Abstract: A method of film fabrication is taught that uses a coating and drying apparatus to fabricate resin films suitable for optical applications. In particular, acrylic films are prepared by simultaneous application of multiple liquid layers to a moving carrier substrate. After solvent removal, the acrylic films are peeled from the sacrificial carrier substrate. Acrylic films prepared by the current invention exhibit good clarity and low birefringence.

Abstract: An improved method of thin film coating is taught that uses a multi-slot coating apparatus to apply multiple liquid layers to a moving substrate. The lowermost layer contacting the substrate is comprised of an organic solvent. The lowermost layer may be a single organic solvent or a blend of several organic solvents. Whether comprised of a single organic solvent or a blend of organic solvents, the viscosity of the lowermost layer is less than 1 cp and the wet thickness of the lowermost layer is not more than about 5 &mgr;m. Additional liquid layers are applied to the moving substrate on the top of the lowermost layer. This method allows for application of coatings at high substrate speeds. This method also allows for the reduction of coating artifacts caused by contamination of the surface of the die.

Abstract: A method is taught for that allows for controlling and optimizing the level of adhesion between a multilayer composite applied to a support web. The method comprises the steps of selecting the support web with or without a subbing layer applied thereto; selecting an organic solvent that is substantially free of other constituents as a carrier layer; forming a multilayer composite including the carrier layer, the carrier layer being the lowermost layer thereof; applying the multilayer composite to the support web or the subbing layer; drying the multilayer composite on the support web, the carrier layer evaporating from the multilayer composite; testing the adhesive strength between the support web or subbing layer and the multilayer composite after drying; and repeating these steps until a desired level of adhesion is found.

Abstract: A method is taught for that allows for controlling and optimizing the level of adhesion between a multilayer composite applied to a support web. The method comprises the steps of selecting the support web with or without a subbing layer applied thereto; selecting an organic solvent that is substantially free of other constituents as a carrier layer; forming a multilayer composite including the carrier layer, the carrier layer being the lowermost layer thereof; applying the multilayer composite to the support web or the subbing layer; drying the multilayer composite on the support web, the carrier layer evaporating from the multilayer composite; testing the adhesive strength between the support web or subbing layer and the multilayer composite after drying; and repeating these steps until a desired level of adhesion is found.

Abstract: An improved method of thin film coating is taught that uses a multi-slot coating apparatus to apply multiple liquid layers to a moving substrate. The lowermost layer contacting the substrate is comprised of an organic solvent. The lowermost layer may be a single organic solvent or a blend of several organic solvents. Whether comprised of a single organic solvent or a blend of organic solvents, the viscosity of the lowermost layer is less than 1 cp and the wet thickness of the lowermost layer is not more than about 5 &mgr;m. Additional liquid layers are applied to the moving substrate on the top of the lowermost layer. This method allows for application of coatings at high substrate speeds. This method also allows for the reduction of coating artifacts caused by contamination of the surface of the die.

Abstract: A transfer member, for example, a transfer drum utilizes a vacuum applied through vacuum openings to the drum surface for holding a receiving sheet. A toner image is transferred to the sheet under the urging of an electric field. The vacuum openings are made small enough to prevent a visible artifact caused by nontransfer of toner in the vicinity of the opening but large enough to still maintain a vacuum contributing to the holding force of the sheet. According to a preferred embodiment, larger vacuum holes are formed in the drum and a conductive insert defining or helping define small vacuum openings is inserted in each vacuum hole. The insert maintains the continuity of the electric field in the hole region, but its geometry provides the small openings to maintain the vacuum. The invention is particularly useful in apparatus in which more than one color toner image is transferred in registry to the receiving sheet.