Method for forming a cast elastomer

A method for directly casting an elastomer film onto a substrate comprising:

• combining a first prepolymer, a first solvent, and a first chain extender to define a first material;
• while advancing a substrate across a surface:
• depositing the first material onto the substrate, the first material flowing laterally across the substrate to form a first layer of substantially uniform thickness over the substrate;
• and
• heating the first layer to:
• induce a first reaction between the first chain extender and the first prepolymer;
• evaporate the first solvent;
• and
• form a cured first layer exhibiting a first relaxation time;
• combining a second prepolymer, a second chain extender, and a second solvent to define a second material;
• and
• while advancing the substrate and the cured first layer across the surface:
• depositing the second material onto the cured first layer opposite the substrate, the second material:
• flowing laterally across the cured first layer to form a second layer of substantially uniform thickness over the cured first layer;
• and
• dissolving a top portion of the cured first layer due to solubility of the cured first layer in the second solvent;
• and
• heating the cured first layer and the second layer to:
• induce a second reaction between the second chain extender and the second prepolymer;
• evaporate the second solvent;
• and
• form a cured second layer, the cured second layer exhibiting a second relaxation time greater than the first relaxation time.

A method for directly casting an elastomer film onto a substrate comprising:

• combining a first prepolymer, a first solvent, and a first chain extender to define a first material;
• while advancing a substrate across a surface:
• depositing the first material onto the substrate, the first material flowing across the substrate to form a first layer over the substrate;
• and
• heating the first layer to form a cured first layer over the substrate exhibiting a first relaxation time;
• combining a second prepolymer, a second chain extender, and a second solvent to define a second material;
• and
• while advancing the substrate and the cured first layer across the surface:
• depositing the second material onto the cured first layer opposite the substrate, the second material flowing across the cured first layer to form a second layer over the cured first layer;
• and
• heating the cured first layer and the second layer to form a cured second layer, the cured second layer exhibiting a second relaxation time greater than the first relaxation time.