Methods of making articles using structured tapes

• US 9,855,730 B2
• Filed: 12/14/2015
• Issued: 01/02/2018
• Est. Priority Date: 12/21/2012
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Wolk, Martin B., Free, Michael Benton, Vogel-Martin, Margaret M., Schwartz, Evan L., Mazurek, Mieczyslaw H., Collier, Terry O.
• Primary Examiner(s): Patel, Vishal I
• Application Number:
  US14/968,362
• Publication Number:
  US 20160096316A1
• Time in Patent Office: 750 Days
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2059/023 Microembossing
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 35/0894 provided with masks or diaphragms
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• CPC Class Codes: B29C 41/24 for making articles of indefinite length
• CPC Class Codes: B29C 59/026 of layered or coated substantially flat surfaces
• CPC Class Codes: B29C 65/528 by CVD or by PVD, i.e. by chemical vapour deposition or by physical vapour deposition
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29L 2009/005 coated
• CPC Class Codes: B29L 2031/3475 Displays, monitors, TV-sets, computer screens
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2383/00 Polysiloxanes
• CPC Class Codes: B32B 2457/20 Displays, e.g. liquid crystal displays, plasma displays
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 37/025 Transfer laminating
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: C23C 16/455 characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
• CPC Class Codes: G03F 7/0002 Lithographic processes using patterning methods other than those involving the exposure to radiation, e.g. by stamping
• CPC Class Codes: G03F 7/2014 : Contact or film exposure of light sensitive plates such as lithographic plates or circuit boards, e.g. in a vacuum frame

Abstract

Methods of making articles using structured tapes are disclosed. The structured tapes may include a structured template layer having a structured surface and an opposed second surface and an uncured backfill layer, the uncured backfill layer has a lower refractive index than the structured template layer, and the uncured backfill layer has a structured surface conforming to the structured surface of the structured template layer and an opposed second surface. The structured tapes may include a structured template layer having a structured surface and an opposed second surface and an uncured backfill layer, the uncured backfill layer has a higher refractive index than the structured template layer, and the uncured backfill layer has a structured surface conforming to the structured surface of the structured template layer and an opposed second surface. The structure tapes may be laminated via the uncured backfill layer to a receptor substrate to form an article.

Claims

1. A method of making an article comprising:

providing a structured tape comprising;

a carrier;

a structured template layer having a structured surface and an opposed second surface, wherein the opposed second surface of the structured template layer is in contact with the carrier;

an uncured backfill layer, wherein the uncured backfill layer has a lower refractive index than the structured template layer, and the uncured backfill layer has a structured surface conforming to the structured surface of the structured template layer and an opposed second surface;

laminating the opposed second surface of the uncured backfill layer to a receptor substrate, without an adhesion promotion layer and wherein the uncured backfill layer is tacky, to form an article.

2. The method of making the article of claim 1, wherein the refractive index of the uncured backfill layer is less than or equal to 1.55.

3. The method of making the article of claim 1, wherein the uncured backfill layer comprises a polymerizable composition of monomers capable of being cured by actinic radiation.

4. The method of making the article of claim 1, wherein the structured template layer is a permanent crosslinked polymer network.

5. The method of making the article of claim 1, wherein the structured template layer is an extrudable polymer.

6. The method of making the article of claim 1, further comprising exposing the article to blanket actinic radiation to cure the uncured backfill layer, thereby forming a structured, cured backfill layer having a lower refractive index than the structured template layer.

7. The method of making the article of claim 6, further comprising removing the carrier after exposing the article to blanket actinic radiation to cure the uncured backfill layer.