US20080131667A1 - Microreplicated article - Google Patents
Microreplicated article Download PDFInfo
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- US20080131667A1 US20080131667A1 US11/870,195 US87019507A US2008131667A1 US 20080131667 A1 US20080131667 A1 US 20080131667A1 US 87019507 A US87019507 A US 87019507A US 2008131667 A1 US2008131667 A1 US 2008131667A1
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- pattern
- web
- article
- patterned
- microreplicated
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/40—Distributing applied liquids or other fluent materials by members moving relatively to surface
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B3/00—Simple or compound lenses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
- B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00278—Lenticular sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2252/00—Sheets
- B05D2252/10—Applying the material on both sides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
- B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
- B05D3/065—After-treatment
- B05D3/067—Curing or cross-linking the coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
- B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
- B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/04—Prisms
- G02B5/045—Prism arrays
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
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- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Ophthalmology & Optometry (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Wood Science & Technology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Optics & Photonics (AREA)
- General Physics & Mathematics (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Eyeglasses (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
A microreplicated article is disclosed. The article includes a web including first and second opposed surfaces. The first surface includes a first microreplicated structure having a plurality of first features. The second surface includes a second microreplicated structure having a plurality of second features. Corresponding opposed features cooperate to form a lens features.
Description
- This application is a continuation of U.S. application Ser. No. 11/747,462, filed May 11, 2007, which is a continuation of U.S. application Ser. No. 10/658,730, filed Sep. 9, 2003, now U.S. Pat. No. 7,224,529, the disclosures of which are incorporated by reference in their entirety herein.
- The disclosure relates generally to the continuous casting of material onto a web, and more specifically to the casting of articles having a high degree of registration between the patterns cast on opposite sides of the web.
- In the fabrication of many articles, from the printing of newspapers to the fabrication of sophisticated electronic and optical devices, it is necessary to apply some material that is at least temporarily in liquid form to opposite sides of a substrate. It is often the case that the material applied to the substrate is applied in a predetermined pattern; in the case of e.g. printing, ink is applied in the pattern of letters and pictures. It is common in such cases for there to be at least a minimum requirement for registration between the patterns on opposite sides of the substrate.
- When the substrate is a discrete article such as a circuit board, the applicators of a pattern may usually rely on an edge to assist in achieving registration. But when the substrate is a web and it is not possible to rely on an edge of the substrate to periodically refer to in maintaining registration, the problem becomes a bit more difficult. Still, even in the case of webs, when the requirement for registration is not severe, e.g. a drift out of perfect registration of greater than 100 microns is tolerable, mechanical expedients are known for controlling the material application to that extent. The printing art is replete with devices capable of meeting such a standard.
- However, in some products having patterns on opposite sides of a substrate, a much more accurate registration between the patterns is required. In such a case, if the web is not in continuous motion, apparatuses are known that can apply material to such a standard. And if the web is in continuous motion, if it is tolerable, as in e.g. some types of flexible circuitry, to reset the patterning rolls to within 100 microns, or even 5 microns, of perfect registration once per revolution of the patterning rolls, the art still gives guidelines about how to proceed.
- However, in e.g. optical articles such as brightness enhancement films, it is required for the patterns in the optically transparent polymer applied to opposite sides of a substrate to be out of registration by no more than a very small tolerance at any point in the tool rotation. Thus far, the art is silent about how to cast a patterned surface on opposite sides of a web that is in continuous motion so that the patterns are kept continuously, rather than intermittently, in registration within 100 microns.
- An aspect of the present disclosure is directed to a microreplicated article. The microreplicated article includes a flexible substrate having first and second opposed surfaces; a first coated microreplicated pattern on the first surface; and a second coated microreplicated pattern on the second surface. The first and second patterns are registered to within 70 microns and the first microreplicated pattern includes features having a first shape and the second microreplicated pattern includes features having a second shape. Each feature of the first pattern cooperates with a corresponding feature of the second pattern to form a lenticular lens.
- In the context of this disclosure, “registration,” means the positioning of structures in a set location in relation to the edge of a web and to other structures on the opposite side of the same web.
- In the context of this disclosure, “web” means a sheet of material having a fixed dimension in one direction and either a predetermined or indeterminate length in the orthogonal direction.
- In the context of this disclosure, “continuous registration,” means that at all times during rotation of first and second patterned rolls the degree of registration between structures on the rolls is better than a specified limit.
- In the context of this disclosure, “microreplicated” or “microreplication” means the production of a microstructured surface through a process where the structured surface features retain an individual feature fidelity during manufacture, from product-to-product, that varies no more than about 100 micrometers.
- In the several figures of the attached drawing, like parts bear like reference numerals, and:
-
FIG. 1 illustrates a perspective view of an example embodiment of a system including a system according to the present disclosure; -
FIG. 2 illustrates a close-up view of a portion of the system ofFIG. 1 according to the present disclosure; -
FIG. 3 illustrates another perspective view of the system ofFIG. 1 according to the present disclosure; -
FIG. 4 illustrates a schematic view of a an example embodiment of a casting apparatus according to the present disclosure; -
FIG. 5 illustrates a close-up view of a section of the casting apparatus ofFIG. 4 according to the present disclosure; -
FIG. 6 illustrates a schematic view of an example embodiment of a roll mounting arrangement according to the present disclosure; -
FIG. 7 illustrates a schematic view of an example embodiment of a mounting arrangement for a pair of patterned rolls according to the present disclosure; -
FIG. 8 illustrates a schematic view of an example embodiment of a motor and roll arrangement according to the present disclosure; -
FIG. 9 illustrates a schematic view of an example embodiment of a means for controlling the registration between rolls according to the present disclosure; -
FIG. 10 illustrates a schematic view of an example embodiment of a roll controlling arrangement according to the present disclosure; -
FIG. 11 illustrates a block diagram of an example embodiment of a method and apparatus for controlling registration according to the present disclosure; -
FIG. 12 illustrates a cross-sectional view of an article made according to the present disclosure. - Generally, the invention of the present disclosure is directed to a flexible substrate coated with microreplicated patterned structures on each side. The microreplicated articles are registered with respect to one another to a high degree of precision. Preferably, the structures on opposing sides cooperate to give the article optical qualities as desired, and more preferably, the structures are a plurality of lens features.
- Referring to
FIG. 12 , illustrated is an example embodiment of a two-sidedmicroreplicated article 1200. Thearticle 1200 includes aweb 1210 substrate having opposed first andsecond surfaces second surfaces microreplicated structures structure 1225 includes a plurality ofarcuate features 1226, which in the embodiment shown are cylindrical lenses with an effective diameter of about 142 microns. Secondmicroreplicated structure 1235 includes a plurality of saw-tooth or pyramidalprismatic features 1236. - In the example embodiment shown, first and
second features - In the example embodiment shown, opposed
microreplicated features lens features 1240. In the example embodiment shown, thelens features 1240 are lenticular lenses. Since the performance of eachlens feature 1240 is a function of the alignment of theopposed features - Optionally, the
article 1200 also includes first andsecond land areas substrate surfaces valleys first land area 1228 is at least about 10 microns on the lens side and thesecond land area 1238 is about at least about 25 microns on the prism side. The land area assists in the features having good adherence to the web and also aid in replication fidelity. - The
article 1200 described above was made using an apparatus and method for producing precisely aligned microreplicated structures on opposed surfaces of the web, the apparatus and methods which are described in detail below. The embodiment produced by Applicants was made using the using a web made from polyethylene terephthalate (PET), 0.0049 inches thick. Other web materials can be used, for example, polycarbonate. - The first microreplicated structure was made on a first patterned roll by casting and curing a curable liquid onto the first side of the web. The first curable liquid was a light sensitive acrylate resin solution including photomer 6010, available from Cognis Corp., Cincinnati, Ohio; SR385 tetrahydrofurfuryl acrylate and SR238 (70/15/15%) 1,6-hexanediol diacrylate, both available from Satomer Co., Expon, Pa.; Camphorquinone, available from Hanford Research Inc., Stratford, Conn.; and Ethyl-4-dimethylamino Benzoate (0.75/0.5%), available from Aldrich Chemical Co., Milwaukee, Wis. The second microreplicated structure was made on a second patterned roll by casting and curing a curable liquid onto the second side of the web. The second curable liquid used was the same as the first curable liquid.
- After each respective structure was cast into a pattern, each respective pattern was externally cured using a curing light source including an ultraviolet light source. A peel roll was then used to remove the microreplicated article from the second patterned roll. Optionally, a release agent or coating can be used to assist removal of the patterned structures from the patterned tools.
- The process settings used to create the article described above are as follows. A web speed of about 1.0 feet per minute with a web tension into and out of casting apparatus of about 2.0 pounds force were used. A peel roll draw ratio of about 5% was used to pull the web off the second patterned tool. A nip pressure of about 4.0 pounds force was used. The gap between the first and second patterned rolls was about 0.010 inches. Resin was supplied to the first surface of the web using a dropper coating apparatus and resin was supplied to the second surface at a rate of about 1.35 ml/min, using a syringe pump.
- Curing the first microreplicated structure was accomplished with an Oriel 200-500 W Mercury Arc Lamp at maximum power and a Fostec DCR II at maximum power, with all the components mounted sequentially. Curing the second microreplicated structure was accomplished with a Spectral Energy UV Light Source, a Fostec DCR II at maximum power, and an RSLI Inc. Light Pump 150 MHS, with all the components mounted sequentially.
- The first patterned roll included a series of negative images for forming cylindrical lenses with a 142 micron diameter at 150 micron pitch. The second patterned roll included a series of negative images for forming a plurality of symmetric prisms with 60 degree included angle at 150 micron pitch.
- Generally, the invention of the present disclosure can be made by a system and method, disclosed hereinafter, for producing two-sided microreplicated structures with side-to-side registration of better than about 100 microns, and preferably better than 50 microns, and more preferably less than 25 microns, and most preferably less than 5 microns. The system generally includes a first patterning assembly and a second patterning assembly. Each respective assembly creates a microreplicated pattern on a respective surface of a web having a first and a second surface. A first pattern is created on the first side of the web and a second pattern is created on the second surface of the web.
- Each patterning assembly includes means for applying a coating, a patterning member, and a curing member. Typically, patterning assemblies include patterned rolls and a support structure for holding and driving each roll. Coating means of the first patterning assembly dispenses a first curable coating material on a first surface of the web. Coating means of the second patterning assembly dispenses a second curable coating material on a second surface of the web, wherein the second surface is opposite the first surface. Typically, first and second coating materials are of the same composition.
- After the first coating material is placed on the web, the web passes over a first patterned member, wherein a pattern is created in the first coating material. The first coating material is then cured or cooled to form the first pattern. Subsequently, after the second coating material is placed on the web, the web passes over a second patterned member, wherein a pattern is created in the second coating material. The second coating material is then cured to form the second pattern. Typically, each patterned member is a microreplicated tool and each tool typically has a dedicated curing member for curing the material. However, it is possible to have a single curing member that cures both first and second patterned materials. Also, it is possible to place the coatings on the patterned tools.
- The system also includes means for rotating the first and second patterned rolls such that their patterns are transferred to opposite sides of the web while it is in continuous motion, and said patterns are maintained in continuous registration on said opposite sides of the web to better than about 100 microns.
- An advantage of the present invention is that a web having a microreplicated structure on each opposing surface of the web can be manufactured by having the microreplicated structure on each side of the web continuously formed while keeping the microreplicated structures on the opposing sides registered generally to within 100 microns of each other, and typically within 50 microns, and more typically within 20 microns, and most typically within 5 microns.
- Referring now to
FIGS. 1-2 , an example embodiment of asystem 110 includingcasting apparatus 120 according to the present disclosure is illustrated. In the depictedcasting apparatus 120, aweb 122 is provided to thecasting apparatus 120 from a main unwind spool (not shown). The exact nature ofweb 122 can vary widely, depending on the product being produced. However, when thecasting apparatus 120 is used for the fabrication of optical articles it is usually convenient for theweb 122 to be translucent or transparent, to allow curing through theweb 122. Theweb 122 is directed aroundvarious rollers 126 into thecasting apparatus 120. - Accurate tension control of the
web 122 is required to achieve the best results the invention is capable of, so theweb 122 is directed over a tension-sensing device (not shown). In situations where it is desirable to use a liner web to protect theweb 122, the liner web is typically separated at the unwind spool and directed onto a liner web wind-up spool (not shown). Theweb 122 is typically directed via an idler roll to a dancer roller for precision tension control. Idler rollers direct theweb 122 to a position between niproller 154 andfirst coating head 156. - In the depicted embodiment,
first coating head 156 is a die coating head. However, other coating methods can be adapted to the apparatus, as one of ordinary skill in the art will appreciate. Theweb 122 then passes between thenip roll 154 and firstpatterned roll 160. The firstpatterned roll 160 has a patternedsurface 162, and when theweb 122 passes between thenip roller 154 and the firstpatterned roll 160 the material dispensed onto theweb 122 by thefirst coating head 156 is shaped into a negative ofpatterned surface 162. - While the
web 122 is in contact with the firstpatterned roll 160, material is dispensed fromsecond coating head 164 onto the other surface ofweb 122. In parallel with the discussion above with respect to thefirst coating head 156, thesecond coating head 164 is also a die coating arrangement including a second extruder (not shown) and a second coating die (not shown). In some embodiments, the material dispensed by thefirst coating head 156 is a composition including a polymer precursor and intended to be cured to solid polymer with the application of ultraviolet radiation. - Material that has been dispensed onto
web 122 by thesecond coating head 164 is then brought into contact with secondpatterned roll 174 with a secondpatterned surface 176. In parallel with the discussion above, in some embodiments, the material dispensed by thesecond coating head 164 is a composition including a polymer precursor and intended to be cured to solid polymer with the application of ultraviolet radiation. - At this point, the
web 122 has had a pattern applied to both sides. Apeel roll 182 may be present to assist in removal of theweb 122 from secondpatterned roll 174. Typically, web tension into and out of the casting apparatus is nearly constant. - The
web 122 having a two-sided microreplicated pattern is then directed to a wind-up spool (not shown) via various idler rolls. If an interleave film is desired to protectweb 122, it is typically provided from a secondary unwind spool (not shown) and the web and interleave film are wound together on the wind-up spool at an appropriate tension. - Referring to
FIGS. 1-3 , first and second patterned rolls are coupled to first andsecond motor assemblies motor assemblies frame 230, either directly or indirectly. Themotor assemblies first motor assembly 210 is fixedly mounted toframe 230.Second motor assembly 220, which is placed into position whenweb 122 is threaded through thecasting apparatus 120, needs to be positioned repeatedly and is therefore movable, both in the cross- and machine direction.Movable motor arrangement 220 is preferably coupled tolinear slides 222 to assist in repeated accurate positioning, for example, when switching between patterns on the rolls.Second motor arrangement 220 also includes asecond mounting arrangement 225 on the backside of theframe 230 for positioning the secondpatterned roll 174 side-to-side relative to the firstpatterned roll 160. Second mountingarrangement 225 preferably includeslinear slides 223 allowing accurate positioning in the cross machine directions. - Referring to
FIG. 6 , a motor mounting arrangement is illustrated. Amotor 633 for driving a tool or patternedroll 662 is mounted to themachine frame 650 and connected through acoupling 640 to arotating shaft 601 of the patternedroller 662. Themotor 633 is coupled to aprimary encoder 630. Asecondary encoder 651 is coupled to the tool to provide precise angular registration control of the patternedroll 662. Primary 630 and secondary 651 encoders cooperate to provide control of the patternedroll 662 to keep it in registration with a second patterned roll, as will be described further hereinafter. - In the example embodiment shown, the
tool roller 662 diameter is typically smaller than itsmotor 633 diameter. To accommodate this arrangement, the twotool roller assemblies tool rollers FIG. 7 . Referring also toFIG. 1 , the first motor arrangement is typically fixedly attached to the frame and the second motor arrangement is positioned using movable optical quality linear slides. - Reduction or elimination of shaft resonance is important as this is a source of registration error allowing pattern position control within the specified limits. Using a
coupling 640 between themotor 633 andshaft 650 that is larger than general sizing schedules specify will also reduce shaft resonance caused by more flexible couplings.Bearing assemblies 660 are located in various locations to provide rotational support for the motor arrangement. - Referring to
FIG. 4 , an example embodiment of acasting apparatus 420 for producing a two-sided web 422 with registered microreplicated structures on opposing surfaces is illustrated. Assembly includes first and second coating means 456, 464, anip roller 454, and first and secondpatterned rolls Web 422 is presented to the first coating means 456, in this example a first extrusion die 456. First die 456 dispenses a first curableliquid layer coating 470 onto theweb 422.First coating 470 is pressed into the firstpatterned roller 460 by means of anip roller 454, typically a rubber covered roller. While on the firstpatterned roll 460, the coating is cured using anexternal curing source 480, for example, a lamp, of suitable wavelength light, typically an ultraviolet light. - A second
curable liquid layer 481 is coated on the opposite side of theweb 422 using a second side extrusion die 464. Thesecond layer 481 is pressed into the secondpatterned tool roller 474 and the curing process repeated for thesecond coating layer 481. Registration of the two coating patterns is achieved by maintaining thetool rollers - Referring to
FIG. 5 , a close-up view of a portion of first and secondpatterned rolls roll 560 has afirst pattern 562 for forming a microreplicated surface.Second pattern roll 574 has a secondmicroreplicated pattern 576. - In the example embodiment shown, first and
second patterns web 522 passes over thefirst roll 560, a first curable liquid (not shown) on afirst surface 524 is cured by a curinglight source 525 near afirst region 526 on the firstpatterned roll 560. A first microreplicatedpatterned structure 590 is formed on thefirst side 524 of theweb 522 after the liquid is cured. The firstpatterned structure 590 is a negative of thepattern 562 on the firstpatterned roll 560. After the firstpatterned structure 590 is formed, a secondcurable liquid 581 is dispensed onto asecond surface 527 of theweb 522. To insure that thesecond liquid 581 is not cured prematurely, thesecond liquid 581 is isolated from thefirst curing light 525, typically by a locating thefirst curing light 525 so that it does not fall on thesecond liquid 581. Alternatively, shielding means 592 can be placed between thefirst curing light 525 and thesecond liquid 581. Also, the curing sources can be located inside their respective patterned rolls where it is impractical or difficult to cure through the web. - After the first
patterned structure 590 is formed, theweb 522 continues along thefirst roll 560 until it enters thegap region 575 between the first and secondpatterned rolls second liquid 581 then engages thesecond pattern 576 on the second patterned roll and is shaped into a second microreplicated structure, which is then cured by asecond curing light 535. As theweb 522 passes into thegap 575 between first and secondpatterned rolls web 522, restrains theweb 522 from slipping while theweb 522 begins moving into thegap 575 and around the secondpatterned roller 574. This removes web stretching and slippages as a source of registration error between the first and second patterned structures formed on the web. - By supporting the
web 522 on the firstpatterned roll 560 while thesecond liquid 581 comes into contact with the secondpatterned roll 574, the degree of registration between the first and secondmicroreplicated structures opposite sides web 522 becomes a function of controlling the positional relationship between the surfaces of the first and secondpatterned rolls patterned rolls gap 575 formed by the rolls minimizes effects of tension, web strain changes, temperature, microslip caused by mechanics of nipping a web, and lateral position control. Typically, the S-wrap maintains theweb 522 in contact with each roll over a wrap angle of 180 degrees, though the wrap angle can be more or less depending on the particular requirements. - To increase the degree of registration between the patterns formed on opposite surfaces of a web, it preferred to have a low-frequency pitch variation around the mean diameter of each roll. Typically, the patterned rolls are of the same mean diameter, though this is not required. It is within the skill and knowledge of one having ordinary skill in the art to select the proper roll for any particular application.
- Because the features sizes on the microreplicated structures on both surfaces of a web are desired to be within fine registration of one another, the patterned rolls need to be controlled with a high degree of precision. Cross-web registration within the limits described herein can be accomplished by applying the techniques used in controlling machine-direction registration, as described hereinafter. Control of registration in the machine direction is required, which heretofore has not been achieved in two-sided microreplicated webs. For example, to achieve about 10 microns end-to-end feature placement on a 10-inch circumference patterned roller, each roller must be maintained within a rotational accuracy of ±32 arc-seconds per revolution. Control of registration becomes more difficult as the speed the web travels through the system is increased.
- Applicants have built and demonstrated a system having 10-inch circular patterned rolls that can create a web having patterned features on opposite surfaces of the web that are registered to within 2.5 microns. Upon reading this disclosure and applying the principles taught herein, one of ordinary skill in the art will appreciate how to accomplish the degree of registration for other microreplicated surfaces.
- Referring to
FIG. 8 , a schematic of amotor arrangement 800 used in Applicants' system is illustrated. Motor arrangement includes amotor 810 including aprimary encoder 830 and adrive shaft 820. Driveshaft 820 is coupled to a drivenshaft 840 of patternedroll 860 through acoupling 825. A secondary, or load,encoder 850 is coupled to the drivenshaft 840. Using two encoders in the motor arrangement described allows the position of the patterned roll to be measured more accurately by locating the measuring device (encoder) 850 near the patternedroll 860, thus reducing or eliminating effects of torque disturbances when themotor arrangement 800 is operating. - Referring to
FIG. 9 , a schematic of the motor arrangement ofFIG. 8 , is illustrated as attached to control components. In the example apparatus shown inFIGS. 1-3 , a similar setup would control eachmotor arrangement -
Motor arrangement 900 communicates with acontrol arrangement 965 to allow precision control of the patternedroll 960.Control arrangement 965 includes adrive module 966 and aprogram module 975. Theprogram module 975 communicates with thedrive module 966 via aline 977, for example, a SERCOS fiber network. Theprogram module 975 is used to input parameters, such as set points, to thedrive module 966.Drive module 966 receivesinput 480 volt, 3-phase power 915, rectifies it to DC, and distributes it via apower connection 973 to control themotor 910.Motor encoder 912 feeds a position signal to controlmodule 966. Thesecondary encoder 950 on the patternedroll 960 also feeds a position signal back to thedrive module 966 via toline 971. Thedrive module 966 uses the encoder signals to precisely position the patternedroll 960. The control design to achieve the degree of registration is described in detail below. - In the example embodiments shown, each patterned roll is controlled by a dedicated control arrangement. Dedicated control arrangements cooperate to control the registration between first and second patterned rolls. Each drive module communicates with and controls its respective motor assembly.
- Various options are available for co-coordinating the two axes such as master/slave-type and parallel configurations, which was used in Applicants' system.
- The control arrangement in the system built and demonstrated by Applicants include the following. To drive each of the patterned rolls, a high performance, low cogging torque motor with a high-resolution sine encoder feedback (512 sine cycles×4096 drive interpolation>>2 million parts per revolution) was used, model MHD090B-035-NG0-UN, available from Bosch-Rexroth (Indramat). Also the system included synchronous motors, model MHD090B-035-NG0-UN, available from Bosch-Rexroth (Indramat), but other types, such as induction motors could also be used. Each motor was directly coupled (without gearbox or mechanical reduction) through an extremely stiff bellows coupling, model BK5-300, available from R/W Corporation. Alternate coupling designs could be used, but bellows style generally combines stiffness while providing high rotational accuracy. Each coupling was sized so that a substantially larger coupling was selected than what the typical manufacturers specifications would recommend. Additionally, zero backlash collets or compressive style locking hubs between coupling and shafts are preferred. Each roller shaft was attached to an encoder through a hollow shaft load side encoder, model RON255C, available from Heidenhain Corp., Schaumburg, Ill. Encoder selection should have the highest accuracy and resolution possible, typically greater than 32 arc-sec accuracy. Applicants' design, 18000 sine cycles per revolution were employed, which in conjunction with the 4096 bit resolution drive interpolation resulted in excess of 50 million parts per revolution resolution giving a resolution substantially higher than accuracy. The load side encoder had an accuracy of +/−2 arc-sec; maximum deviation in the delivered units was less than +/−1 arc-sec.
- Preferably, each shaft is designed to be as large a diameter as possible and as short as possible to maximize stiffness, resulting in the highest possible resonant frequency. Precision alignment of all rotational components is desired to ensure minimum registration error due to this source of registration error. One of ordinary skill in the art will recognize that there are various ways to reduce registration error due to alignment of the rotational components.
- The control strategy for each axis is implemented as follows:
- Referring to
FIG. 11 , in Applicants' system identical position reference commands were presented to each axis simultaneously through a SERCOS fiber network at a 2 ms update rate. Each axis interpolates the position reference with a cubic spline, at the position loop update rate of 250 microsecond intervals. The interpolation method is not critical, as the constant velocity results in a simple constant times time interval path. The resolution is critical to eliminate any round off or numerical representation errors. Axis rollover must also be addressed. It is critical that each axis' control cycle is synchronized at the current loop execution rate (62 microsecond intervals). - The
top path 1151 is the feed forward section of control. The control strategy includes aposition loop 1110, avelocity loop 1120, and acurrent loop 1130. Theposition reference 1111 is differentiated, once to generate the velocity feed forward terms 1152 and a second time to generate the acceleration feedforward term 1155. Thefeed forward path 1151 helps performance during line speed changes and dynamic correction. - The
position command 1111 is subtracted fromcurrent position 1114, generating anerror signal 1116. Theerror 1116 is applied to aproportional controller 1115, generating thevelocity command reference 1117. Thevelocity feedback 1167 is subtracted from thecommand 1117 to generate thevelocity error signal 1123, which is then applied to a PID controller. Thevelocity feedback 1167 is generated by differentiating the motorencoder position signal 1126. Due to differentiation and numerical resolution limits, a lowpass Butterworth filter 1124 is applied to remove high frequency noise components from theerror signal 1123. A narrow stop band (notch)filter 1129 is applied at the center of the motor roller resonant frequency. This allows substantially higher gains to be applied to thevelocity controller 1120. Increased resolution of the motor encoder also would improve performance. The exact location of the filters in the control diagram is not critical; either the forward or reverse path are acceptable, although tuning parameters are dependent on the location. - A PID controller could also be used in the position loop, but the additional phase lag of the integrator makes stabilization more difficult. The current loop is a traditional PI controller; gains are established by the motor parameters. The highest bandwidth current loop possible will allow optimum performance. Also, minimum torque ripple is desired.
- Minimization of external disturbances is important to obtaining maximum registration. This includes motor construction and current loop commutation as previously discussed, but minimizing mechanical disturbances is also important. Examples include extremely smooth tension control in entering and exiting web span, uniform bearing and seal drag, minimizing tension upsets from web peel off from the roller, uniform rubber nip roller. In the current design, a third axis geared to the tool rolls is provided as a pull roll to assist in removing the cured structure from the tool.
- The web material can be any suitable material on which a microreplicated patterned structure can be created. Examples of web materials are polyethylene terephthalate, polymethyl methacrylate, or polycarbonate. The web can also be multi-layered. Since the liquid is typically cured by a curing source on the side opposite that on which the patterned structure is created, the web material must be at least partially translucent to the curing source used. Examples of curing energy sources are infrared radiation, ultraviolet radiation, visible light radiation, microwave, or e-beam. One of ordinary skill in the art will appreciate that other curing sources can be used, and selection of a particular web material/curing source combination will depend on the particular article (having microreplicated structures in registration) to be created.
- An alternative to curing the liquid through the web would be to use a two part reactive cure, for example, an epoxy, which would be useful for webs that are difficult to cure through, such as metal web or webs having a metallic layer. Curing could be accomplished by in-line mixing of components or spraying catalyst on a portion of the patterned roll, which would cure the liquid to form the microreplicated structure when the coating and catalyst come into contact.
- The liquid from which the microreplicated structures are created is typically a curable photopolymerizable material, such as acrylates curable by UV light. One of ordinary skill in the art will appreciate that other coating materials can be used, and selection of a material will depend on the particular characteristics desired for the microreplicated structures. Similarly, the particular curing method employed is within the skill and knowledge of one of ordinary skill in the art. Examples of curing methods are reactive curing, thermal curing, or radiation curing.
- Examples of coating means that useful for delivering and controlling liquid to the web are, for example, die or knife coating, coupled with any suitable pump such as a syringe or peristaltic pump. One of ordinary skill in the art will appreciate that other coating means can be used, and selection of a particular means will depend on the particular characteristics of the liquid to be delivered to the web.
- Various modifications and alterations of the present invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not limited to the illustrative embodiments set forth herein.
Claims (25)
1. An article, comprising:
a flexible substrate having first and second opposed surfaces;
a first cured liquid pattern disposed on the first surface; and
a second cured liquid pattern disposed on the second surface, wherein the first and second cured liquid patterns are registered to within 100 microns.
2. The article of claim 1 , wherein at least one of the first and second cured liquid patterns is a radiation cured liquid pattern.
3. An article, comprising:
a flexible substrate having first and second opposed surfaces;
a first pattern disposed on the first surface and forming a first land area between the first pattern and the first surface; and
a second pattern disposed on the second surface and forming a second land area between the second pattern and the second surface, wherein the first and second patterns are registered to within 100 microns.
4. The article of claim 3 , wherein the substrate is multi-layered.
5. The article of claim 3 , wherein the first pattern is microreplicated from a first structured tool and the second pattern is microreplicated from a second structured tool.
6. The article of claim 3 , wherein the first pattern comprises a plurality of cylindrical lenses.
7. The article of claim 3 , wherein the second pattern comprises a plurality of prismatic features.
8. The article of claim 3 , wherein the first pattern has a first pitch and the second pattern has a second pitch.
9. The article of claim 8 , wherein the first pitch is the same as the second pitch.
10. An article comprising:
a flexible substrate having first and second opposed surfaces;
a first pattern disposed on the first surface and comprising a plurality of cylindrical lenses; and
a second pattern disposed on the second surface and forming a first land area between the second pattern and the second surface, wherein the first and second patterns are registered to within 100 microns.
11. The article of claim 10 further comprising a second land area between the first pattern and the first surface.
12. An article comprising:
a flexible substrate having first and second opposed surfaces;
a first pattern disposed on the first surface and comprising a plurality of cylindrical lenses; and
a second pattern disposed on the second surface and comprising a plurality of prismatic features, wherein the first and second patterns are registered to within 100 microns.
13. The article of claim 12 further comprising a first land area between the second pattern and the second surface.
14. A system, comprising:
a first patterned tool comprising a first pattern;
a second patterned tool comprising a second pattern;
a flexible substrate disposed between the first and second patterned tools;
a third pattern disposed on the first surface, the third pattern being a replica of the first pattern; and
a fourth pattern disposed on the second surface, the fourth pattern being a replica of the second pattern, wherein the third and fourth patterns are registered to within 100 microns.
15. The system of claim 14 , wherein the first and second patterns are not the same.
16. The system of claim 14 , wherein the third pattern comprises a cured liquid.
17. The system of claim 14 , wherein the fourth pattern comprises a cured liquid.
18. The system of claim 14 , wherein the third pattern comprises a liquid and the fourth pattern comprises a cured liquid.
19. The system of claim 14 , wherein the third pattern comprises a plurality of cylindrical lenses.
20. The system of claim 14 , wherein the fourth pattern comprises a plurality of prismatic features.
21. The system of claim 14 , wherein the third pattern is a negative of the first pattern.
22. The system of claim 14 , wherein the fourth pattern is a negative of the second pattern.
23. A method of making an article, comprising the steps of:
forming a first pattern on a first major surface of a moving substrate;
forming a second pattern on a second major surface of the moving substrate, wherein the first and second patterns are registered to within about 100 microns.
24. The method of claim 23 , wherein the first major surface forms an interface between the first pattern and the moving substrate.
25. The method of claim 23 , wherein the second major surface forms an interface between the second pattern and the moving substrate.
Priority Applications (1)
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US11/870,195 US20080131667A1 (en) | 2003-09-09 | 2007-10-10 | Microreplicated article |
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Also Published As
Publication number | Publication date |
---|---|
US20070211347A1 (en) | 2007-09-13 |
WO2005025845A1 (en) | 2005-03-24 |
BRPI0414184A (en) | 2006-10-31 |
JP2007504974A (en) | 2007-03-08 |
US7417798B2 (en) | 2008-08-26 |
US20050052750A1 (en) | 2005-03-10 |
MXPA06002718A (en) | 2006-06-05 |
CN1863669A (en) | 2006-11-15 |
US7224529B2 (en) | 2007-05-29 |
BRPI0414184B1 (en) | 2015-06-09 |
EP1663626A1 (en) | 2006-06-07 |
CN100519157C (en) | 2009-07-29 |
KR20060116803A (en) | 2006-11-15 |
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