Precision control of web material having micro-replicated lens array
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-059/00
G02B-003/00
B29C-059/02
B29C-059/04
B29D-011/00
B29C-043/58
출원번호
US-0583887
(2011-03-30)
등록번호
US-9977154
(2018-05-22)
국제출원번호
PCT/US2011/030419
(2011-03-30)
§371/§102 date
20120926
(20120926)
국제공개번호
WO2011/123485
(2011-10-06)
발명자
/ 주소
Hofeldt, David L.
Brott, Robert L.
Carlson, Daniel H.
Dobbs, James N.
Jaworski, Andrzej P.
Jerry, Glen A.
Strand, John T.
Sykora, Michael J.
Stensvad, Karl K.
출원인 / 주소
3M INNOVATIVE PROPERTIES COMPANY
대리인 / 주소
Baum, Scott A.
인용정보
피인용 횟수 :
0인용 특허 :
28
초록▼
A manufacturing system includes a sensing system that provides high-resolution feedback for web guiding and tension control. The system may be especially useful for web material that is manufactured to include micro-replicated structures with micron size scale. A micro-replication station forms a pa
A manufacturing system includes a sensing system that provides high-resolution feedback for web guiding and tension control. The system may be especially useful for web material that is manufactured to include micro-replicated structures with micron size scale. A micro-replication station forms a pattern of micro-replicated lenses on a web material. The sensing system illuminates a measurement area on the web material and detects an angular distribution of light exiting a set of the micro-replicated lenses within the first measurement area. A control system that adjusts at least one process control parameter of the transport system based on the detected angular distribution.
대표청구항▼
1. A method of manufacturing a patterned web material, the method comprising: conveying web material by a transport system through a first micro-replication station;forming a first pattern of micro-replicated lenses on the web material with the first micro-replication station;illuminating a set of t
1. A method of manufacturing a patterned web material, the method comprising: conveying web material by a transport system through a first micro-replication station;forming a first pattern of micro-replicated lenses on the web material with the first micro-replication station;illuminating a set of the micro-replicated lenses by directing light from a first light source through the first pattern of micro-replicated lenses on the web material so as to exit from the micro-replicated lenses, the exiting light comprising a plurality of light angles;simultaneously directly detecting from the plurality of light angles a plurality of light intensities of an angular distribution of the light directed through and exiting from the micro-replicated lenses of the web material, the simultaneous direct detection taking place by passing the light directed through and exiting from the micro-replicated lenses through a multi-element lens, using optical properties of the multi-element lens to produce a Fourier transform of the angular distribution of the light entering the multi-element lens, and recording the Fourier transform of the angular distribution of the light entering the multi-element lens using an array sensor positioned at a focal length of the multi-element lens;analyzing the plurality of directly detected light intensities of the angular distribution of the light directed through and exiting from the first pattern of micro-replicated lenses; anddetermining an alignment error of the web material based on the analysis of the plurality of directly detected light intensities. 2. The method of claim 1, further comprising adjusting at least one process control parameter of the transport system based on the determined alignment error. 3. The method of claim 2, wherein the adjusting of the at least one process control parameter comprises adjusting a cross-web position of the web material as the web material is conveyed to the first micro-replication station. 4. The method of claim 2, wherein the adjusting of the at least one process control parameter comprises adjusting a down-web position of the web material as the web material is conveyed to the first micro-replication station. 5. The method of claim 2, wherein the adjusting of the at least one process control parameter comprises adjusting both a cross-web position and a down-web position of the web material as the web material is conveyed to the first micro-replication station. 6. The method of claim 2, wherein the adjusting of the at least one process control parameter comprises adjusting a tension of the web material as the web material is conveyed to the first micro-replication station. 7. The method of claim 2, further comprising displaying the adjusted process control parameter to an operator as a recommended adjustment. 8. The method of claim 1, further comprising recording the alignment error in a database. 9. The method of claim 1, wherein the alignment error exceeds a threshold, further comprising marking the web material upon the alignment error exceeding the threshold. 10. The method of claim 1, further comprising: forming a second pattern of micro-replicated features on the web material with a second micro-replication station,wherein the first pattern of micro-replicated lenses is formed with the first micro-replication station to repeat on a first surface of the web material in a cross-web direction, andwherein the second pattern of micro-replicated features is formed with the second micro-replication station to repeat on an opposing surface of the web material opposite from the first pattern of micro-replicated lenses. 11. The method of claim 10, wherein illuminating the set of the micro-replicated lenses by directing the light from the first light source through the first pattern of the micro-replicated lenses on the web material further comprises: illuminating the set of the micro-replicated features within a measurement area on the opposing surface to direct the light from the first light source through the set of the micro-replicated features and through the set of the micro-replicated lenses on the first surface of the web material. 12. The method of claim 11, wherein the set of the micro-replicated features comprise micro-replicated prisms. 13. The method of claim 12, wherein the alignment error of the web material represents an error from an expected alignment between the set of micro-replicated lenses and the set of micro-replicated prisms within the measurement area. 14. The method of claim 10, wherein illuminating the set of the micro-replicated lenses by directing the light from the first light source through the first pattern of micro-replicated lenses on the web material further comprises: illuminating a set of the micro-replicated features within a first measurement area on the opposing surface with the first light source to direct the light through the set of the micro-replicated features and through the set of the micro-replicated lenses on the first surface of the web material. 15. The method of claim 10, wherein illuminating the set of the micro-replicated lenses by directing the light from the first light source through the first pattern of the micro-replicated lenses on the web material further comprises: illuminating a set of the micro-replicated features within a first measurement area on the opposing surface with the first light source and with a second light source to direct light from the first and second light sources through the set of the micro-replicated features within the first measurement area on the opposing surface and through the set of the micro-replicated lenses on the first surface of the web material,wherein the simultaneously directly detecting from a plurality of light angles a plurality of light intensities of an angular distribution of the light from the first light source directed through and exiting from the set of the micro-replicated lenses on the first surface of the web material further comprises simultaneously directly detecting from a plurality of light angles a plurality of light intensities of an angular distribution of the light from the second light source directed through and exiting from the set of the micro-replicated lenses on the first surface of the web material, andwherein the alignment error is determined as a first measurement area alignment error based on a comparison of the simultaneously directly detected plurality of light intensities of the angular distribution of the light from the first light source that is directed through and exits from the set of micro-replicated lenses with the simultaneously directly detected plurality of light intensities of the angular distribution of the light from the second light source that is directed through and exits from the set of micro-replicated lenses. 16. The method of claim 15, wherein the second pattern of micro-replicated features comprises a set of micro-replicated prisms within the first measurement area, and further wherein the alignment error associated with the first measurement area represents an error from an expected alignment between the set of micro-replicated lenses and the set of micro-replicated prisms within the first measurement area. 17. The method of claim 15, wherein the alignment error associated with the first measurement area provides a sub-micron alignment resolution. 18. The method of claim 15, wherein determining the alignment error further comprises: constructing a first one-dimensional projection based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light from the first light source that is directed through and exits from the set of micro-replicated lenses;constructing a second one-dimensional projection based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light from the second light source that is directed through and exits from the set of micro-replicated lenses; anddetermining a crossing-point for the first one-dimensional projection and the second one-dimensional projections, wherein the crossing-point specifies an angular position where the first and second one-dimensional projections overlap relative to a cross-web direction of the web material. 19. The method of claim 15, further comprising: illuminating a second set of the micro-replicated features within a second measurement area with a third light source and a fourth light source to direct light through the second set of micro-replicated features and a second set of the micro-replicated lenses on the first surface of the web material;simultaneously directly detecting from a plurality of light angles a plurality of light intensities of an angular distribution of the light from the third light source directed through and exiting from the second set of micro-replicated lenses;simultaneously directly detecting from a plurality of light angles a plurality of light intensities of an angular distribution of the light from the fourth light source directed through and exiting from the second set of micro-replicated lenses by passing the light from the fourth light source directed through and exiting from the second set of micro-replicated lenses through the multi-element lens and recording a Fourier transform of the angular distribution of the light from the fourth light source entering the lens using the array sensor positioned at the focal length of the multi-element lens; anddetermining a second measurement area alignment error based on a comparison of the simultaneously directly detected plurality of light intensities of the angular distribution of the light from the third light source that is directed through and exits from the second set of micro-replicated lenses with the simultaneously directly detected plurality of light intensities of the angular distribution of the light from the fourth light source that is directed through and exits from the second set of micro-replicated lenses. 20. The method of claim 19, further comprising adjusting a process control parameter based on the alignment error associated with the first measurement area and the alignment error associated with the second measurement area. 21. The method of claim 19, further comprising: calculating a relative difference between the alignment error associated with the first measurement area and the alignment error associated with the second measurement area; andcontrolling a tension or a strain of the web material as the web material is conveyed to the micro-replication station based on the calculated relative difference. 22. The method of claim 1, wherein forming the first pattern of micro-replicated lenses on the web material comprises forming the first pattern of micro-replicated lenses on a first surface of the web material, the method further comprising: determining the alignment error as an alignment error between the micro-replicated lenses and features of a micro-replication tool for forming a pattern of micro-replicated features on a second side of the web material opposing the first side of the web material based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light directed through and exiting from the micro-replicated lenses; andcontrolling a relative position of the web material with respect to the micro-replication tool based on the determined alignment error. 23. The method of claim 1, wherein the alignment error provides a sub-micron alignment resolution. 24. The method of claim 1, further comprising: automatically positioning converting equipment relative to the web material in a cross-web direction based on the determined alignment error to position the converting equipment at areas of the web material in which alignment of the micro-replicated lenses of the web material is within a defined tolerance limit; andwith the converting equipment, converting the web into product using the areas of the web in which the alignment of the micro-replicated lenses of the web material are within the defined tolerance limit. 25. The method of claim 24, wherein automatically positioning the converting equipment comprises moving the converting equipment or the web in the cross-web direction to cut product from areas of the web in which the alignment of the micro-replicated features of the web material is within the tolerance limit. 26. A method of manufacturing a patterned web material, the method comprising: conveying web material by a transport system through a replication station;forming a pattern of replicated lenses on the web material with the replication station;after forming the pattern of replicated lenses on the web material, directing light from a light source through the pattern of replicated lenses on the web material so as to exit from the replicated lenses, the exiting light comprising a plurality of light angles;simultaneously directly detecting from the plurality of light angles a plurality of light intensities of an angular distribution of the light directed through and exiting from the replicated lenses using an array sensor, the simultaneous direct detection taking place by passing the light directed through and exiting from the pattern of replicated lenses through a multi-element lens, using optical properties of the multi-element lens to produce a Fourier transform of the angular distribution of the light entering the multi-element lens, and recording the Fourier transform of the angular distribution of the light entering the lens using an array sensor positioned at a focal length of the multi-element lens; andadjusting at least one process control parameter of the web transport system based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light directed through and exiting from the replicated lenses of the web material. 27. A method of manufacturing a patterned web material, the method comprising: conveying web material by a transport system through a micro-replication station;forming micro-replicated optical features on a first surface of the web material with the micro-replication station;after forming the micro-replicated optical features on the web material, directing light from a light source through the micro-replicated optical features on the web material so as to exit from the micro-replicated optical features, the exiting light comprising a plurality of light angles;simultaneously directly detecting from the plurality of light angles a plurality of light intensities of an angular distribution of the light directed through and exiting from the micro-replicated optical features, the simultaneous direct detection taking place by passing the light directed through and exiting from the micro-replicated optical features through a multi-element lens, using optical properties of the multi-element lens to produce a Fourier transform of the angular distribution of the light entering the multi-element lens, and recording the Fourier transform of the angular distribution of the light entering the multi-element lens using an array sensor positioned at a focal length of the multi-element lens; andadjusting at least one process control parameter of the web transport system based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light directed through and exiting from the micro-replicated optical features of the web material. 28. The method of claim 27, further comprising: forming micro-replicated features with a second micro-replication tool on a second surface of the web material opposing the first surface of the web material and opposite from a pattern of the micro-replicated optical features, the second micro-replication tool forming part of a second micro-replication station; anddetermining whether the micro-replicated optical features on the first surface of the web material are in an expected registration with the micro-replicated features on the second surface of the web material based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light directed through and exiting from the micro-replicated optical features on the first surface of the web material. 29. The method of claim 27, further comprising: forming micro-replicated features on a second surface the web material on an opposing surface of the web material opposite from a pattern of the micro-replicated optical features on the first surface of the web material with a second micro-replication station; anddetermining whether the micro-replicated optical features on the first surface of the web material are in an expected registration with features of the second micro-replication station for forming the micro-replicated features on the second surface based on the simultaneously directly detected plurality of light intensities of the angular distribution of the light directed through and exiting from the micro-replicated optical features of the web material.
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