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filingDate 2002-11-27-04:00^^<http://www.w3.org/2001/XMLSchema#date>
inventor http://rdf.ncbi.nlm.nih.gov/pubchem/patentinventor/MD5_849701a4690fdd6073c3aa66c24bf3ba
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publicationDate 2004-09-08-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationNumber EP-1453987-A2
titleOfInvention Process for making angstrom scale and high aspect functional platelets
abstract A process for making functional or decorative flakes or platelets economically and at high production rates comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition, and the intervening release layers are preferably solvent soluble thermoplastic or lightly crosslinked polymeric materials applied by vapor deposition sources contained in the vapor deposition chamber. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable organic solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free. The solvent and dissolved release material are then removed by centrifuging to produce a cake of concentrated flakes which can be air milled and let down in a preferred vehicle and further sized and homogenized for final use in inks, paints or coatings. In one embodiment the finished flakes comprise single-layer thin metal or metal alloy flakes or flakes of inorganic materials, and in another embodiment flakes are coated on both sides with protective polymeric coatings that were applied from suitable vacuum deposition sources or the like contained in the vapor deposition chamber. The release coat material can be a radiation curable, crosslinkable vapor deposited polymeric material of low crosslink density. Exposure to a high energy radiation source crosslinks the release material sufficiently to produce essentially tack-free, solvent soluble release coat layers. In one embodiment, the multi-layer vapor deposit is built up on an endless belt passing from the vapor deposition chamber through a vacuum lock to a separate adjacent stripping chamber. Both chambers are maintained at vacuum pressures below atmospheric while depositing the flake material on the endless belt. The vapor deposit is periodically removed by reducing the belt speed, idling the vacuum deposition sources in the deposition chamber, and sealing a vapor deposit collection device to the stripping chamber through vacuum locks below the endless belt in the stripping chamber. The vacuum locks maintain the stripping chamber at its vacuum pressure below atmospheric during the process of removing the multi-layer vapor deposited material from the endless belt.
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