WO2005116915A1 - Cards and laminates incorporating multilayer optical films - Google Patents
Cards and laminates incorporating multilayer optical films Download PDFInfo
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- WO2005116915A1 WO2005116915A1 PCT/US2005/017264 US2005017264W WO2005116915A1 WO 2005116915 A1 WO2005116915 A1 WO 2005116915A1 US 2005017264 W US2005017264 W US 2005017264W WO 2005116915 A1 WO2005116915 A1 WO 2005116915A1
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- multilayer optical
- optical film
- adhesive
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
- B42D—BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
- B42D25/00—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
- B42D—BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
- B42D25/00—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof
- B42D25/20—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof characterised by a particular use or purpose
- B42D25/21—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof characterised by a particular use or purpose for multiple purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
- B42D—BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
- B42D25/00—Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof
- B42D25/40—Manufacture
- B42D25/45—Associating two or more layers
- B42D25/465—Associating two or more layers using chemicals or adhesives
- B42D25/47—Associating two or more layers using chemicals or adhesives using adhesives
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/08—Mirrors
- G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
- G02B5/0825—Multilayer mirrors, i.e. having two or more reflecting layers the reflecting layers comprising dielectric materials only
- G02B5/0841—Multilayer mirrors, i.e. having two or more reflecting layers the reflecting layers comprising dielectric materials only comprising organic materials, e.g. polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/24—All layers being polymeric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2425/00—Cards, e.g. identity cards, credit cards
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- B42D2035/34—
Definitions
- the present invention relates to multilayer optical films.
- the invention further relates to laminates and cards that incorporate multilayer optical films, and methods relating thereto. At least some embodiments of such films, laminates, and cards have at normal incidence a high average transmission of visible light and selectively reflect or otherwise block at least a portion of electromagnetic radiation whose wavelength is greater than about 700 n .
- BACKGROUND Multilayer optical films which can provide desirable transmission and/or reflection properties at least partially by an arrangement of optically thin layers ("microlayers") of differing refractive index, are known. It has long been known to make such multilayer optical films by depositing a sequence of inorganic materials in microlayers on a substrate in a vacuum chamber. Typically, the substrate is a relatively thick piece of glass, limited in size due to constraints on the vacuum chamber volume and/or the degree of uniformity possible by the deposition process.
- a visible light transmissive card can comprise a first and second relatively thick polymer layer between which is disposed a multilayer optical film.
- the thick polymer layers can each have a thickness of at least 5 mils (125 ⁇ m), or at least about 10 mils (250 ⁇ m), and the multilayer optical film can have a reflection band at normal incidence substantially covering the wavelength range 800-1000 nm.
- the card also includes a plurality of adhesive layers between the multilayer optical film and the first and second polymer layers, but the card is constructed in such a way that it has a haze no greater than 12%, or nor greater than 10%.
- a card can comprise a relatively thick first and second polymer layer between which is disposed a multilayer optical film, where the multilayer optical film has a reflection band at normal incidence covering a desired spectral region.
- the card also includes a plurality of adhesive layers between the multilayer optical film and the first and second polymer layers.
- the multilayer optical film can comprise alternating layers of coPEN and a copolyester such as PETG.
- the multilayer optical film can also comprise two or more packets of microlayers separated by protective boundary layers.
- only a single layer of adhesive lies between the multilayer optical film and each of the thick polymer layers.
- Such adhesive layers are preferably at least half of a mil thick, but collectively make up no more than about 2 or 3 mils in thickness.
- the card, laminate, and film are all substantially free of polyvinyl chloride (PVC).
- FIG. 1 is a greatly magnified perspective view of a known multilayer optical film
- FIG. 2 is a schematic sectional view of a known laminate construction comprising a multilayer optical film
- FIG. 3 is a spectral transmission graph for a known multilayer optical film and for a known clear card having incorporated therein such a multilayer optical film
- FIG. 4 is a schematic sectional view of a card or portion thereof undergoing a peel test
- FIG. 5 is a graph showing representative peel strength tests on known cards incorporating a known laminate construction
- FIG. 6 is a schematic sectional view of a new laminate construction comprising a new multilayer optical film
- FIG. 7 is a spectral transmission graph for such new multilayer optical film alone, and for a card incorporating the new laminate construction.
- FIG. 1 depicts a known multilayer optical film 20.
- the film comprises individual microlayers 22, 24.
- the microlayers have different refractive index characteristics so that some light is reflected at interfaces between adjacent microlayers.
- the microlayers are sufficiently thin so that light reflected at a plurality of the interfaces undergoes constructive or destructive interference in order to give the film the desired reflective or transmissive properties.
- each microlayer For optical films designed to reflect light at ultraviolet, visible, or near-infrared wavelengths, each microlayer generally has an optical thickness (i.e., a physical thickness multiplied by refractive index) of less than about 1 ⁇ m. Thicker layers can, however, also be included, such as skin layers at the outer surfaces of the film, or protective boundary layers disposed within the film that separate packets of microlayers.
- the reflective and transmissive properties of multilayer optical film 20 are a function of the refractive indices of the respective microlayers.
- Each microlayer can be characterized at least in localized positions in the film by in-plane refractive indices n x , n y , and a refractive index n z associated with a thickness axis of the film. These indices represent the refractive index of the subject material for light polarized along mutually orthogonal x-, y-, and z-axes, respectively (see FIG. 1). In practice, the refractive indices are controlled by judicious materials selection and processing conditions.
- Film 20 can be made by co-extrusion of typically tens or hundreds of layers of two alternating polymers
- the resulting film is composed of typically tens or hundreds of individual microlayers whose thicknesses and refractive indices are tailored to provide one or more reflection bands in desired region(s) of the spectrum, such as in the visible or near infrared.
- adjacent microlayers preferably exhibit a difference in refractive index ( ⁇ n x ) for light polarized along the x-axis of at least 0.05. If the high reflectivity is desired for two orthogonal polarizations, then the adjacent microlayers also preferably exhibit a difference in refractive index ( ⁇ n y ) for light polarized along the y-axis of at least 0.05. Otherwise, the refractive index difference ⁇ n y can be less than 0.05 and preferably about 0 to produce a multilayer stack that reflects normally incident light of one polarization state and transmits normally incident light of an orthogonal polarization state.
- the refractive index difference ( ⁇ n z ) between adjacent microlayers for light polarized along the z-axis can also be tailored to achieve desirable reflectivity properties for the p-polarization component of obliquely incident light.
- the x-axis will be considered to be oriented within the plane of the film such that the magnitude of ⁇ n x is a maximum.
- the magnitude of ⁇ n y can be equal to or less than (but not greater than) the magnitude of ⁇ n x .
- the selection of which material layer to begin with in calculating the differences ⁇ n x , ⁇ n y , ⁇ n z is dictated by requiring that ⁇ n x be non-negative.
- the z-index mismatch ⁇ n z between microlayers can be controlled to be substantially less than the maximum in-plane refractive index difference ⁇ n x , such that ⁇ n z ⁇ 0.5* ⁇ n x . More preferably, ⁇ n z ⁇ 0.25 * ⁇ n x .
- a zero or near zero magnitude z-index mismatch yields interfaces between microlayers whose reflectivity for p-polarized light is constant or near constant as a function of incidence angle. Furthermore, the z-index mismatch ⁇ n z can be controlled to have the opposite polarity compared to the in-plane index difference ⁇ n x , i.e.
- known self-assembled periodic structures such as cholesteric reflecting polarizers and certain block copolymers, can be considered multilayer optical films for purposes of this application. Cholesteric mirrors can be made using a combination of left and right handed chiral pitch elements.
- VLT cards visible light transmissive cards
- ATMs Automated Teller Machines
- Such machines typically include edge sensors that utilize infrared (TR) light to detect the presence of the card. Unless the cards block such IR light sufficiently, the edge sensor is not tripped and the card reading machine does not acknowledge the presence of the card.
- TR infrared
- Some card manufacturing equipment also uses IR edge sensors. Cards produced on such equipment must also block the necessary IR light. ISO standard No.
- VLT cards (Rev. 2003) is believed to specify an optical density (OD) > 1.3 (corresponding to ⁇ 5% transmission) throughout the range 850-950 nm, and an OD > 1.1 (corresponding to ⁇ 7.9% transmission) throughout the range 950-1000 nm.
- OD optical density
- a challenge for VLT cards has been to be as highly transparent as possible over the visible wavelengths, but then to substantially block most IR light at least from about 800 to 1000 nm. In this wavelength range, average transmission of less that 5% is preferred, but transmission of 8% is also acceptable. In some card detection systems, average IR transmission as high as 10% or 15% may also be acceptable.
- VLT cards are also commonly expected to retain their integrity and appearance, and not delaminate in use.
- Laminate 30 comprises: outer polyvinyl chloride (PVC) layers 32a, 32b; a central multilayer optical film 34 (the individual microlayers and skin layers of which are not shown for ease of illustration), which film 34 is highly transparent in the visible and has an IR reflection band; and compound bonding layers 36a, 36b.
- Laminate 30 also includes thin layers of primer 38a, 38b applied to the major surfaces of the multilayer optical film 34.
- Bonding layers 36a and 36b sold by Transilwrap Company of Franklin Park, Illinois as KRTY 1/1/1 adhesive, consist of a layer of polyethylene terephthalate (PET) 41a, 41b to which layers of hot melt adhesive 40al, 40a2, and 40bl, 40b2 have been applied to the respective major surfaces of the PET layers as shown.
- Construction details of the known IR filter laminate 30 are as follows: PVC layer 32a: nominal thickness 1 mil (25 ⁇ m)
- Compound bonding layer 36a nominal thickness 3 mils (75 ⁇ m).
- Transilwrap KRTY 1/1/1 Transilwrap KRTY 1/1/1.
- Adhesive layer 40al nominal thickness 1 mil (25 ⁇ m).
- Composition includes polyethylene and polyethyl acrylate.
- PET layer 41a nominal thickness 1 mil (25 ⁇ m).
- Adhesive layers 40a2, 40bl, 40b2 same as layer 40al.
- Primer layer 38a nominal thickness about 0.1-0.2 ⁇ m.
- the layer is derived from a coated composition that includes a first and second sulfopolyester component, a surfactant (Triton X-100) and a crosslinker (Neocryl CX- 100), all in a deionized water base.
- the coating composition is typically from 5% to 10% solids.
- the first sulfopolyester component is made by a standard polyester reaction chemistry using a batch kettle process with the following reaction products: sulfosodium isophthalic acid (2.75 mol%), terephthalic acid (23.5 mol %), isophthalic acid (23.75 mol%), neopentyl glycol (16.5 mol%), and ethylene glycol (33.5 mol%).
- the second sulfopolyester component is Eastek 1100, a product of the Lawter Chemical Division of Eastman Chemical. The MOF should be treated with a corona discharge prior to coating on the primer layer.
- Multilayer optical film 34 nominal thickness 2.55 mil (65 ⁇ m).
- outer PET skin layers that are each nominally 12- 13 ⁇ m thick, and a single central packet of 275 microlayers characterized by a thickness gradient.
- Primer layer 38b same as layer 38a.
- Compound bonding layer 36b same as layer 36a.
- PVC layer 32b same as layer 32a.
- Overall laminate 30 nominal thickness 10.5 mil (265 ⁇ m)
- the IR filter laminate 30 is constructed by unwinding and feeding five separate sheets — PVC layers 32a, 32b, compound bonding layers 36a, 36b, and primed multilayer optical film 34 — into a heated nip, thereby forming a roll of such laminate 30.
- Laminate 30 is then cut into large sheets, and inserted between two similarly sized sheets of thick PVC card stock (nominal thickness about 9 mils (225 ⁇ m)), along with printing, integrated circuit chips, and so forth as desired, in a lamination press that subjects the assembled elements to heat and pressure sufficient to fuse adjacent PVC layers together.
- Lamination temperatures can range from about 280 - 300 °F (137 - 149°C).
- FIG. 3 shows a typical measured spectral transmission 50 of the clearest portion of such a card (unobstructed by printing, IC chip, etc.).
- FIG. 3 also depicts the measured spectral transmission 52 of a typical multilayer optical film 30 by itself. (These spectral transmission measurements were made on a Perkin-Elmer Lambda- 19 spectrophotometer, at normal incidence, and used an integrating sphere to collect all light transmitted through the card, regardless of scattering direction in the output hemisphere.
- the measured spectral transmission does not correct for surface reflections.
- the reflection band of the multilayer optical film shifts to shorter wavelengths as the angle of incidence increases.
- the transmission of the finished card in the visible portion of the spectrum is lower than that of the bare multilayer optical film 30. This is believed to be due to color additives in the PVC layers, and scattering or haze caused by the four relatively thick (1 mil) adhesive layers and the PVC layers.
- the haze of the finished cards is a function of the card sheet lamination conditions of time, temperature, and pressure, but typically ranges from 20-41%. Some experimental trials at particularly high temperatures, however, have achieved haze readings as low as 14%.
- the "haze” is as measured under standard laboratory conditions on a B YK Gardner HazegardTM Plus hazemeter.
- the haze of the multilayer optical film 30 by itself, measured in the same way, is typically about 3%.
- Another card property that can be an important consideration is the durability or susceptibility of the card to delamination.
- Existing standards for cards recommend that the "peel forces" between any laminated layers be above 3.5 N/cm (meaning Newtons of force per width in centimeters of a card laminate) over the entire length of the peel, although higher values such as at least 7 N/cm or even 10 N/cm are also desirable.
- FIG. 4 depicts schematically a VLT card or card sheet 54 (or portion thereof) undergoing a peel test to measure delamination strength between adhesive layer 36a and multilayer optical film 30.
- the outer skin layers and central microlayer packet of film 30 are shown (not to scale) for illustrative purposes.
- thick PVC card stock layers 56a, 56b each about 10 mils thick (resulting from the respective 1-mil PVC layers 32a, 32b fused to the thick PVC card stock sheets and any additional PVC overlay layers). Primer layers, printing, and other card elements are not shown for simplicity.
- a cut can be made into the card sheet, or a thin polymer tab 55 can be inserted as shown at the interface under test before the card sheet lamination step. After lamination, the peel is initiated at the cut or tab, and the peel force per linear width is monitored together with the length of the peel.
- VLT card sheets 54 were cut into strips 12.5 cm long. The maximum peel length in a test of such strips is then 25 cm, since each half can peel up to 12.5 cm.
- VLT cards that are consistently below 20%, more preferably below 14%, 12%, or even 10%, while still: (1) maintaining a high average visible light transmission of at least 50% and more preferably of at least 70% or even 80%, and (2) maintaining adequate IR blocking so that the cards are compatible with card reading machines. It would also be advantageous to improve the strength and integrity (relative to delamination failures) of cards that incorporate multilayer optical film in their construction. Finally, it would be advantageous to provide a multilayer optical film laminate construction that avoids the formation of extraneous polymer filaments during die cutting processes.
- Multilayer optical film 34 described above is tough and flexible, but the interlayer adhesion of the PET and coPMMA layers is not high. Special care must therefore be taken in selection of the adhesive for bonding this film to the thick PVC card stock in a card construction. If the adhesive is too hard or brittle, or too thin, forces applied to the opposite card halves are focused to a small region in the cleavage area between the two halves. A thick soft adhesive spreads the peel forces over a wider area at the cleavage point of delamination when pulling apart the halves of a card during a peel test. For this reason the measured peel strength between the thick PVC card stock and the MOF for the known cards discussed above is much higher than the peel strength between the microlayers or other layers of the multilayer optical film itself.
- the tradeoff for using an adhesive of excess thickness or softness however can be card punching problems that may arise, such as angel hair or dies gumming up. Since there are practical limits to the adhesive thickness and softness, the MOF construction itself can be modified to produce a card with a higher peel strength between MOF and adhesive while preventing rupture of the MOF. MOF constructions with higher interlayer adhesion than the known PET/coPMMA system can be produced. We have also found that the resistance of the MOF to rupture can also depend on the presence of a skin layer having good tensile strength.
- the force that results in a rupture of the MOF during a peel test depends on at least four parameters: the thickness of the adhesive, the softness/hardness (durometer) of the adhesive, the strength of the adhesive bond to the MOF, the interlayer adhesion value of the MOF itself, and in some cases the tensile strength of the MOF skin layer. These parameters can all be controlled to yield a card peel force well in excess of the ISO recommended value of 3.5 N/cm while simultaneously preventing spontaneous rupture of the MOF during a peel test. A series of card constructions with variation in all of these parameters were laminated and tested to measure the peel and rupture forces for the adhesive and MOF. The dissimilar materials of the MOF are a root cause of the delamination of the card laminate.
- the adhesives tested are listed in the examples below.
- the durometer of the various adhesives was measured with a nano-indentation method. This method is useful because it can measure the modulus and hardness of an adhesive layer at its major surface before lamination into a card, or at its edge after the card has been laminated. Further details of the nano-indentation method are provided below.
- the tensile strength of the MOF skin layer can become important in constructions where the MOF interlayer adhesion is low.
- MOF skin thickness values and materials were tested in the examples below, where such skin layers were composed of coPEN for the coPEN/PETG films, or PET for the PET/coPMMA films.
- adhesives may actually be compound bonding layers comprising a layer of polymer material and a layer of adhesive. Jf a primer was used in a particular example, the primer described above in connection with layers 38a, 38b, which is made by 3M Company, of St. Paul, MN was used.
- Example 1
- Peel test results typically are 15 to 20 N/cm, but almost always result in an MOF rupture before the end of the strip.
- Example 2 Same MOF construction as Example 1, but the adhesive is thinner and slightly softer.
- the peel forces ranged from 12 to 17 N/cm, and although the peel forces are smaller than for the KRTY adhesive of Example 1, occasional ruptures of the MOF were observed.
- Example 2 Again, the same MOF construction as Example 1. But the adhesive of this example is over twice as hard as those of Examples 1 and 2. As a result, 5 out of 10 peels resulted in a ruptured film, even though the average peel force was only 9 N/cm.
- the MOF used the same polymer materials as those of Examples 1-3, but arranged in a different construction as follows: there were two packets of alternating microlayers, each packet having 223 microlayers, the packets differing in thickness by a factor of 1.3, each packet being bounded by a 2 micron thick boundary layers of oriented PET (fusing in the middle to form a 4 micron separation between the packets).
- the outer boundary layers of oriented PET thus can be characterized as skin layers.
- the effect of the MOF skin layer on the peel tests is illustrated in this Example.
- This multilayer optical film of PET/coPMMA was coextruded with an outer layer of PETG instead of the usual thick PET skin layer.
- the amorphous PETG layer has a low tensile strength compared to the oriented PET.
- the peel test resulted in a ruptured MOF after short peels of about 1 cm.
- MOF made with PET/coPMMA and with 12 micron oriented PET skins showed average peel lengths greater than about 3 cm. This difference is attributed to the higher tensile strength of the thicker PET skin layer of Example 1.
- the MOF used in this example has the same layer structure as in Example 4, with the PET replaced by coPEN and the coPMMA replaced by PETG.
- the protective boundary layers were PETG and the outer skin layers were also PETG, resulting in an MOF construction with no strain hardened skins.
- the outer skin layers of PETG are considered as primer layers for this film.
- this MOF with no strain hardened skins can survive a peel test in a laminate of PVC with a soft adhesive.
- the superior interlayer adhesion of the coPEN and PETG compared to PET and coPMMA results in a much higher delamination peel strength in a card.
- the average peel force was 19 N/cm.
- This example uses the same MOF construction as in Example 5.
- multilayer infrared reflecting film samples of coPEN/PETG were constructed with outer skin layers of PETG.
- PETG and similar amorphous polyesters bond aggressively to PVC under heat and pressure which is typically used in card manufacturing.
- thick card stock of PVC can be directly bonded to the IR blocking optical film with no additional adhesive layers.
- the PETG is much harder than the Transilwrap KRTY or ZZ adhesives. When subjected to the standard peel test, the MOF ruptures immediately.
- the MOF of this example used the same polymer materials, coPEN and PETG, as those of Examples 5-6, in the following construction: there were two packets of alternating microlayers, each packet having 223 microlayers, the packets differing in thickness by a factor of 1.16, each packet being bounded by a 2 micron thick boundary layer of PETG (fusing in the middle to form a 4 micron separation between the packets). A 12 micron layer of oriented coPEN was coextruded as a skin layer. The optical transmission spectrum of this MOF, and of the MOF in the card laminate, is shown as curve 82 in Figure 7. Peel force average on 10 strips was 22.4 N/cm, with no ruptures of the MOF.
- Example 9 This example used the same construction and polymer materials for the MOF as Example 7, but with a measurably softer adhesive. Although the ZZ adhesive layer in this 2/1 construction should be the same as in the 3/1 construction, there may be lot-to-lot variations in the adhesive harness values. Peel force average on 10 strips was 25.6Nt/cm, which is higher than that of Example 7. This is consistent with the lower measured hardness value of this adhesive. Again, no ruptures occurred on these peel tests. Example 9
- the MOF of this example used the same construction and materials as Examples 5 and 6. Although not as hard as the adhesive of example 6, the hardness of this adhesive (33 MPa), combined with an excellent bond of this adhesive with the priming layer, resulted in immediate rupture of the coPEN/PETG MOF on all test strips. Ji the bonding of this adhesive to the MOF were adjusted to a lower value via a change in the type of primer layer, one may be able to reduce or eliminate the rupture of the MOF used here.
- the MOF of this example used the same construction and materials as Examples 7 and 8. Somewhat softer than the Bemis 5214 adhesive, card laminates made with the Quest 3/1 adhesive did not have any coPEN/PETG MOF ruptures during the peel tests. This is in contrast to Example 3 wherein 5 out of 10 PET/coPMMA laminates made with this same adhesive ruptured during peel tests. The average peel force was 9 N/cm, which is consistent with peel forces measured in Example 3 which used the same primer layer on the MOF.
- Example 11 was constructed with all of the materials of Example 1, including the MOF, with the omission of the adhesive layer on one side of the Transilwrap product.
- PET/coPMMA product into a PVC card laminate The KRTY coated side of the 1-1 construction was placed facing the MOF and the non-coated side of the PET was facing the PVC. This did not produce a commercially useable card because the PVC does not bond well to the PET, but nonetheless, a laminate with 50% less adhesive than Example 1 could be made for testing haze, transmission and clarity.
- the laminate was pressed for 15 minutes at 285 °F at 100 PSI, similar to all of the other examples. As shown in the haze and clarity table below, the haze was reduced to less than 9%, and the clarity increased to 97.
- Examples 7 and 8 clearly show that by changing to the appropriate material set, an MOF based card can be made that does not rupture in a peel test, and will result in a card with superior durability and less haze.
- the thinner adhesive is also expected to result in less angel hair in card punching.
- Further laminate samples were constructed using a multilayer optical film similar to that of Examples 5 and 6, but where the PETG was replaced with PMMA.
- the protective boundary layers within the MOF were of coPEN; the skin layers were also of coPEN and were 12 microns thick.
- the adhesive and primer were the same as in Example 1. During peel tests, the samples ruptured immediately. No meaningful measurements could be obtained.
- Haze, transmission and clarity values were obtained on 0.75 mm thick card laminates made with all of the adhesives using a Haze-gard Plus instrument from B YK Gardner. The manufacturer describes the clarity parameter as a measure of "see-through quality”. Haze and clarity data:
- the use of a thinner adhesive layer,' and the option to select from a variety of adhesives can provide a card with improved clarity and reduced manufacturing problems.
- the appropriate choice of MOF construction can maintain acceptable physical properties such as delamination strength and the capability to pass the standard flex tests.
- the MOF skin layer can be made with higher tensile strength, or the interlayer adhesion of the MOF layers can be increased.
- the skin layers of the existing IR film laminate product are currently at about
- the film can be laminated on both sides to another film such as e.g., a Transilwrap 3/lzz or 3/1 KRTY adhesive film, with the PVC layers facing outward.
- another film such as e.g., a Transilwrap 3/lzz or 3/1 KRTY adhesive film, with the PVC layers facing outward.
- the strips can be scored with a razor so that the cut penetrates into the optical film layers.
- the strip can then be bent along the cut until it snaps, creating a delamination along some boundary between layers of the optical film.
- a 90 degree or 180 degree peel force test can then.be made with the resulting sample. Care must be taken in making the coPEN/PETG multilayer film to insure a high interlayer adhesion.
- the orientation conditions must be properly controlled to insure that the finished film also has similar adhesion between layers.
- the orientation process typically involves stretch ratios of about 3 to 1 or more, in each in-plane direction. This results in about a ten-fold or more reduction in all layer thicknesses, including the interlayer mixing zone of adjacent layers.
- the high index layers are designed to crystallize upon orientation as well, which can also affect the cohesive strength of the material within a single layer. Thus the process of orienting a film can result in a reduction of the cohesive forces that resist delamination of an oriented multilayer film compared to the cast web interlayer adhesion.
- shrinkage issues can typically be resolved by variation of the card processing parameters such as heat up rates, press temperatures and pressures, and cool down rates, pressures, and temperatures.
- Selection of PVC grades or other sheet materials that more closely match the shrinkage rates of the optical film can also reduce the tendency of the film to wrinkle during card manufacturing.
- an JJR. filter laminate 70 comprises thin outer PVC layers 72a, 72b
- MOF can be incorporated into cards made from materials other than PVC.
- the requirements for the adhesive are still as described above.
- a relatively thick (greater than about 10 microns) soft (less than 30 Mpa) adhesive must still be used in combination with an MOF with relatively high interlayer cohesion such as the coPEN/PETG examples described above.
- Common materials useful for such cards are PETG and polypropylene.
- the same adhesives described here for bonding to MOF will also bond to PETG.
- an appropriate surface treatment such as a corona discharge and primer layer may be needed.
- Oriented polyester layers can also be incorporated into a card in order to reduce the PVC content, with bonding to the thick cardstock layers accomplished by appropriate priming layers such as e.g. sulfopolyesters, or coextruded PETG layers.
- the IR filter laminate of FIG. 6 can be composed entirely of PVC-free materials, but can then be used with either PVC or non-PVC cardstock depending upon the card manufacturer's needs or requirements.
- Card for purposes of this application means a substantially flat, thin, stiff article that is sufficiently small for personal use. Examples include but are not limited to financial transaction cards (including credit cards, debit cards, and smart cards), identification cards, and health cards.
- Infrared or “IR” for purposes of this application refers to electromagnetic radiation whose wavelength is about 700 nm or more. This of course includes but is not limited to near infrared wavelengths from about 700 nm to about 2500 nm.
- Multilayer optical film (or “MOF”) for purposes of this application means a film that comprises a stack of layers that reflect electromagnetic radiation by constructive interference. Exemplary multilayer optical films can be entirely polymeric in composition for ease of manufacture, handling, and tailorability.
- Cholesteric reflective polarizers and mirrors are also considered to be multilayer optical film for purposes of this application.
- “Reflection band” for purposes of this application means a spectral region of relatively high reflectance bounded on either side by regions of relatively low reflectance.
- “Visible light” for purposes of this application means electromagnetic radiation whose wavelength is in the range from about 400 nm to about 700 nm.
- a “visible light transmissive card” or “VLT card” for purposes of this application means a card that has at least one area through which at least a portion of visible light is transmitted, which area preferably has an average transmission (measured with an integrating sphere to collect all light scattered in forward directions through the card) over the range from 400 to 700 nm of at least 50%, more preferably at least 70% or even 80%.
- transparent card also encompasses cards that may have a substantial amount of haze (and hence be translucent) and cards that are tinted or otherwise colored, such as by the incorporation of a dye or pigment, or by suitable placement of the reflection band of a multilayer optical film.
- Indenter XP from MTS Nano Instruments, Minneapolis, MN or Berlin Germany.
- the nominal loading rate is set at 10 nm/s with spatial drift setpoint set at 0.3 nm/s maximum.
- a constant strain rate experiment at 0.05 /s to a depth of 1500 nm, is used to test as-received films in a 'top down' mode. Cross-sectioned samples are tested to 500 nm depth.
- the region to be characterized is located as seen top-down as viewed through a video screen with 400X magnification.
- the test regions are selected locally with 400 X video magnification of the XP to insure that tested regions are representative of the desired sample material, i.e.
- Nanoindentation Measurements the sample surface is located via a surface find function where the probe approaches the surface with a spring stiffness in air that changes significantly when the surface is encountered. Once the surface is encountered, load- displacement data is acquired as the probe indents the surface. This data is then transformed to Hardness and Elastic Modulus material properties based on the methodology described below. The experiment is repeated in different areas of the sample so that a statistical assessment can be made of the mechanical properties.
- Elastic Modulus - the Elastic Modulus determined directly from the load-displacement data is a composite Modulus, i.e. the Modulus of the indenter- to-sample mechanical system.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
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CN2005800162931A CN1957362B (en) | 2004-05-22 | 2005-05-18 | Cards and laminates incorporating multilayer optical films |
EP05750496A EP1751700B1 (en) | 2004-05-22 | 2005-05-18 | Cards and laminates incorporating multilayer optical films |
JP2007527378A JP2008500211A (en) | 2004-05-22 | 2005-05-18 | Cards and laminates incorporating multilayer optical films |
ES05750496T ES2397640T3 (en) | 2004-05-22 | 2005-05-18 | Cards and laminates that incorporate multi-layer optical films |
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US57358304P | 2004-05-22 | 2004-05-22 | |
US60/573,583 | 2004-05-22 |
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PCT/US2005/017264 WO2005116915A1 (en) | 2004-05-22 | 2005-05-18 | Cards and laminates incorporating multilayer optical films |
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US (1) | US7271951B2 (en) |
EP (2) | EP2330535A1 (en) |
JP (2) | JP2008500211A (en) |
CN (1) | CN1957362B (en) |
ES (1) | ES2397640T3 (en) |
TW (1) | TW200608046A (en) |
WO (1) | WO2005116915A1 (en) |
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- 2005-05-18 EP EP05750496A patent/EP1751700B1/en active Active
- 2005-05-18 ES ES05750496T patent/ES2397640T3/en active Active
- 2005-05-18 WO PCT/US2005/017264 patent/WO2005116915A1/en active Application Filing
- 2005-05-18 CN CN2005800162931A patent/CN1957362B/en active Active
- 2005-05-18 JP JP2007527378A patent/JP2008500211A/en not_active Withdrawn
- 2005-05-18 US US11/132,114 patent/US7271951B2/en active Active
- 2005-05-20 TW TW094116534A patent/TW200608046A/en unknown
-
2011
- 2011-10-07 JP JP2011222939A patent/JP5324634B2/en active Active
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EP0962806A2 (en) * | 1993-12-21 | 1999-12-08 | Minnesota Mining And Manufacturing Company | Multilayered optical film |
US6034813A (en) * | 1998-08-24 | 2000-03-07 | Southwall Technologies, Inc. | Wavelength selective applied films with glare control |
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US6630283B1 (en) * | 2000-09-07 | 2003-10-07 | 3M Innovative Properties Company | Photothermographic and photographic elements having a transparent support having antihalation properties and properties for reducing woodgrain |
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Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009541799A (en) * | 2006-06-23 | 2009-11-26 | スリーエム イノベイティブ プロパティズ カンパニー | Multilayer optical film, method for producing the same, and transaction card having the same |
JP2014013418A (en) * | 2006-06-23 | 2014-01-23 | 3M Innovative Properties Co | Multilayer optical film, method for manufacturing the same, and transaction card having the same |
JP2016026325A (en) * | 2006-06-23 | 2016-02-12 | スリーエム イノベイティブ プロパティズ カンパニー | Multilayer optical film, method of making the same, and transaction card having the same |
JP2017204000A (en) * | 2006-06-23 | 2017-11-16 | スリーエム イノベイティブ プロパティズ カンパニー | Multilayer optical film, method of making the same, and transaction card having the same |
US9023482B2 (en) | 2008-03-31 | 2015-05-05 | 3M Innovative Properties Company | Primer layer for multilayer optical film |
TWI663387B (en) * | 2018-05-30 | 2019-06-21 | 大陸商業成科技(成都)有限公司 | Strain monitoring method of curve laminating |
US11906252B2 (en) | 2019-05-31 | 2024-02-20 | 3M Innovative Properties Company | Composite cooling film and article including the same |
Also Published As
Publication number | Publication date |
---|---|
ES2397640T3 (en) | 2013-03-08 |
EP2330535A1 (en) | 2011-06-08 |
EP1751700A1 (en) | 2007-02-14 |
US7271951B2 (en) | 2007-09-18 |
JP2008500211A (en) | 2008-01-10 |
TW200608046A (en) | 2006-03-01 |
JP2012030599A (en) | 2012-02-16 |
JP5324634B2 (en) | 2013-10-23 |
CN1957362A (en) | 2007-05-02 |
EP1751700B1 (en) | 2012-10-24 |
US20050259326A1 (en) | 2005-11-24 |
CN1957362B (en) | 2011-05-25 |
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