Abstract: A method of producing metal flakes (72?) is provided. The method includes: applying a layer of ionic liquid (70) to a substrate (24); forming a layer of metal (70) on the substrate (24) over the ionic liquid (70); and removing the layer of metal (70) from the substrate (24).

Abstract: Processes for forming platelet materials, such as flakes, including but not limited to, metal flakes, such as aluminum flakes, are described. The processes involve the application of a release system to a support or drum which is subsequently dissolved to release one or more non-dissolving layer(s), such as one or more metal layer(s), formed thereon. A particular group of dispersing agents are described which when incorporated in the release system, lead to improved process efficiency and more consistent product. Additional features and aspects of the processes are described.

Abstract: A method of producing metal flakes (72?) is provided. The method includes: applying a layer of ionic liquid (70) to a substrate (24); forming a layer of metal (70) on the substrate (24) over the ionic liquid (70); and removing the layer of metal (70) from the substrate (24).

Abstract: A process for preparing embossed fine particulate thin metal flakes having high levels of brightness and color intensity. The process comprises forming a release coat on a flexible polymeric carrier film, embossing the release coat with a diffraction grating pattern that is monoruled at an angle above 45°, vacuum metalizing the embossed release surface with a highly reflective metal such as aluminum, and solubilizing the metalized release coat in a solvent for removing the metal from the carrier to form embossed metal flakes that replicate the embossment pattern. The flakes are recovered from the solution containing the solvent and release coat polymer while avoiding high shear, particle sizing or other application of energy that would excessively break up the flakes, so that the D50 particle size of the flakes is maintained at or above 75 microns.

Abstract: A process for preparing embossed fine particulate thin metal flakes having high levels of brightness and color intensity. The process comprises forming a release coat on a flexible polymeric carrier film, embossing the release coat with a diffraction grating pattern that is monoruled at an angle above 45°, vacuum metalizing the embossed release surface with a highly reflective metal such as aluminum, and solubilizing the metalized release coat in a solvent for removing the metal from the carrier to form embossed metal flakes that replicate the embossment pattern. The flakes are recovered from the solution containing the solvent and release coat polymer while avoiding high shear, particle sizing or other application of energy that would excessively break up the flakes, so that the D50 particle size of the flakes is maintained at or above 75 microns.