Inventors:
Kang Lee - Westminster CA, US
Nanda Nathan - Huntington Beach CA, US
Engin Arik - Thousand Oaks CA, US
Thomas Forrester - Hacienda Heights CA, US
Tomasz Jannson - Torrance CA, US
Edward M. Kaiser - Redondo Beach CA, US
Kevin H. Yu - Temple City CA, US
Assignee:
Asahi Kasei Kabushiki Kaisha - Osaka
International Classification:
B29C 65/02
B29C 65/52
B29C 65/56
B32B 37/10
B32B 37/14
B32B 37/26
B32B 38/06
B32B 38/10
B29C 65/54
B32B 37/02
B32B 37/04
US Classification:
156715, 156289, 1563069, 156714, 156719
Abstract:
A method and system referred to as PALM (Patterning by Adhesive of Large Relief Three-Dimensional Microstructures) with large reliefs exceeding 1 μm and being as large as 100 μm. The microstructures can be either deterministic (such as microprisms), or random (such as diffusers), the first obtained by copying an original supermaster, and latter obtained by copying a laser speckle pattern. The master process entails copying a supermaster into the form of the microstructure constituting a pattern on the patterning cylinder (called a drum), to be then continuously multiplied in the PALM system, in a continuous roll-to-roll web process. The latter method, together with the related system, is the subject of this invention. The rolls continuously repeat the master pattern, copying by adhesive with large viscosity on acrylic (hybrid) as well as by a monolithic process. The monolithic process can be accomplished using temperature and pressure, or by UV-cured polymerization.