Method for producing a film element
10179472 ยท 2019-01-15
Assignee
Inventors
- Ludwig Brehm (Adelsdorf, DE)
- Haymo Katschorek (Obermichelbach, DE)
- Norbert Laus (Furth-Burgfarnbach, DE)
Cpc classification
B42D25/328
PERFORMING OPERATIONS; TRANSPORTING
B42D25/445
PERFORMING OPERATIONS; TRANSPORTING
B42D25/41
PERFORMING OPERATIONS; TRANSPORTING
B42D25/351
PERFORMING OPERATIONS; TRANSPORTING
B42D25/45
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/12535
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B2307/40
PERFORMING OPERATIONS; TRANSPORTING
B32B38/10
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/24917
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T428/12361
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B44F1/02
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/24752
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B44F1/02
PERFORMING OPERATIONS; TRANSPORTING
B42D25/445
PERFORMING OPERATIONS; TRANSPORTING
B42D25/41
PERFORMING OPERATIONS; TRANSPORTING
B42D25/351
PERFORMING OPERATIONS; TRANSPORTING
B42D25/45
PERFORMING OPERATIONS; TRANSPORTING
B42D25/328
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention concerns a process for producing a film element having mutually registered metallic layers (11, 16) and a film element which can be produced by such a process. A first metallic layer (11) provided on a first surface of a flexible single-layer or multi-layer carrier film (10) and a masking layer (13) provided on the second surface of the carrier film (10), opposite to the first surface, are structured in accurate register relationship with each other by means of mutually synchronized structuring procedures. After structuring of the first metallic layer (11) and the masking layer (13) one or more further layers are applied to the first metallic layer (11). Applied to the one or more further layers (15) is a second metallic layer (16) to which a first photoactivatable layer (17) is applied. The first photoactivatable layer (17) is structured by means of trans-exposure through the masking layer (13), the first metallic layer, the one or more further layers and the second metallic layer (16) from the side of the masking layer (13) by means of electromagnetic radiation of a wavelength to which the first photoactivatable layer (17) is sensitive, or the first photoactivatable layer is exposed controlledly through the masking layer from the side of the film body that is opposite to the masking layer.
Claims
1. A film element comprising: a flexible single-layer or multi-layer carrier film; a first metallic layer provided on a first surface of the carrier film; a masking layer provided on a second surface of the carrier film opposite to the first surface; a second metallic layer arranged on the side of the first surface; and one or more further layers arranged between the first and second metallic layers, wherein the masking layer comprises a pattern of regions including regions in which material of the masking layer is present and regions in which material of the masking layer is not present, and wherein the first metallic layer and the second metallic layer respectively comprises first regions in which the metal of the metallic layer is provided and second regions in which the metal of the metallic layer is not provided, the first and second regions of the first metallic layer are arranged in accordance with a first regular one-dimensional or two-dimensional raster and the first and second regions of the second metallic layer are arranged in accordance with a second regular one-dimensional or two-dimensional raster, wherein the first and second rasters are oriented in mutually accurate register relationship, and wherein the raster widths of the first and second rasters coincide and wherein the first and second rasters are so oriented relative to each other that the first regions of the first metallic layer are arranged in the region of the second regions of the second metallic layer and vice-versa.
2. A film element comprising: a flexible single-layer or multi-layer carrier film; a first metallic layer provided on a first surface of the carrier film; a masking layer provided on a second surface of the carrier film opposite to the first surface; a second metallic layer arranged on the side of the first surface; and one or more further layers arranged between the first and second metallic layers, wherein the masking layer comprises a pattern of regions including regions in which material of the masking layer is present and regions in which material of the masking layer is not present, and wherein the first metallic layer and the second metallic layer respectively comprises first regions in which the metal of the metallic layer is provided and second regions in which the metal of the metallic layer is not provided, the first and second regions of the first metallic layer are arranged in accordance with a first regular one-dimensional or two-dimensional raster and the first and second regions of the second metallic layer are arranged in accordance with a second regular one-dimensional or two-dimensional raster, wherein the first and second rasters are oriented in mutually accurate register relationship, and wherein the first and second rasters are identical rasters arranged in a phase displacement of about 180 relative to each other.
3. A film element according to claim 1, wherein the pattern of regions of the masking layer in which material of the masking layer is present is in coincident superposed relationship with the pattern of regions of the second metallic layer in which material of the second metallic layer is present.
4. A film element according to claim 1, wherein the carrier film comprises a first replication layer, and wherein the one or more further layers arranged between the first and second metallic layers comprises a second replication layer, and wherein a first optical-diffraction relief structure is shaped into a surface of the first replication layer and a second optical-diffraction relief structure is shaped into a surface of the second replication layer.
5. A film element according to claim 4, wherein the metal of the first metallic layer is disposed on the first optical-diffraction relief structure and the metal of the second metallic layer is disposed on the second optical-diffraction relief structure.
6. A film element according to claim 1, wherein the first metallic layer comprises silver and is of a layer thickness of 20 to 40 nm.
7. A film element according to claim 1, wherein the second metallic layer comprises copper and is of a layer thickness of 10 to 50 nm.
8. A film element according to claim 1, wherein the second metallic layer comprises two or more mutually superposed sublayers of different metals.
9. A film element according to claim 1, wherein the masking layer comprises a metal or a metal alloy.
10. A film element according to claim 1, wherein the masking layer comprises two or more layers and in that respect includes one or more metal layers.
11. A film element according to claim 1, wherein the carrier film has a release layer which permits release of a film body including the first and second metallic layers from the film element.
12. A film element according to claim 1, wherein the carrier film has a release layer which permits release of a film body including the masking layer from the film element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention is described by way of example hereinafter by means of a number of embodiments with reference to the accompanying drawing.
(2)
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(5)
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(10)
(11)
(12)
DETAILED DESCRIPTION OF THE INVENTION
(13) Reference is made to
(14) Firstly for that purpose the film body 21 shown in
(15) In a first production step the metallic layers 11 and 13 are applied to the carrier film 10 over the full surface area for example by means of sputtering or vapour deposition. The metallic layers 11 and 13 comprise for example aluminium, silver, copper, gold or an alloy of those materials. Preferably a different metallic material is used for the metallic layers 11 and 13 and those layers are also applied in different layer thicknesses to the carrier film 10, as is described in detail hereinafter. Thus the metallic layer 13 preferably comprises copper and is of a layer thickness of 100 to 200 nm, further preferably about 200 nm. The metallic layer 11 preferably comprises silver with a layer thickness of between 20 and 40 nm, preferably about 30 nm.
(16) Then in a second production step the photoactivatable layers 12 and 14 are applied to the metallic layer 11 and the metallic layer 13 respectively over the full surface area, for example printing, spraying on or pouring. A negative resist is selected as the photoactivatable material, which is suitable for the exposure wavelength adopted in the following exposure procedure. Thus for example a negative resist designed for UV light is used, which is applied in a layer thickness of 100 to 2000 nm, preferably approximately 800 nm, to the metallic layer 11 and 14 respectively.
(17) It is also possible instead of a negative resist to also use a positive resist, that is to say a photoresist which upon exposure loses its protective action against the acid or lye of the subsequent etching procedure so that the exposed regions are removed in the etching procedure. Thus it is for example possible, as the photoactivatable layer, to apply a negative resist of a thickness of between 100 and 800 nm, preferably a thickness of 200 to 300 nm, which is designed for exposure in the wavelength range of 248 nm (for example exposure with a CO.sub.2 laser).
(18) In a subsequent production step the film body 21 is structured by means of two mutually synchronised exposure procedures, as is described hereinafter with reference to
(19)
(20) In a first exposure procedure the film body 22 is now exposed with the light 41 through the mask 31 from the side of the metallic layer 11 so that in the regions 121 of the photoactivatable layers, that are beneath the regions 34 of the mask 31, the photoactivatable layer 12 is exposed and thus activated and in the regions 122 of the photoactivatable layers, that are beneath the regions 33 of the mask 31, it is not exposed and is thus not activated. In the same fashion in a second exposure procedure the film body 22 is exposed from the side of the metallic layer 13 with the light 42 so that in the region 142 of the photoactivatable layer 14, beneath the regions 35, the layer is not exposed and is thus not activated while in the region 141 of the photoactivatable layer 14, beneath the regions 36 of the mask 32, the photoactivatable layer 40 is exposed and thus activated.
(21) The two exposure masks 31 and 32 are arranged in accurate register relationship with each other so that the two photoactivatable layers 12 and 14 are structured in mutually accurate register relationship by the two exposure processes.
(22) By virtue of the screening action of the metal layers 13 and 11 it is possible in that case (with a suitable choice in respect of the illumination strength and the exposure time) to perform the first and second exposure steps simultaneously and at the same time. The exposure device shown in
(23)
(24) The exposure device 5 has two exposure units 51 and 52 arranged at mutually opposite sides of the film body 21 and positioned in opposite relationship. The exposure unit 51 has an exposure mask 31, a plurality of light sources 53 and a collimator 54 which ensures that the light generated by the light sources 53 is incident on the exposure mask 31 with a parallel beam configuration. The exposure unit 52 has the exposure mask 32 and also a collimator 54 and a plurality of light sources 53. The exposure units 51 and 52 are preferably connected together by a holding frame and are fixed thereby at least when performing the exposure operation in register relationship with each other.
(25) Exposure of the film body 21 by the exposure device 5 is effected in the stop-and-go mode of operation. The film body 21 is fed to the exposure device 5. The exposure units 51 and 52 are pressed against the film body 21 so that the masks 31 and 32 lie on the film body 21 and fix same. Exposure is then effected at both sides, the light strength and the exposure time being matched to the photoactivatable layers 12 and 14. In order further to avoid mutual influencing of the two exposure procedures which take place at the same time, it is also possible to use photoresists which respond to different wavelengths, for the photoactivatable layers 12 and 14.
(26) After the exposure operation the exposed part of the film body 21, that is to say the film body 22, is moved out of the exposure device 5 and the procedure begins again from the outset.
(27) It is also possible for the exposure units 51 and 52 not to be positioned in mutually opposite relationship but to be positioned in mutually juxtaposed relationship so that exposure of the front and rear sides of a region of the film body 21 is effected in time-displaced relationship. It is also possible to use drum exposure units for the exposure operation.
(28)
(29) After the exposure operation and thus structuring of the photoactivatable layers 12 and 14, in a subsequent development and etching procedure the regions of the metallic layers 11 and 13 are removed, in which the photoactivatable layer 12 or 14 respectively has been activated, that is to say destroyed (when using a positive resist) or not activated, that is to say not hardened (when using a negative resist). Thus the film body 22 is fed for example to an etching bath in which the metallic layer 11 and the metallic layer 13 which are arranged beneath the unexposed regions 122 of the photoactivatable layer 12 or beneath the unexposed regions 142 of the photoactivatable layer 14 are removed. After a washing and a drying process one or more further layers are then applied to the metallic layer 11 which is now structured and then a further metallic layer and a further photoactivatable layer are applied over the full surface area to the layer or layers.
(30)
(31) The layer 15 is followed by a further metallic layer 16 which preferably involves a thin copper layer of a thickness of 10 to 50 nm, preferably 30 nm. The metallic layer 16 can however also comprise another material, for example silver or aluminium, or a succession of a plurality of different metallic layers. The metallic layer 16 is followed by the photoactivatable layer 17 which in the
(32) Now in a next step the film body 23 is exposed from the side of the metallic layer 13, as shown in
(33)
(34) Regions in which the metallic layer 13 is provided but the metallic layer 11 is not provided: T.sub.13.
(35) Regions in which the metallic layer 13 and the metallic layer 11 are provided: T.sub.13T.sub.11.
(36) Regions in which neither the metallic layer 13 nor the metallic layer 11 are provided: 100%.
(37) Regions in which the metallic layer 13 is not provided but the metallic layer 11 is provided: T.sub.11.
(38) In order thus to ensure successful exposure of the photoactivatable layer 17 even for the situation in which regions 111 and 132 overlap, the ratio T.sub.11 to T.sub.13 must be greater than or equal to 15. In addition the illumination strength and the illumination time are then so selected that the photoactivatable layer 17 is still activated in the regions in which the regions 132 and 111 overlap and is not yet activated in the regions in which the regions 131 and 112 overlap. That can be easily ascertained by suitable measurement series.
(39) In a further step the film body 25 is then subjected to a developing and etching procedure insofar as in the regions 172 in which the photoactivatable layer 17 has not been activated the metallic layer 16 is removed and in the regions 171 in which the photoactivatable layer has been activated it remains protected by the photoresist and thus remains on the layer 15. After washing, stripping and drying that therefore gives the film element 25 shown in
(40)
(41) As already described hereinbefore with reference to
(42) In this case the release layer 63 and then the replication layer 64 are applied over the full surface area to the plastic film 62. An optically effective surface relief, for example a diffraction grating or a hologram, is then introduced into the replication layer 64, for example by means of heat and pressure, using a replication roller or by means of UV replication. Then in accordance with the embodiments of
(43) In this case the refractive index of the protective lacquer layer 68 and the two replication layers 64 and 66 is so selected that the refractive index of those layers is identical or differs only slightly from each other so that, in the regions in which a metallic layer is not applied to the surface structures, the optical effect of the surface structure is extinguished. In addition it is also possible to dispense with the use of the replication lacquer layers 54 and 68 and the shaping of optically effective surface reliefs in those layers (then for example a transparent lacquer layer is provided instead of the replication layer 66).
(44) In this case the metallic layer 65 and the metallic layer 61 are structured in a process step as shown in
(45) In the same manner the metal layer 67 comprises regions 671 in which the metallic layer is provided and regions 672 in which the metallic layer is not provided, the regions 671 and 672 also being oriented in accordance with a regular line raster. As indicated in
(46) If circularly transformed line rasters are used as the rasters for the metallic layers 65 and 67, an optical image 91 as is shown in
(47) The optical image 91 is formed by a succession of concentric circles, a circle being formed alternately by a region 671 of the metal layer 67 and a region 651 of the metallic layer 65. If the two metallic layers 65 and 67 are structured in mutually accurate register relationship in the above-described manner, the viewer sees a regular succession of concentric circles. With just slight register inaccuracy in structuring of the layers 65 and 67 the optical image changes markedly for the viewer: thus
(48)
(49) The film body 6 in
(50)
(51) As shown in