—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating high and low refractive indices, wherein the first coating layer on the core surface has the high refractive index comprising at least one optically active layer with at least one organic material layer, e.g. liquid crystal polymers
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    • C09C1/0051—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating low and high refractive indices, wherein the first coating layer on the core surface has the low refractive index
    • C09C1/0057—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating low and high refractive indices, wherein the first coating layer on the core surface has the low refractive index comprising at least one light-absorbing layer
    • C09C1/006—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating low and high refractive indices, wherein the first coating layer on the core surface has the low refractive index comprising at least one light-absorbing layer consisting of a metal or an alloy
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    • C09C1/0051—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating low and high refractive indices, wherein the first coating layer on the core surface has the low refractive index
    • C09C1/0075—Pigments exhibiting interference colours, e.g. transparent platelets of appropriate thinness or flaky substrates, e.g. mica, bearing appropriate thin transparent coatings comprising a stack of coating layers with alternating low and high refractive indices, wherein the first coating layer on the core surface has the low refractive index comprising at least one optically active layer with at least one organic material layer, e.g. liquid crystal polymers
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Abstract

本申请涉及制造薄膜装置的无溶剂方法。一种形成薄膜装置的方法包括：用多层薄膜包覆网；和施加机械力以从网释放多层薄膜。公开了形成薄膜装置的另外的方法。

Description

制造薄膜装置的无溶剂方法
相关申请
本申请要求于2018年3月14日提交的美国临时申请第62/643,038号的优先权，该申请的公开内容据此通过引用并入。
发明领域
本公开内容总体上涉及形成薄膜装置的方法，所述方法包括：用多层薄膜包覆网(web)；和施加机械力以从该网释放多层薄膜。
发明背景
薄膜装置通常在具有释放层的网上制造，该释放层在多层结构和网之间。在某些情况下，释放层是氯化钠释放层，所述释放层在包覆薄膜装置之前被蒸发。在其他情况下，释放层是由聚对苯二甲酸乙二醇酯网提供的丙酮可溶性聚合物释放层。在两种情况下，薄膜在湿法工艺中被剥离去，所述湿法工艺使用丙酮/水或100％丙酮溶解释放层。危险且可燃的丙酮(溶剂)的使用需要用于如剥离的薄膜的剥离、冲洗、过滤和干燥的专用工艺设备。
对于从具有释放层的网移除多层结构而不使用苛性溶剂(caustic solvent)的方法，例如使用更简单且更不昂贵的干燥工艺替代当前的湿法工艺的方法存在需求。另外，或可选择地，对于从不具有释放层的网移除多层结构的方法存在需求。这样的方法将是更简单的工艺，并且由于另外的材料的消除，将更具有成本效益。
发明概述
在一个方面，公开了一种形成薄膜装置的方法，所述方法包括：用多层薄膜包覆网；和施加机械力以从网释放多层薄膜。
在另一个方面，公开了一种形成薄膜装置的方法，所述方法包括用第一层包覆网；用反射物层(reflector layer)包覆第一层；用第二层包覆反射物层，以形成多层薄膜；和通过干燥技术从网释放多层薄膜。
在又一个方面，公开了一种形成薄膜装置的方法，所述方法包括：提供具有释放层的网；用多层薄膜包覆释放层；和施加机械力以从网释放多层薄膜。
各个实施方案的另外的特征和优点将部分地在以下的描述中阐述，并且部分地从描述中将是明显的或者可以通过实践各个实施方案而得知。各个实施方案的目的和其他优点将借助于在本文的描述中特别指出的要素和组合来实现和获得。
附图说明
从详细描述和附图中可以更充分地理解在其若干方面和实施方案中的本公开内容，在附图中：
图1示出了根据本公开内容的实施例的用于进行该方法的方面的转移方法；
图2是根据本公开内容的实施例的薄膜装置的横截面图；
图3是根据本公开内容的实施例的薄膜装置的横截面图；
图4是根据本公开内容的实施例的薄膜装置的横截面图；以及
图5是根据本公开内容的实施例的薄膜装置的横截面图。
贯穿本说明书和附图，相同的附图标记表示相同的要素。
发明详述
应当理解，前述的一般性描述和以下的详述两者仅是示例性的和解释性的，并且意图提供对本教导的各个实施方案的解释。每幅图中示出的层/部件可以关于特定的图被描述，但是应理解，特定的层/部件的描述将适用于其他图中的等效的层/部件。
在其广泛和变化的实施方案中，公开了用于形成薄膜装置10的方法，所述方法包括：用多层薄膜20包覆网40；和施加机械力以从网40释放多层薄膜20。在一个方面，网40不包括释放层30，并且多层薄膜20被直接沉积到网40上。多层薄膜20可以包括两层或更多层，例如3层、4层、5层或6层或更多层，例如7层。在一个方面，多层薄膜20可以包括3层。在另一个方面，多层薄膜20可以包括5层。多层薄膜20可以包括法布里-珀罗结构(Fabry-Perotstructure)。法布里-珀罗结构可以具有5层或更多层，以提供薄膜干涉效应(thin filminterference effect)。法布里-珀罗结构中存在的层的数目可以变化，这不仅取决于期望的光学性质，而且取决于其他性质，例如，磁性性质。该方法可以被用于制造薄膜装置10，例如专用效果颜料。包括多层薄膜20的层在下文更充分地讨论。
在一个方面，形成薄膜装置10的方法可以包括用第一层包覆网40；用反射物层包覆第一层；用第二层包覆反射物层以形成多层薄膜20；和通过干燥技术从网40释放多层薄膜20。在一个方面，网40不包括释放层30，并且多层薄膜20例如第一层被直接沉积到网40上。该方法还可以包括收集释放的多层薄膜20。该方法还可以包括研磨释放的多层薄膜20。第一层、反射物层和第二层在下文更充分地讨论。
在另一个方面，公开了形成薄膜装置10的方法，所述方法包括：提供具有释放层30的网40；用多层薄膜20包覆释放层30；和施加机械力以从网40释放多层薄膜20。在一个方面，多层薄膜20可以包括3层。在另一个方面，多层薄膜20可以包括5层。多层薄膜20可以包括法布里-珀罗结构。法布里-珀罗结构可以具有5层或更多层，以提供薄膜干涉效应。法布里-珀罗结构中存在的层的数目可以变化，这不仅取决于期望的光学性质，而且取决于其他性质例如磁性性质。该方法可以被用于制造薄膜装置10，例如专用效果颜料。包括多层薄膜20的层在下文更充分地讨论。在一个方面，被包覆在释放层30上的多层薄膜20可以包括被包覆在释放层30上的第一层；所述第一层包覆有反射物层；并且所述反射物层包覆有第二层以形成多层薄膜20。第一层、反射物层和第二层在下文更充分地讨论。
在本文公开的方法中使用的网40可以是可以容纳释放层30和多层薄膜20中的至少一种的任何材料。在一个方面，网40可以是微观结构网40，例如聚对苯二甲酸乙二醇酯(PET)。网40可以是柔性的。在某些方面，网40可以包括释放层30。在其他方面，网40可以不存在释放层30，使得多层薄膜20，例如第一层，可以被直接包覆到网40上。
在本文公开的方法的某些中使用的释放层30可以以至网40的低粘附力(lowadhesion)被设置在网40的表面上。在一个方面，相比于至网40的低粘附力，释放层30可以以至多层薄膜20的第一层的更低粘附力存在。以此方式，释放层30可以更容易地从网40移除，而不是多层薄膜20的第一层。在一个方面，释放层30可以是水溶性的。在研磨工艺之后且在钝化/功能化湿法工艺之前，释放层30可以从多层薄膜20移除，例如，如与包含金属层例如铝层的颜料一起使用。干燥技术，例如干燥剥离工艺，可以在不存在释放层30的情况下进行，或可以在具有至网40的低粘附力的释放层30的情况下进行。释放层30不必要存在于网40和多层薄膜20之间。
释放层30可以选自聚乙烯醇制剂、多糖制剂(葡聚糖)、聚丙烯酸制剂、聚乙酸乙烯酯制剂、聚乙烯吡咯烷酮制剂、羧甲基纤维素制剂及其组合。释放层30可以是水溶性的，但对于用于包覆多层薄膜20的溶剂是不溶性的，所述多层薄膜20包括第一层、反射物层和第二层。另外，释放层30的分子量可以改变，以改进在水中的溶解度。例如，如果第一层具有基于水的制剂，那么释放层30应当具有在水中的低的溶解度。释放层30应当保持其完整性持续多层薄膜20的至少第一层的包覆和干燥所需的时间段。
在一个方面，释放层30可以是聚乙烯醇(PVA)制剂。此制剂无毒、澄清且惰性。它是具有优良的成膜性质的水溶性聚合物。PVA的涂层对疏水性聚合物例如聚邻苯二甲酸乙二醇酯(PET)的表面具有低的粘附力，并且在大多数有机溶剂中不溶。当一个或多个含溶剂层(solvent-borne layer)被包覆到预包覆在疏水性聚合物片材(网)上的PVA层上时，PVA层不仅在包覆工艺期间保持完整，而且能够通过施加机械力，例如来自压缩空气或水流的冲击，使得层与聚合物片材(网)方便地分离。以此方式，PVA层可以起释放层30的作用。
PVA层可以通过将PVA水溶液包覆到网40上来形成。充分水解的PVA和部分水解的(例如，86％-88％水解的)PVA两者均可以被用于形成释放层30。此外，具有在从Mw 10,000至200,000的范围内的分子量的PVA可以适合于释放层30。部分水解的PVA可以产生澄清的涂层和在冷水中的高溶解度，而充分水解的PVA由于其强的分子内氢键相互作用而可以产生较硬的涂层。低分子量可以实现迅速的水溶解和低的溶液粘度。相反地，高分子量可以导致缓慢的水溶解和高的溶液粘度。
具有0.01％至30％PVA的制剂可以被用于包覆网40并形成释放层30。除了PVA之外，添加剂例如表面活性剂、变形剂(deforming agent)、有机溶剂、防污剂等还可以被包括在形成释放层30的制剂中，以增强涂层性能。取决于网40的性质，有效的PVA释放层可以具有在从约1nm至约10微米的范围内例如在从约50nm至约1100nm的范围内的层厚度。
PVA可以在室温或升高的温度通过交联剂交联。合适的交联剂包括但不限于二醛例如乙二醛和戊二醛；二羧酸例如丙二酸、琥珀酸、戊二酸、己二酸等；硼酸；以及某些多价金属离子例如Al3+。PVA层的交联可以致使其在水中不溶，并能够起用于含水涂层(water-borne coating)的释放材料的作用。
在一个方面，聚丙烯酸(PAA)-PVA混合物可以被用作释放层30。混合物至网40的粘附力可以通过添加碱例如氢氧化钠以控制中和的羧酸基团的含量来调节。当PAA与氢氧化钠反应时，它形成羧酸钠盐。据已经发现，PAA-PVA释放层30至网40的粘附力可以随着羧酸盐含量的含量增加而降低。以此方式，通过控制羧酸盐在释放层30中的量来调节多层薄膜20的释放是可能的。
释放层30可以包括无机盐和/或有机盐。用于释放层30的合适的盐的非限制性实例包括氯化钠、硫酸钠、氯化钾、乙酸钠及其组合。盐可以改变释放层30的性质，并且可以减小释放层30和网40之间的粘附力。
多层薄膜20可以包括第一层、反射物层、第二层和另外的层例如吸收层和/或磁性层中的至少一种。另外的层可以位于多层薄膜20中的多个位置。例如，多层薄膜20可以包括法布里-珀罗结构，例如吸收层/介电层/反射物层/介电层/吸收剂层。
在公开的方法中，第一层和第二层可以各自独立地是有机层或复合的有机层/无机层。第一层和第二层可以各自独立地包括以下中的至少一种：无色颗粒、有机着色剂颜料、有机着色剂染料、无机有色颗粒、有机吸收剂颗粒、无机吸收剂颗粒、有机高折射率介电颗粒(organic high index dielectric particle)、无机高折射率介电颗粒(inorganichigh index dielectric particle)、有机低折射率介电颗粒(organic low indexdielectric particle)、无机低折射率介电颗粒(inorganic low index dielectricparticle)、无机金属颗粒、无机复合材料以及无机合金。第一层和第二层的分子和/或颗粒可以具有不产生米氏散射(Mie scattering)的尺寸，当分子尺寸或颗粒尺寸大于入射光的波长时，可以产生米氏散射。这与瑞利散射(Rayleigh scattering)形成对比，瑞利散射是当入射光的波长大于颗粒尺寸时的情况。
无机高折射率介电颗粒和无机低折射率颗粒的非限制性实例包括SiO2、TiO2、Al2O3、ZrO2、WO3、VO5、ITO、Ta2O5、CeO2、Y2O3、ZnS、ZnO、In2O3、La2O3、MgO、Nd2O3、Pr6O11、Fe2O3、Fe3O4、SiO、SnO2、FeOx、MgF2、AlF3、CeF3、LaF3、LiF、CaF2、TiC、TiN、金属陶瓷、类金刚石碳、金属碳化物、金属氮化物、金属硼化物、金属碳氮化物(metal carbonitride)、金属氧碳化物(metal oxycarbide)、金属氧氮化物(metal oxynitride)、金属氧碳氮化物(metaloxycarbonitride)、硼氮化物(boron carbide)及其组合。
有机吸收剂颗粒和无机吸收剂颗粒的非限制性实例包括碳、石墨、硅、锗、金属陶瓷、混合在介电基质中的金属以及能够充当可见光谱中的均匀或选择性吸收剂的其他物质。金属陶瓷和不同的合金，例如铬镍铁合金、不锈钢、哈司特镍基合金(hastelloy)等，还可以被用于它们的光学性质和物理性质。某些金属碳化物、金属氮化物、金属硼化物、金属碳氮化物、金属氧碳化物、金属氧氮化物、金属氧碳氮化物还可以被用于它们在嵌入在有机基质中时的吸收性质。
第一层和/或第二层可以包括可以使用的有机单体和聚合物，丙烯酸酯(例如，甲基丙烯酸酯)、环氧树脂、全氟烯烃、聚四氟乙烯(特氟隆)、氟化乙烯丙烯(FEP)、聚酯类、聚乙烯类、聚酰胺类、聚酰亚胺类、聚氨酯类、聚丙烯酸酯类、聚甲基丙烯酸酯类、聚碳酸酯类、聚脲类、乙酸丁酸纤维素、乙酸丙酸纤维素、硝酸纤维素及其组合。
第一层和/或第二层可以包括无机介电颗粒，以不仅改变最终薄膜颜料薄片(final thin film pigment flake)的视觉外观，而且改变它的其他功能。通过添加无机颗粒产生的功能性质包括但不限于电性质和/或磁性质、荧光性质、上转换性质(up-converting property)(例如，将近红外激光束转换成可见光或将光的低能量颜色例如红色转换成较高能量颜色，如蓝色或绿色)、阻燃剂以及静电耗散。
有机着色剂颜料和有机着色剂染料的非限制性实例包括苝、紫环酮(perinone)、喹吖啶酮、喹吖啶酮醌(quinacridonequinone)、蒽嘧啶、蒽醌、蒽嵌蒽醌(anthanthrone)、苯并咪唑酮、双偶氮缩合(disazo condensation)、偶氮(azo)、喹诺酮、氧杂蒽、甲亚胺、喹酞酮、靛蒽酮、酞菁、三芳基碳鎓离子、二噁嗪、氨基蒽醌、异吲哚啉、二酮吡咯并吡咯、硫靛、噻嗪靛(thiazineindigo)、异吲哚啉、异吲哚啉酮、皮蒽酮、异紫蒽酮、三芳甲烷(miyoshimethane)、三芳基甲烷、还原染料、硫染料及其混合物。
多层薄膜20可以包括包覆在PVA-PET上的第一层环氧树脂、丙烯酸酯或环氧树脂-丙烯酸酯混杂物(hybrid)。第一层可以使用含溶剂制剂，使用狭缝式模具包覆器(slot diecoater)或牵伸包覆器(drawdown coater)来包覆。在一个方面，此第一层可以通过施加的机械力例如空气剥离方法从PET网40被成功地剥离。
在又一个方面，多层薄膜20可以包括所有包括诸如(HL)n、(LH)n、(HL)nH、(LH)nL及其组合的设计的介电薄膜干涉结构，其中n是从约1至约100的整数，例如从约2至4的整数。L层和H层各自是在选择的设计波长处的QWOT。其他合适的设计还可以通过具有不同光学厚度的高介电涂层和低介电涂层的组合获得，并且在某些设计中，某些层可能不具有相同波长的QWOT。类似地，某些光学设计可以是对称的。
包括第一层、第二层、反射物层和另外的层的多层薄膜20可以使用沉积工艺来沉积。在一个方面，每个层可以使用选自以下的工艺作为涂层被独立地施加：狭缝式模制、凹版印刷、微型凹版印刷(microgravure)、喷涂、幕帘式包覆(curtain coating)、计量棒、迈耶棒包覆(myer bar coating)、柔版印刷和胶版印刷。在另一个方面，每个层可以在真空下使用选自物理气相沉积和化学气相沉积的工艺作为涂层被独立地施加。在又一个方面，第一层和第二层可以使用选自以下的工艺被施加：狭缝式模制、凹版印刷、微型凹版印刷、喷涂、幕帘式包覆、计量棒、迈耶棒包覆、柔版印刷和胶版印刷；并且反射物层在真空下使用选自物理气相沉积和化学气相沉积的工艺来施加。
多层薄膜20的反射物层可以在真空下被沉积。反射物层可以包括具有反射性质的任何材料，例如金属。具有反射性质的材料的非限制性实例包括铝、银、铜、金、铂、锡、钛、钯、镍、钴、铑、铌、铬及其化合物、组合或合金。其他合适的反射性合金和化合物的非限制性实例包括青铜、黄铜、氮化钛及类似物，以及上文列出的金属的合金，例如银-钯。反射物层可以具有固有颜色，例如铜、金、银铜合金、黄铜、青铜、氮化钛及其化合物、组合或合金。
反射物层还可以包括掺入到有机基质中的具有反射性质的颗粒。针对在真空下沉积的反射物层描述的相同材料可以被用作添加剂颗粒，进入合适的有机基质中。此外，可以使用勃拉谢尔银工艺(Brashear silver process)的变形来沉积银反射物层。
基于包括铝的反射物层的专用效果颜料可以使用钝化处理来进一步加工，以避免铝层的氧化。
多层薄膜20可以独立地包括在第一层、反射物层、第二层和/或另外的层的每种中的内聚和粘合促进剂材料。这些材料可以被直接添加至每个层或多层薄膜20的界面。合适的粘合促进剂包括但不限于包含羟基基团、硫醇基团、胺基团、羧酸基团、磷酸基团或硅氧烷基团的分子和树脂。
本文公开的方法可以包括使用干燥技术，例如施加机械力以从网40和/或具有释放层30(如果存在的话)的网40释放多层薄膜20。在一个方面，机械力的施加可以使得多层薄膜20形成薄片，所述薄片可以被释放并且进一步加工。在另一个方面，机械力的施加不形成薄片，而形成具有特定的光学和功能设计的自支撑薄膜装置10。
施加的机械力可以包括局部张力，以使多层薄膜20断裂以形成薄片。在一个方面，局部张力可以通过与网40的背部接触的锋利的刀来帮助。施加的局部张力之后可以是高速度气体、空气或蒸气的施加。特别地，空气剥离工艺可以包括：(1)对网40施加张力，以引起多层薄膜20中的裂缝，以形成薄膜装置，例如薄片，以及(2)针对多层薄膜20，施加压缩的空气流，以从网40吹去多层薄膜20的薄片。
在另一个方面，施加的机械力可以包括局部超声施加。在另一个方面，施加的机械力可以包括从网40直接拉动多层薄膜20。施加的机械力还可以包括在施加振动力时拉伸多层薄膜20。施加的机械力还可以包括通过将真空叶片紧密靠近多层薄膜20放置进行抽真空以将多层薄膜20从网40吸进收集室中，来将多层薄膜20从网40剥离去。薄膜装置例如薄片的收集可以通过例如在图1中示出的薄膜装置转移法(thin film device transfermethod)的薄膜装置转移法来实现。
释放的多层薄膜20可以被进一步加工，例如收集和/或研磨。在一个方面，释放的多层薄膜20呈可以被收集的薄片的形式，例如通过适当的气流通风系统被收集到旋风分离器中。收集的薄片可以被研磨。研磨可以是选自以下的工艺：喷射碾磨、低温研磨、基于液体介质的超声研磨、粉碎以及高剪切湿法研磨。然后，薄片可以被冲洗和/或干燥。在一个方面，干燥步骤是不必要的，因为某些铝钝化工艺需要水，例如十二烷基膦酸钠、辛基膦酸、十八烷基膦酸、十二烷基磷酸钾，以及用诸如二氧化硅、二氧化钛、氧化锆、二氧化铈、氧化铝或它们的组合的材料的溶胶-凝胶包封处理。
在又一个方面，薄膜装置10可以包括多层薄膜20和释放层30。释放层30可以改变光学性质，并且可以将功能并入薄膜装置10。释放层30可以存在于多层薄膜20的一侧上，或可以存在于多层薄膜20的两侧上，如图2和图3示出的。如果释放层30存在于多层薄膜20的两侧上，那么每个释放层30可以相同或不同。例如，一个释放层30可以起与网40原始接触的释放层30的作用，并且第二释放层30可以为薄膜提供另外的功能。
在一个方面，释放层30可以被包覆在网40的两侧上，以降低制造成本，如图4中是示出的。第一提议的制造结构将类似于：多层薄膜/释放层/网/释放层/多层薄膜。
在又一个方面，释放层30和多层薄膜20的堆叠可以在网40上形成，以降低制造成本。第二提议的制造结构将类似于：网/释放层/多层薄膜/释放层/多层薄膜20，如图5中示出的。这可以提供来自网40的相同表面的两倍量的薄片。另外，第一提议的制造结构(图4)和第二提议的制造结构(图5)可以被组合以进一步降低成本和增加产量。
实施例1
将包括三层的多层薄膜20直接沉积到PET的网40上，即不存在释放层。多层薄膜20包括使用狭缝模具工艺沉积的具有有机红色着色剂的复合混杂丙烯酸酯-环氧树脂的第一有机层。使用真空沉积，将铝的反射物层包覆到第一层上。使用狭缝模具工艺并包括具有有机红色着色剂的复合混杂丙烯酸酯-环氧树脂，将第二层包覆到反射物层上。
将机械力施加至多层薄膜20，以从网40释放多层薄膜20。通过在与网40的背部接触的锋利的刀的帮助下，施加张力至网40，机械力包括多层薄膜20的断裂。刀不直接接触多层薄膜20以避免对多层薄膜20的损坏。然后，将包覆在网40上的多层薄膜20暴露于高流量/高速度空气流以吹去断裂的涂层。刀的施加(断裂)和空气的施加几乎同时进行。以此方式，多层薄膜20从网40释放，并形成薄膜装置，例如薄片。通过适当的空气流动通风系统，将薄片收集到旋风分离器中。使用喷射磨机研磨技术，将薄片即释放的多层薄膜20研磨。
实施例2
将包括三层的多层薄膜20直接沉积到PET的网40上，所述网具有由水溶性聚合物制剂(PVA)制成的释放层30。多层薄膜20包括使用狭缝模具工艺沉积的具有有机红色着色剂的复合混杂丙烯酸酯-环氧树脂的第一有机层。使用真空沉积，将铝的反射物层包覆到第一层上。使用狭缝模具工艺并包括具有有机红色着色剂的复合混杂丙烯酸酯-环氧树脂，将第二层包覆到反射物层上。
将机械力施加至多层薄膜20，以从网40释放多层薄膜20。通过在与网40的背部接触的锋利的刀的帮助下，施加张力至网40，机械力包括多层薄膜20的断裂。刀不直接接触多层薄膜20以避免对多层薄膜20的损坏。然后，将包覆在网40上的多层薄膜20暴露于高流量/高速度空气流以吹去断裂的涂层。刀的施加(断裂)和空气的施加几乎同时进行。以此方式，多层薄膜20从网40释放，并形成薄膜装置，例如薄片。通过适当的空气流动通风系统，将薄片收集到旋风分离器中。使用喷射磨机研磨技术，将薄片即释放的多层薄膜20研磨。
实施例3
形成基于铬的第三层、硫化锌的第一层、铝的反射物层、硫化锌的第二层以及铬的第四层的五层薄膜。多层薄膜20具有硫化锌介电层(第一层和第二层)的光学厚度，以产生非绿色或缓慢绿色转换设计(slow green color shifting design)。使用盒式包覆器(boxcoater)将第一层和第二层真空物理气相沉积在PET网40上。PET网40包括PVA的释放层30(60nm至200nm)。PVA释放层30是可空气剥离的和水溶性的。绿色多层薄膜20具有以下结构：8nm Cr/368nm ZnS/80nm Al/368nm ZnS/8nm Cr。
实施例4
形成基于铬的第三层、氟化镁的第一层、铝的反射物层、氟化镁的第二层以及铬的第四层的五层薄膜干涉。多层薄膜20具有氟化镁介电层(第一层和第二层)的光学厚度，以产生红色/金色转换设计。将第一层和第二层辊对辊地(roll to roll)真空物理气相沉积在PET网40上。PET网40包括具有不同厚度(60nm至200nm)的PVA的释放层30。使用K101对照K-手持包覆器(K101Control K-Hand Coater)，使用分别对应于4微米、12微米和50微米的K-条数(K-Bars number)0、2和5，包覆PVA层。在所有情况下，PVA涂层制剂具有2.2％固体，PVA层的干燥物理厚度分别是88nm、264nm和1100nm。具有三个PVA释放层30的多层是可空气剥离的和水溶性的。较厚的PVA层趋向于使得空气剥离工艺更有效。红色/金色多层薄膜20具有以下结构：10nm Cr/250nm MgF2/80nm Al/250nm MgF2/10nm Cr。
一种形成薄膜装置的方法，包括：提供具有水溶性释放层的网；用多层薄膜包覆所述水溶性释放层；和施加机械力以从所述网释放所述多层薄膜。权利要求18所述的方法，其中，所述多层薄膜包括法布里-珀罗结构。权利要求18所述的方法，其中，所述多层薄膜包括被包覆在所述水溶性释放层上的第一层；用反射物层包覆所述第一层；和用第二层包覆所述反射物层以形成所述多层薄膜。权利要求18所述的方法，其中，所述释放层选自聚乙烯醇制剂、多糖制剂、聚丙烯酸制剂、聚乙酸乙烯酯制剂、聚乙烯吡咯烷酮制剂、羧甲基纤维素制剂及其组合。
从前面的描述中，本领域技术人员可以理解，本教导可以以多种形式实施。因此，虽然已经结合其特定的实施方案和实施例描述了这些教导，但是本教导的真实范围不应当被如此限制。可以做出各种变化和修改，而不偏离本文教导的范围。
本范围公开内容将被广泛地解释。意图本公开内容公开实现本文公开的装置、活动和机械动作的等效物、设备(means)、系统和方法。对于所公开的每个装置、物品、方法、设备、机械元件或机构，意图本公开内容还涵盖在其公开内容中，并且教导了用于实践本文公开的许多方面、机构和装置的等效物、设备、系统和方法。另外，本公开内容涉及涂层及其许多方面、特征和要素。这样的装置在其使用和操作中可以是动态的，本公开内容意图涵盖使用该装置和/或制造的物品的等效物、设备、系统和方法，及其与本文公开的操作和功能的描述和精神一致的许多方面。本申请的权利要求同样被广泛地解释。
本文中在其许多实施方案中对本发明的描述在本质上仅仅是示例性的，并且因此不偏离本发明的主旨的变形意图在本发明的范围内。这样的变形不应被视为偏离本发明的精神和范围。

Claims (10)

1.一种形成薄膜装置的方法，所述方法包括：
用多层薄膜包覆网；和
施加机械力以从所述网释放所述多层薄膜。
2.如权利要求1所述的方法，其中所述多层薄膜包括3层。
3.如权利要求1所述的方法，其中所述多层薄膜包括法布里-珀罗结构。
4.一种形成薄膜装置的方法，所述方法包括：
用第一层包覆网；
用反射物层包覆所述第一层；
用第二层包覆所述反射物层，以形成多层薄膜；和
通过干燥技术从所述网释放所述多层薄膜。
5.如权利要求4所述的方法，还包括收集所释放的多层薄膜；并且还包括研磨所释放的多层薄膜。
6.如权利要求4所述的方法，其中所述干燥技术是施加的机械力产生局部张力以使所述多层薄膜断裂，随后施加高速度气体、空气或蒸气。
7.如权利要求4所述的方法，其中所述干燥技术是局部超声施加的施加的机械力。
8.如权利要求4所述的方法，其中所述干燥技术是直接从所述网拉动所述多层薄膜的施加的机械力。
9.如权利要求4所述的方法，其中所述干燥技术是在施加振动力时拉伸所述多层薄膜的施加的机械力。
10.如权利要求4所述的方法，其中所述干燥技术是通过紧密放置真空叶片抽真空以将所述多层薄膜从所述网剥离去的施加的机械力。
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