METHOD FOR PRODUCING MICRO- OR NANOSTRUCTURES IN POLYMERIC FILM MATERIALS

• US 20160107371A1
• Filed: 10/03/2013
• Published: 04/21/2016
• Est. Priority Date: 10/05/2012
• Status: Abandoned Application

• Current Assignee: Iscent Oy
• Original Assignee: Iscent Oy
• Inventors: HURME, Eero, RAUKOLA, Jaakko, KALIMA, Valtteri
• Application Number:
  US14/895,799
• Publication Number:
  US 20160107371A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2059/023 Microembossing
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/28 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
• CPC Class Codes: B29C 59/022 characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
• CPC Class Codes: B29C 59/04 using rollers or endless belts
• CPC Class Codes: B29C 59/046 for layered or coated substantially flat surfaces
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29L 2011/00 Optical elements, e.g. lenses, prisms

Abstract

The invention relates to a method for producing micro- or nanostructures in polymer film materials having thermoforming properties in an extrusion process. The method according to invention comprises providing a molten thermoforming polymer film (1) from an extruder (2), driving a molten polymer film (1) through a nip (3) wherein the molten thermoforming polymer film (1) is contacted with a cooling roller (4) supporting a master film with a surface relief pattern (5) and a pressure roller (6), so that micro- or nanostructures are replicated onto the polymer film by the action of pressure and cooling at the nip. The master film is a polymeric master film it is driven continuously from the master film feed roller (9) through the nip (3) to the receiver roller (10).

Claims

1. A method for producing micro- or nanostructures in polymer film materials having thermoforming properties in an extrusion process, the method comprising:

providing a molten thermoforming polymer film from an extruder, driving a molten polymer film through a nip wherein the molten thermoforming polymer film is contacted with a cooling roller supporting a master film with a surface relief pattern and a pressure roller, so that micro- or nanostructures are replicated onto the polymer film by the action of pressure and cooling at the nip, characterized in that the master film with a surface relief pattern is a polymeric master film and wherein it is driven continuously from the master film feed roller through the nip to the receiver roller.

2. The method according to claim 1, wherein the replicated polymer film is coated on a substrate material.

3. The method according to claim 1, wherein the replication temperature is 15-350°

C.

4. The method according to claim 1, wherein the pressure at the nip is 0.5-10 bar.

5. The method according to claim 1, wherein the speed of the molten polymer film at the nip is 1-400 m/min.

16. The method according to claim 1, wherein the replication temperature is 50-100°

C.

17. The method according to claim 1, wherein the pressure at the nip is 2-6 bar.

18. The method according to claim 1, wherein the speed of the molten polymer film at the nip is 40-100 m/min.

6. A master film with a surface relief pattern for producing micro- or nanostructures in film materials having thermoforming or thermosetting properties, wherein that the master film is a polymeric master film.

7. The master film according to claim 6, wherein the master film comprises a base film.

8. The master film according to claim 6, comprising one or more coating layers.

9. The master film according to claim 6, wherein the base film comprises a thermoplastic and/or thermosetting polymer.

10. The master film according to claim 6, wherein the base film and/or the coating layer(s) comprise fillers, materials increasing heat conductivity, insulators, release agents, lubricants, wetting agents and/or adhesive materials.

11. The master film according to claim 7, wherein the base film comprises 2-6 base layers, preferably 2-3 base layers.

12. The master film according to claim 11, wherein the base layer comprises flexible substrates such as thermoplastic and/or thermosetting polymer, carton, paperboard, paper and metal foil and the thermoplastic and/or thermosetting polymer layer is on the top of the base film.

13. The master film according to claim 6, wherein the polymeric master film comprises a base film, an abrasion resistance coating layer on a surface relief pattern of the base film and an adhesive layer on the bottom surface.

14. The method according to claim 6, wherein the master film with a surface relief pattern is partly masked.

19. The master film according to claim 9, wherein the thermoplastic and/or thermosetting polymer is selected from the group of polyethylene terephthalate PET, polycarbonate PC, polyvinylchloride PVC, glycol-modified polyethylene terephthalate copolyester PETG, polymethylmethacrylate PMMA, cyclo-olefin polymer COP, cyclo-olefin copolymer COC, polyurethane PU, polypropylene PP, polyethylene PE, polystyrene PS, polysulfone PSU, triacetyl cellulose TAC, polymethylpentene PMP, cross-linked polyethylene, and a mixture thereof.

20. The master film according to claim 7, wherein the base film comprises 2-3 base layers.

21. The master film according to claim 11, wherein the flexible substrates are selected from the group of thermoplastic and/or thermosetting polymer, carton, paperboard, paper, and metal foil, and wherein the thermoplastic and/or thermosetting polymer layer is on the top of the base film.

15. (canceled)