PROCESS AND APPARATUS FOR MICROREPLICATION

• US 20080274225A1
• Filed: 07/17/2008
• Published: 11/06/2008
• Est. Priority Date: 08/02/2002
• Status: Abandoned Application

• Current Assignee: Ali R. Mehrabi, Chunhwa Wang, David N. Edwards, Eng-Pi Chang, Hsiao Ken Chuanq, Philip Yi Zhi Chu, Reza Mehrabi, Rishikesh K. Bharadwai, Robert J. Fermin, Ronald F. Sieloff
• Original Assignee: Ali R. Mehrabi, Chunhwa Wang, David N. Edwards, Eng-Pi Chang, Hsiao Ken Chuanq, Philip Yi Zhi Chu, Reza Mehrabi, Rishikesh K. Bharadwai, Robert J. Fermin, Ronald F. Sieloff
• Inventors: Edwards, David N., Sieloff, Ronald F., Mehrabi, Ali R., Mehrabi, Reza, Chang, Eng-Pi, Fermin, Robert J., Wang, Chunhwa, Bharadwai, Rishikesh K., Chuanq, Hsiao Ken, Yi Zhi Chu, Philip
• Application Number:
  US12/174,652
• Publication Number:
  US 20080274225A1
• Time in Patent Office: Days
• US Class Current: 425/174.4
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 35/0272 using lost heating elements, i.e. heating means incorporated and remaining in the formed article for preforms with internal stresses B29C61/0625; joining using lost heating elements B29C65/34; making electrically conductive articles B29C70/882
• CPC Class Codes: B29C 35/0888 using transparant moulds
• CPC Class Codes: B29C 59/02 by mechanical means, e.g. pressing B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627
• CPC Class Codes: B29C 59/04 using rollers or endless belts
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 156/1041 Subsequent to lamination
• CPC Class Codes: Y10T 156/1737 Discontinuous, spaced area, and/or patterned pressing

Abstract

A method of embossing a sheet material includes: heating at least a portion of the sheet directly or indirectly with radiant energy from a radiant energy source; pressing a tool against the heated portion of the sheet, thereby patterning a surface of the sheet; and separating the sheet and the tool. The radiant energy may travel through a solid material that is relatively transparent to radiation, on its way to being absorbed by a relatively-absorptive material. The relatively-transparent material may be an unheated portion of the sheet, and the relatively-absorptive material may be either the tool or the heated portion of the sheet. Alternatively, the relatively-transparent material may be the tool, and the relatively-absorptive material may be all or part of the sheet. The method may be performed as one or more roll-to-roll operations.

Claims

1. An embossing system, comprising:

a plurality of rollers, arrayed on opposite sides of a passage for receiving therein a sheet material to be embossed;

a radiant heater operatively configured to heat the sheet material while in the passage; and

a patterned belt in the passage, for patterning the sheet material.

2. The system of claim 1,

wherein the radiant heater includes radiant energy sources;

and

wherein the radiant heater further includes one or more reflectors operatively coupled to the at least some of the radiant energy sources, to thereby direct radiant energy from the radiant energy sources to the passage.

3. The system of claim 2,

wherein in radiant energy sources and the reflectors are in at least some of the rollers;

and

wherein the at least some of the rollers include radiantly-transparent roller material that allows radiant energy from the radiant energy sources to pass therethrough.

4. The system of claim 1,

wherein in radiant energy sources are in at least some of the rollers;

and

wherein the at least some of the rollers include radiantly-transparent roller material that allows radiant energy from the radiant energy sources to pass therethrough.

5. An embossing system, comprising:

a pair of belts arrayed on opposite sides of a passage for receiving therein a sheet material to be embossed; and

a radiant heater operatively configured to heat the sheet material while in the passage.

6. The system of claim 5,

wherein one of the belts includes a radiantly-transparent material;

and

wherein the radiant heater is configured to pass radiant energy into the passage through the radiantly-transparent material.

7. The system of claim 6, wherein the other belt includes a radiantly-absorptive material.

8. The system of claim 5,

wherein the radiant heater includes:

at least one radiant energy source that produces radiant energy; and

at least one reflector; and

wherein the at least one radiant energy source and the at least one reflector are configured such that the at least reflector directs at least some of the radiant energy toward the passage.

9. An embossing system, comprising:

a pair of press platforms configured to press a sheet material therebetween; and

a radiant heater configured to deliver radiant energy between the press platforms.

10. The system of claim 9,

wherein one of the press platforms includes a radiantly-transparent material;

and

wherein the radiant heater is configured to pass the radiant energy through the radiantly-transparent material.

11. The system of claim 10, further comprising a pressure-producing device operatively coupled to the press platforms to press the platforms together.