Method and apparatus for peeling a thin film from a liner

Abstract

A method and apparatus are provided for peeling a thin film, typically 100 microns or less in thickness, from a liner by use of a rotatable peel rod supported in an air bearing. The air bearing comprises a support plate having arcuate surfaces which are substantially coaxial with a cylindrical film-bearing segment of the peel rod. Air openings in the arcuate surfaces conduct a flow of air into an air bearing gap between the arcuate surfaces and the peel rod.

1 . An apparatus for removing a film from a liner comprising a rotatable peel rod supported in an air bearing.  
   
   
       2 . The apparatus according to  claim 1  wherein said peel rod comprises a film-bearing segment which is essentially cylindrical and has a center axis, and wherein said air bearing comprises a support plate having one or more arcuate surfaces which are substantially coaxial with said film-bearing segment of said peel rod, said support plate comprising one or more air openings in said arcuate surfaces for conducting a flow of air into an air bearing gap between said arcuate surfaces and said film-bearing segment of said peel rod.  
   
   
       3 . The apparatus according to  claim 2  additionally comprising a source of super-ambient air pressure functionally connected to said air openings so as to provide a flow of air into said air bearing gap.  
   
   
       4 . The apparatus according to  claim 3  wherein said air openings comprise a groove in said arcuate surface traversing substantially the entire length of said air bearing gap.  
   
   
       5 . The apparatus according to  claim 4  additionally comprising a liner support roller positioned adjacent to said peel rod so as to form a nip.  
   
   
       6 . The apparatus according to  claim 5  additionally comprising a film idler roll positioned so as to receive a film passing over said peel rod and maintain said film in a stable orientation relative to said peel rod.  
   
   
       7 . The apparatus according to  claim 6  additionally comprising a frame to which said film idler roll is rotatably attached, to which said liner support roller is rotatably attached, and to which said support plate is fixedly attached.  
   
   
       8 . A method for removing a film from a liner comprising the steps of: 
 passing a bilayer of a film and a liner over a rotatable peel rod supported in an air bearing such that said film contacts said peel rod; and    peeling said film from said liner.    
   
   
       9 . The method according to  claim 8  wherein said peel rod comprises a film-bearing segment which is essentially cylindrical and has a center axis, and wherein said air bearing comprises a support plate having one or more arcuate surfaces which are substantially coaxial with said film-bearing segment of said peel rod, said support plate comprising one or more air openings in said arcuate surfaces for conducting a flow of air into an air bearing gap between said arcuate surfaces and said film-bearing segment of said peel rod.  
   
   
       10 . The method according to  claim 9 , wherein said air openings comprise a groove in said arcuate surfaces traversing substantially the entire length of said air bearing gap.  
   
   
       11 . The method according to  claim 10 , wherein said air openings are functionally connected to a source of super-ambient air pressure such that a flow of air into said air bearing gap is provided.  
   
   
       12 . The method according to  claim 11  wherein said step of passing a bilayer of a film and a liner over a rotatable peel rod comprises passing said bilayer into a nip formed between said peel rod and a liner support roller positioned adjacent to said peel rod.  
   
   
       13 . The method according to  claim 12 , wherein contact is maintained between said liner and said liner support roller during said peeling step.  
   
   
       14 . The method according to  claim 13  additionally comprising the step of passing said film peeled from said liner over a film idler roll positioned so as to maintain said film in a stable orientation relative to said peel rod during said peeling step.  
   
   
       15 . The method according to  claim 8  wherein said film has a thickness of 100 micrometers or less.  
   
   
       16 . The method according to  claim 9  wherein said film has a thickness of 100 micrometers or less.  
   
   
       17 . The method according to  claim 12  wherein said film has a thickness of 100 micrometers or less.  
   
   
       18 . The method according to  claim 8  additionally comprising the step of casting said film on said liner.  
   
   
       19 . The method according to  claim 9  additionally comprising the step of casting said film on said liner.  
   
   
       20 . The method according to  claim 12  additionally comprising the step of casting said film on said liner.  
   
   
       21 . The method according to  claim 18  additionally comprising a step of cutting the cast film on one or more edges so as to provide a clean edge prior to removing said film from said liner.  
   
   
       22 . The method according to  claim 19  additionally comprising a step of cutting the cast film on one or more edges so as to provide a clean edge prior to removing said film from said liner.  
   
   
       23 . The method according to  claim 20  additionally comprising a step of cutting the cast film on one or more edges so as to provide a clean edge prior to removing said film from said liner.  
   
   
       24 . The method according to  claim 8  wherein said film is a polymer electrolyte membrane.  
   
   
       25 . The method according to  claim 9  wherein said film is a polymer electrolyte membrane.  
   
   
       26 . The method according to  claim 12  wherein said film is a polymer electrolyte membrane.