Process for transferring microstructures to a final substrate

• US 10,173,405 B2
• Filed: 08/17/2012
• Issued: 01/08/2019
• Est. Priority Date: 08/17/2012
• Status: Active Grant

• Current Assignee: Visual Physics LLC (Crane Company)
• Original Assignee: Visual Physics LLC (Crane Company)
• Inventors: Gosnell, Jonathan D., Jordan, Gregory R., Kennedy, Caroline B.
• Primary Examiner(s): Gray, Linda L
• Application Number:
  US14/421,394
• Publication Number:
  US 20150217550A1
• Time in Patent Office: 2,335 Days
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2315/08 Glass
• CPC Class Codes: B32B 2457/208 Touch screens
• CPC Class Codes: B32B 2519/00 Labels, badges
• CPC Class Codes: B32B 2554/00 Paper of special types, e.g. banknotes
• CPC Class Codes: B32B 37/025 Transfer laminating
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 38/18 Handling of layers or the laminate
• CPC Class Codes: B42D 15/00 Printed matter of special format or style not otherwise provided for
• CPC Class Codes: B42D 2035/20 Optical effects
• CPC Class Codes: B42D 2035/44 Miniaturised markings
• CPC Class Codes: B42D 25/29 Securities; Bank notes
• CPC Class Codes: B42D 25/355 Security threads
• CPC Class Codes: B42D 25/455 using heat
• CPC Class Codes: B42D 25/47 using adhesives
• CPC Class Codes: B44C 1/1716 : Decalcomanias provided with a particular decorative layer, e.g. specially adapted to allow the formation of a metallic or dyestuff layer on a substrate unsuitable for direct deposition
• CPC Class Codes: B44C 1/172 : Decalcomanias provided with a layer being specially adapted to facilitate their release from a temporary carrier
• CPC Class Codes: B81C 1/00206 : Processes for functionalising a surface, e.g. provide the surface with specific mechanical, chemical or biological properties
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

A process and a transfer film for transferring microstructures to a flexible or rigid final substrate that offers advantages in both speed and precision is provided. The inventive process involves subjecting a transfer film in a continuous roll-to-roll process to the following operations: either forming microstructures on, or transferring microstructures to a surface of the transfer film; and then transferring the microstructures from the transfer film onto a surface of the final substrate. The microstructures are single or multi-layer structures that are made up of: voids in a substantially planar surface, the voids optionally filled or coated with another material; raised areas in a substantially planar surface; or combinations thereof.

Claims

1. A transfer film for transferring microstructures to a final substrate, the transfer film comprising a carrier film having a planar surface on its side toward the microstructures, one or more fully cured binder layers on a surface of the carrier film, the microstructures, and one or more fully cured conformal release coating layers on a surface of the microstructures between the one or more fully cured binder layers and the microstructures, wherein the microstructures are single or multi-layer structures, each layer having one planar surface and an opposing surface that comprises:

voids in a substantially planar surface, the voids optionally filled or coated with another material;

raised areas in a substantially planar surface;

or combinations thereof, and wherein the one or more fully cured binder layers is strongly bonded to the carrier film and to the one or more fully cured conformal release coating layers on a surface of the microstructures.

2. The transfer film of claim 1, wherein the one or more cured binder layers is made up of one or more energy curable polyacrylates and a free radical photoinitiator.

3. The transfer film of claim 1, wherein the microstructures are a single layer structure having one planar surface and an opposing surface that comprises:

voids in a substantially planar surface, the voids optionally filled or coated with another material;

raised areas in a substantially planar surface;

or combinations thereof.