Patent Application
20060105148
This invention relates to surfaces with fractal micro-features and more particularly, to patterned material deposition on surface with fractal micro-features.
The use of microstructured surfaces are known to affect the wetting properties of the surface and may be constructed to prevent the wetting of the surface. For example, US20020084290A1 entitled “Method and apparatus for dispensing small volume of liquid, such as with a wetting-resistant nozzle” by Materna, et al published 20020704 describes a wetting-resistant nozzle for accurately and precisely dispensing small volumes of liquids and describes the use of surface roughness to increase the hydrophobic character of the surface. Such microstructures may be formed with a mold. Means for creating such molds are known and described in, for example, US6641767 B2 entitled “Methods for replication, replicated articles, and replication tools” by Zhang et al, issued 20031104. US6641767B2 describes a method of replicating a structured surface that includes providing a tool having a structured surface having a surface morphology of a crystallized vapor deposited material; and replicating the structured surface of the tool to form a replicated article. A replicated article includes at least one replicated surface, wherein the replicated surface includes a replica of a crystallized vapor deposited material. A replication tool includes: a tool body that includes a tooling surface; and a structured surface on the tooling surface, wherein the structured surface includes crystallized vapor deposited material or a replica of crystallized vapor deposited material. US 2004/0026832 A1 by Gier et al published 20040212 describes an embossing method for producing a microstructured surface relief. Such molded or embossed microstructured surfaces typically have fractal or random surface structures having sizes in the nanometer to tens of microns range.
Alternatively, a random roughness microstructurerd surface having similar feature sizes in the nanometer to tens of microns range may be created by abrasive mechanical means such as sandblasting, abrasive water jet, rubbing with sandpaper or abrasive, and the like. It would also be possible to prepare a microstructured rough surface by adding material onto an originally manufactured smooth surface, such as by adhering grains of particulate matter of a suitable size using a suitable adhesive. Such coatings or abrading can be performed using rollers in contact with the surface.
In many continuous manufacturing processes, it is necessary to coat a continuous surface with a material. In many cases, such coatings must be patterned over the surface. Existing techniques for applying such patterned coatings, or patterning previously applied coatings, include ink-jet, ablation, and a variety of coating hoppers. However, such techniques are either expensive, slow, or are not readily employed for patterning continuous substrates.
There is a need therefore for an improved means to pattern a coated surface that reduces the cost of manufacture and improves the speed of manufacture.
In accordance with one embodiment, the invention is directed towards an article comprising:
a) a substrate having first regions having a microstructured surface and second regions not having a microstructured surface, where the first regions and second regions are relatively differentially wettable; and
b) a patterned layer formed on the substrate from a coating that preferentially wets the relatively more wettable regions of the substrate.
In accordance with a further embodiment, the invention is directed towards a method of making a patterned coating, comprising the steps of:
a) providing a substrate having first regions having a microstructured surface and second regions not having a microstructured surface, where the first regions and second regions are relatively differentially wettable; and
b) coating the substrate with a coating material that preferentially wets the relatively more wettable regions of the substrate to form a patterned layer on the substrate.
Articles of the invention comprising a patterned layer on a surface have the advantage that they may be constructed at a high speed and at a low cost.
Referring to
Substrate 10 may comprise rigid or flexible materials, may be transparent or opaque, and may be manufactured using continuous roll or batch processes. Materials such as glasses, plastics, and metals, e.g., may be employed. In a preferred embodiment, substrate 10 comprises a transparent polymeric material. Such plastic substrates may provide high light transmission properties, are inexpensive, and a sheet of polymeric material can be readily formed with microstructures. Suitable polymer materials include polyolefins, polyesters, polyamides, polycarbonates, cellulosic esters, polystyrene, polyvinyl resins, polysulfonamides, polyethers, polyimides, polyvinylidene chloride, polyvinylidene fluoride, polyurethanes, polyphenylenesulfides, polytetrafluoroethylene, polyacetals, polysulfonates, polyester ionomers, and polyolefin ionomers, as well as copolymers and blends thereof. Polyolefins, particularly polypropylene, polyethylene, polymethylpentene, and mixtures thereof may be particularly suitable. Polyolefin copolymers, including copolymers of propylene and ethylene such as hexene, butene and octene can also be used. Polyolefin polymers are suitable because they are low in cost and have good strength and surface properties and have been shown to be soft and scratch resistant. Polycarbonate polymers are also particularly suitable, as they have high light transmission and strength properties. Copolymers and/or mixtures of these polymers can be used. Applicants have constructed substrate surfaces having replicated fractal-like microstructures varying in size from 20 to 100 nm using polycarbonate and polyester substrate materials.
The size, shape, and locations of the microstructured surface areas may be optimized for specific applications. The microstructure features formed in the first regions 20 may be regularly arranged or may be random. For example, the profile of the microstructures can vary to complement a variety of materials so as to maximize the lifetime, clarity, and physical properties of the substrate material as well as the wettability of the regions. The substrate material may be transparent or opaque, rigid or flexible, for example glass, metal, metal foil, or plastic. In many applications, a transparent, flexible material is useful, particularly for display applications.
Referring to
The microstructured surface regions may have self-similar fractal surface structures at a variety of different sizes. Such fractal surfaces are known to affect the wetting properties of the surface and may be constructed to prevent the wetting of the surface of any material molded with microstructures from the patterned roller 80. The microstructured surfaces once formed may be coated with a suitable material to further increase the hydrophobic or lyophobic nature of the surface. Suitable materials may be taken from classes of polymers including fluorocarbons, perfluorocarbons, polysiloxanes and mixtures thereof. For example, TEFLON™ (polytetrafluoroethylene) is a widely-known and available hydrophobic material with low surface energy. Such materials may be added prior to the microstructured patterning step in specific locations or onto specific locations after the patterned roller has formed such microstructures.
Referring to
The coating may then be dried or cured 120, for example by heat with a heated roller 94 (
The pattern-coated substrate of the present invention can be integrated into a flat-panel display by using either the cover or the substrate of the flat-panel display as the substrate surface 10. The flat-panel display may emit light through a transparent cover or through a transparent substrate. For example, patterned conductive coatings obtained in accordance with the invention may provide electrical conductivity within a flat-panel display, such as an OLED display, or within an electrically operated touch screen. Electrical devices or conductors may be applied to the substrate surface 10 in electrical connection to the patterned coating.
Injection roll molding has been shown to more efficiently replicate the desired microstructures compared to embossing and vacuum forming. It is further contemplated that the surface may be cut into the desired size for application to an LCD or OLED flat-panel display, for example. The present invention may be used in conjunction with any flat-panel display, including but not limited to OLED and liquid crystal display devices.
Alternatively means to form a patterned microstructured surface include abrasive mechanical means such as sandblasting, abrasive water jet, rubbing with sandpaper or abrasive, and the like. It is also possible to prepare a rough microstructured patterned surface by adding material onto an originally manufactured smooth surface, such as by adhering grains of particulate matter of a suitable size using a suitable adhesive. Such patterned coatings or abrading can be performed using rollers in contact with the surface.
The entire contents of the patents and other publications referred to in this specification are incorporated herein by reference.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
