Polymer casting method and apparatus

• US 7,074,358 B2
• Filed: 12/13/2001
• Issued: 07/11/2006
• Est. Priority Date: 12/13/2001
• Status: Expired due to Term

• Current Assignee: IKONICS Corporation (TeraWulf, Inc.)
• Original Assignee: IKONICS Corporation (TeraWulf, Inc.)
• Inventors: Komatsu, Toshifumi, Gybin, Alexander Sergeievich
• Primary Examiner(s): McDowell, Suzanne E.
• Application Number:
  US10/017,466
• Publication Number:
  US 20030111771A1
• Time in Patent Office: 1,671 Days
• Field of Search: 264/400, 264/482, 264/494, 264/219
• US Class Current: 264/400
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 39/02 for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: G03F 7/0017 for the production of embossing, cutting or similar devices; for the production of casting means
• CPC Class Codes: Y10T 428/1481 Dissimilar adhesives

Abstract

Methods and materials used to make detailed cast objects are disclosed. The cast objects are formed in mold created from a photosensitive laminate. The mold is formed by selectively removing portions of the photosensitive laminate. The invention is particularly well suited to make thin molded articles, but can also be used to make thicker molded articles by using multiple photosensitive layers or laminates.

Claims

1. A method for forming a cast article, the method comprising:

providing a photosensitive film, the film comprising at least one layer containing a photosensitive material;

selectively exposing at least a portion of the photosensitive material of the film;

removing a portion of the layer containing the photosensitive material, the removed portion corresponding to either the exposed or unexposed portion of the photosensitive material, to form a relief surface in the film; and

applying a casting material to the relief surface after formation of the relief surface to form a cast article;

wherein the photosensitive layer comprises less than 75% by weight of a water soluble, photosensitive vinyl polymer having pendent hydroxyl groups and being capable of photo-generated insolubility and less than 75 weight percent of a polymeric film-forming binder.

2. The method of claim 1, wherein the photosensitive material is developable with aqueous media.

3. The method of claim 1, wherein the photosensitive material comprises a photopolymer.

5. The method of claim 1, wherein the photosensitive material comprises a photoinitiator and a monomer, an oligomer, or a combination of monomer and oligomer.

6. The method of claim 5, wherein the photosensitive material comprises an ethylenically unsaturated material.

7. The method of claim 5, wherein the photosensitive material comprises an acrylate material.

8. The method of claim 1, wherein the photosensitive material comprises a water-soluble, photosensitive vinyl polymer.

9. The method of claim 8, wherein the water soluble, photosensitive vinyl polymer comprises a polyvinyl alcohol polymer.

10. The method of claim 1, wherein the photosensitive material comprises less than 50 weight percent of a photopolymer, about 30 to 90 weight percent of a binder resin, and about 0 to 40 weight percent of a compatible plasticizers.

11. The method of claim 10, wherein the photosensitive material comprises about 15 to 50 weight percent of a photopolymer having pendant, photo-crosslinkable, styryl groups, about 50 to 80 weight percent of a binder resin, and about 0 to 15 weight percent of a compatible plasticizer.

12. The method of claim 1, wherein the first layer further comprises a plasticizer.

13. The method of claim 1, wherein the laminate further comprises a support layer.

14. The method of claim 1 wherein the first layer of the laminate is from 1 to 100 mils thick.

15. The method of claim 1, wherein the photosensitive laminate film is flexible.

16. The method of claim 1, wherein the casting material is selected from the group consisting of plaster, polymeric resins, uv-curable materials, and low-melting point metals.

17. The method of claim 1, wherein the casting material is used to form a flexographic printing plate.

4. The method of clam 3, wherein the photopolymer has pendant, photo-crosslinkable, styryl groups.