Methods for forming microstructures on a substrate using a mold
Assignee3M Innovative Properties Company
InventorsRaymond Chiu, Kenneth Dillon
Life of this patent
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Abstract
In a method of making a microstructured assembly, a substantially uniform coating of a curable material is formed on a substrate with the coating defining a leading edge. The coating is contacted with a mold starting at the leading edge to form in the curable material a plurality of barrier regions connected by intervening land regions. The curable material is cured and the mold is removed. Optionally, the coating includes a binder. Such a coating can optionally be debinded. In addition, the coating can be fired to form ceramic microstructures.
Claims15
A method of making a microstructured assembly, the method comprising:
- forming a substantially uniform coating of a curable material comprising a ceramic material and a fugitive binder on a substrate;
- contacting the coating with a mold that is substantially optically clear to curing radiation, thereby forming in the curable material a plurality of barrier regions connected by intervening land regions such that curable material is between the mold and the substrate;
- radiation curing the curable material at least through the mold;
- removing the mold;
- and
- firing the curable material thereby forming fused microstructures wherein the firing substantially burns out the fugitive binder such that the microstructures are substantially free of carbon residue.
A method of making a microstructured assembly, the method comprising:
- disposing a curable material on a substrate having a first end, wherein the curable material comprises a ceramic material and a fugitive binder;
- contacting the curable material with a mold that is substantially optically clear to curing radiation, starting at the first end and proceeding at a substantially uniform contact speed and applying a substantially uniform contact pressure such that curable material is between the mold and the substrate;
- forming the curable material, using the mold, into a plurality of barrier regions connected by intervening land regions, wherein the land regions have a substantially uniform center thickness;
- radiation curing the curable material at least through the mold;
- removing the mold;
- and
- firing the curable material thereby forming fused microstructures wherein the firing substantially burns out the fugitive binder such that the microstructures are substantially free of carbon residue.
A method of making a microstructured assembly, the method comprising:
- forming a substantially uniform coating of a curable material, the coating defining a leading edge and defining a coating area that is smaller than a surface area of the substrate, wherein the curable material comprises a ceramic material and a fugitive binder;
- contacting the coating with a mold, wherein the mold is substantially optically clear to curing radiation, starting at the leading edge, the mold forming the curable material into a plurality of barrier regions connected by intervening land regions without substantially enlarging the coating area such that curable material is between the mold and the substrate;
- radiation curing the curable material at least through the mold;
- removing the mold;
- and
- firing the curable material thereby forming fused microstructures wherein the firing substantially burns out the fugitive binder such that the microstructures are substantially free of carbon residue.
Dependencies are inferred from the claim text.