Methods of using nanostructured transfer tape and articles made therefrom

• US 10,052,856 B2
• Filed: 09/06/2016
• Issued: 08/21/2018
• Est. Priority Date: 12/21/2012
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Free, Michael Benton, Wolk, Martin B., Collier, Terry O., Mazurek, Mieczyslaw H., Schwartz, Evan L.
• Primary Examiner(s): SENGUPTA, SONYA MAZUMDAR
• Application Number:
  US15/257,099
• Publication Number:
  US 20160375666A1
• Time in Patent Office: 714 Days
• Field of Search: 156247, 156249, 1562728, 1562755, 156289
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2059/023 Microembossing
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 35/0894 provided with masks or diaphragms
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• CPC Class Codes: B29C 41/24 for making articles of indefinite length
• CPC Class Codes: B29C 59/026 of layered or coated substantially flat surfaces
• CPC Class Codes: B29C 65/528 by CVD or by PVD, i.e. by chemical vapour deposition or by physical vapour deposition
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29L 2009/005 coated
• CPC Class Codes: B29L 2031/3475 Displays, monitors, TV-sets, computer screens
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2383/00 Polysiloxanes
• CPC Class Codes: B32B 2457/20 Displays, e.g. liquid crystal displays, plasma displays
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 37/025 Transfer laminating
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: C23C 16/455 characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
• CPC Class Codes: G03F 7/0002 Lithographic processes using patterning methods other than those involving the exposure to radiation, e.g. by stamping
• CPC Class Codes: G03F 7/2014 : Contact or film exposure of light sensitive plates such as lithographic plates or circuit boards, e.g. in a vacuum frame

Abstract

A method of making patterned structured solid surfaces is disclosed that includes filling a structured template with backfill material to produce a structured transfer film, patternwise curing the backfill material to produce cured areas and uncured areas in the structured transfer film, and laminating the structured transfer film to a receptor substrate. The structured template is capable of being removed to form structured and unstructured backfill layers. The structured and unstructured backfill layers may then be blanket cured. The backfill layer can include at least two different materials, one of which can be an adhesion promotion layer. In some embodiments the backfill layer includes a silsesquioxane such as polyvinyl silsesquioxane. The structured transfer film is a stable intermediate that can be covered temporarily with a release liner for storage and handling.

Claims

1. A method of making patterned structured solid surfaces comprising:

filling a structured template with backfill material to produce a structured transfer film;

patternwise curing the backfill material to produce an intermediate transfer film comprising cured areas and uncured areas in the structured transfer film;

laminating the intermediate transfer film to a receptor substrate;

removing the structured template and allowing the uncured areas to reflow such that the cured areas form structured areas and the uncured areas form unstructured areas of a laminated backfill layer; and

blanket curing the structured and unstructured areas of the laminated backfill layer.

3. A method of making patterned structured solid surfaces according to claim 1, wherein one or more layers are applied over the intermediate transfer film before lamination to increase adhesion of the backfilled material to the receptor substrate.

4. A method of making patterned structured solid surfaces according to claim 1, wherein the backfill material comprises a silsesquioxane.

5. A method of making patterned structured solid surfaces according to claim 1, wherein the intermediate transfer film is temporarily laminated to a release liner.

6. A method of making patterned structured solid surfaces according to claim 1, wherein the receptor substrate comprises glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite.

7. A method of making patterned structured solid surfaces according to claim 1, wherein patternwise curing comprises photocuring through a photomask.

8. A method of making patterned structured solid surfaces according to claim 1, wherein allowing the uncured areas to reflow further comprise applying heat.

9. The method of claim 1, wherein the patternwise curing comprises exposing select portions of the backfill material to a laser beam.

10. The method of claim 1, wherein the structured template comprises a release coating.

2. A method of making patterned structured solid surfaces comprising:

filling a structured template with backfill material to produce a structured transfer film;

patternwise curing the backfill material in an oxygen environment to produce an intermediate transfer film comprising cured areas and uncured areas in the structured transfer film;

laminating the intermediate transfer film to a receptor substrate;

removing the structured template such that the cured areas form structured areas and the uncured areas form unstructured areas of a laminated backfill layer; and

blanket curing the structured and unstructured areas of the laminated backfill layer.

11. A method for making a patterned structured solid surface, the method comprising:

filling a structured template with backfill material to produce a structured transfer film, the structured template comprising nanostructures or microstructures;

laminating the structured transfer film onto a receptor substrate;

curing the backfill material patternwise to form an intermediate laminated film comprising cured areas and uncured areas of backfill material;

removing the structured template and allowing the uncured areas to reflow to form unstructured areas; and

blanket curing the cured and uncured areas of the backfill material.

12. The method of claim 11, wherein the patternwise curing is performed in an oxygen environment.

13. The method of claim 11, wherein one or more layers are applied over the structured transfer film before lamination to increase adhesion of the backfill material to the receptor substrate.

14. The method of claim 11, wherein the backfill material comprises a silsesquioxane.

15. The method of claim 11, wherein the structured transfer film is temporarily laminated to a release liner.

16. The method of claim 11, wherein the receptor substrate comprises glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite.

17. The method of claim 11, wherein patternwise curing comprises photocuring through a photomask or exposing select portions of the backfill material to a laser beam.

18. The method of claim 11, wherein allowing the uncured areas to reflow further comprises applying heat.

19. The method of claim 11, wherein the structured template comprises a release coating.