Generally, film casting consists of the following: “a) preparation of a specific and well controlled preparation of a polymer solution, b) casting the polymer solution in the form of a thin film onto a temporary substrate, c) coagulating the resulting film of the polymer solution in a nonsolvent and d) removing the temporary substrate and e) drying the microporous membrane.”
(Kools, US Patent 7,743,929, 6/29/2010)

Casting 
Processing 

Solution Casting

Recent US Patents

9/28/2010
7,803,293
Optical film manufacturing method, optical film manufacturing apparatus and optical film

Nagashima of Konica Minolota Opto, Japan  found that high quality optical films can be produced by casting a dope in which a thermoplastic resin is dissolved in a solvent, on a support so as to form a web; peeling and conveying the web from the support.  The drying conditions at several positions were adjusted by the temperature, velocity or volume of the drying air to produce the needed uniformity.  (RDC 12/7/2010)

6/29/2010
7,743,929
Process of Forming Multilayered Structures

Kools of Milipore, Massachusetts have formed a multilayer film “by simultaneously co-casting a plurality of polymer solutions onto a support to form a multilayered liquid sheet and immersing the sheet into a liquid coagulation bath to effect phase separation and form a porous membrane.”  (RDC 1/12/2011)

Recent Journal Articles

1/7/2011
Polarizer effect and structure of iodinated before and after casting poly(vinyl alcohol) film
(397–405)
Journal of Applied Polymer  Science 120 #1 (2011)
Shin, Lyoo and Lee manufactured poly(vinyl alcohol) (PVA)/iodine polarizing film by iodating PVA  in solution before casting (IBC film) and iodinating again after casting (IBC + IAC film) and then the IBC + IAC film was drawn in boric acid aqueous solution (IBC + IAC polarizing film), to improve the durability of the polarizing film under a humid and warm atmosphere.  (RDC 1/10./2011)