Microcontact printing with high relief stamps in a roll-to-roll process

A method comprising:

• tensioning a web material with a tension of at least about 0.1 pounds per lineal inch between a first roller and second roller, wherein the web material moves at a speed of greater than about 10 feet per minute;
• mounting an elastomeric polymeric stamp on a print roller having an air supported sleeve made out of a metal shell floated on an air layer, further wherein the stamp comprises a base surface and an arrangement of pattern elements having a trapezoidal cross-sectional shape and extending outwardly away from the base surface and the print roller, wherein each of the pattern elements comprises a substantially planar stamping surface with a lateral dimension of about 0.25 microns to about 5 microns and a height with respect to the base surface, and wherein an aspect ratio of the height to the lateral dimension is about 1.5 to about 5.0;
• inking the stamping surface with an ink composition comprising an organosulfur compound;
• contacting the stamping surface with a major surface of the web material between the first roller and the second roller for a print time of about 0.1 second to about 30 seconds such that the functional group on the organosulfur compound binds to the major surface of the web material to provide a self-assembled monolayer (SAM) of the organosulfur compound thereon according to the array of pattern elements on the stamping surface;
• and
• removing the stamping surface from the major surface of the web material.

A method comprising:

• unwinding a web material from a support roller, wherein the web material moves at a speed of greater than about 10 feet per minute;
• mounting a poly(dimethylsiloxane) stamp on a print roller having an air supported sleeve made out of a metal shell floated on an air layer, further wherein the stamp comprises a substantially planar base surface and a continuous, regular array of pattern elements having a trapezoidal cross-sectional shape and extending outwardly away from the base surface and the print roller, wherein the pattern elements each have a substantially planar stamping surface with a lateral dimension of about 0.25 microns to about 5 microns and a height with respect to the base surface, and wherein an aspect ratio of the height to the lateral dimension is about 1.5 to about 5.0;
• inking the stamping surface with an ink composition comprising an organosulfur compound and an organic solvent;
• contacting the stamping surface with a major surface of the web material for a print time of about 0.1 second to about 30 seconds such that a thiol functional group on the organosulfur compound binds to the major surface of the web material to provide a self-assembled monolayer (SAM) of the organosulfur compound thereon according to the array of pattern elements on the stamping surface, wherein the SAM comprises a reduced incidence of at least one of:
• (1) repeating defects;
• and (2) air entrainment defects, compared to a SAM produced by a poly(dimethylsiloxane) stamp comprising pattern elements having a trapezoidal cross-sectional shape and an aspect ratio of less than about 1.5;
• and
• removing the stamping surface from the major surface of the web material.

A system, comprising:

• a first roller and a second roller, and a moving web of material tensioned between the first roller and the second roller;
• an elastomeric stamp mounted on a print roller having an air supported sleeve made out of a metal shell floated on an air layer, and contacting the web material between the first roller and the second roller, wherein the stamp comprises a base surface and an arrangement of pattern elements having a trapezoidal cross-sectional shape and extending outwardly away from the base surface and the print roller, wherein the pattern elements each comprise a substantially planar stamping surface with a lateral dimension of about 0.25 microns to about 5 microns and a height with respect to the base surface, and wherein an aspect ratio of the height to the lateral dimension is about 1.5 to about 5.0;
• and
• an apparatus for inking the stamping surface with an organosulfur compound having a thiol functional group selected to bind to a major surface of the web material to form a self-assembled monolayer (SAM) thereon according to the array of pattern elements on the stamping surface.