Reproduction of relief patterns

• US 20030025227A1
• Filed: 07/30/2002
• Published: 02/06/2003
• Est. Priority Date: 08/02/2001
• Status: Abandoned Application

• Current Assignee: Zograph LLC
• Original Assignee: Zograph LLC
• Inventors: Daniell, Stephen
• Application Number:
  US10/208,325
• Publication Number:
  US 20030025227A1
• Time in Patent Office: Days
• US Class Current: 264/2.5
• CPC Class Codes: B29D 11/00278 Lenticular sheets B29D11/00269 takes precedence
• CPC Class Codes: B29D 11/00365 Production of microlenses lenticular sheets B29D11/00278

Abstract

A relief master is formed by assembly of previously molded, machined, or otherwise fabricated relief structures. The relief structures may be quite small and include a relief geometry, i.e., a topology of interest, and a positioning feature. The relief structures are mounted on a rigid (e.g., metal) substrate that includes a plurality of positioning features complementary to the positioning features in the relief structures. The relief master is assembled through selective application and positioning of the small-scale relief structures, and can then be used as a pattern for diverse surface replication processes, including the fabrication of durable metal mold faces for casting, embossing, compression molding, and injection molding of complex patterned surfaces.

Claims

1. A method of replicating a surface, the method comprising the steps of:

a. providing a rigid substrate having positioning features;

b. providing a plurality of relief structures each having a relief geometry and a positioning feature complementary to the substrate positioning features;

c. joining the relief structures to the substrate by mating the substrate positioning features and the relief-structure positioning features, thereby forming a relief master; and

d. replicating the relief master.

2. The method of claim 1 wherein the substrate positioning features are holes and the relief-structure positioning features are shafts received in the holes.

3. The method of claim 1 wherein the replicating step comprises:

a. fabricating a mold complementary to the relief master; and

b. using the mold to repetitively form surfaces corresponding to the relief master.

4. The method of claim 3 wherein the using step comprises casting from the mold.

5. The method of claim 3 wherein the using step comprises embossing with the mold.

6. The method of claim 3 wherein the using step comprises injection molding with the mold.

7. The method of claim 1 wherein the replicating step comprises:

a. fabricating a mold complementary to the relief master; and

b. using the mold to repetitively form surfaces corresponding to the relief master.

8. The method of claim 7 wherein the using step includes electroforming.

9. The method of claim 7 wherein the using step includes mechanical deformation.

10. The method of claim 1 wherein the feature elements are identical and produced by molding.

11. The method of claim 2 wherein the substrate positioning features are blind holes.

12. The method of claim 2 wherein the substrate positioning features are through-holes.

13. The method of claim 2 wherein the holes have sloping sidewalls.

14. The method of claim 1 wherein the wherein the substrate positioning features and the relief-structure positioning features are off-round to facilitate alignment of the relief structures with respect to the substrate.

15. The method of claim 1 wherein the joining step is preceded by a step of inducing dimensional disparity between the relief structures and the substrate by differential temperature-dependent expansion or contraction thereof.

16. The method of claim 1 wherein the joining step further comprises using an adhesive to retain the relief structures on the substrate.

17. The method of claim 1 wherein the joining step comprises friction-fitting the relief-structure positioning features with the substrate positioning features.

18. The method of claim 1 wherein the joining step is achieved using a pick-and-place insertion device.

19. A relief master comprising (a) a rigid substrate having positioning features and (b) a plurality of identical relief structures each having a relief geometry and a positioning feature complementary to the substrate positioning features, the relief structures being joined to the substrate and forming a surface pattern by mating of the substrate positioning features and the relief-structure positioning features.

20. The relief master of claim 19 wherein the substrate positioning features are holes and the relief-structure positioning features are shafts received in the holes.

21. The relief master of claim 19 wherein the substrate positioning features are blind holes.

22. The relief master of claim 19 wherein the substrate positioning features are through-holes.

23. The relief master of claim 20 wherein the holes have sloping sidewalls.

24. The relief master of claim 20 wherein the wherein the substrate positioning features and the relief-structure positioning features are off-round to facilitate alignment of the relief structures with respect to the substrate.

25. The relief master of claim 20 wherein the relief structures are retained on the substrate by an adhesive.

26. The relief master of claim 20 wherein the relief structures are retained on the substrate by friction.