Flexible mold comprising cured polymerizable resin composition
Assignee3M Innovative Properties Company
InventorsYorinobu Takamatsu, Akira Yoda
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Abstract
The present invention relates to methods of making a flexible mold from a polymerizable resin composition, the flexible mold, the polymerizable resin composition, as well as methods of using the flexible mold.
Claims21
A method of making a flexible mold comprising providing a polymeric transfer mold having a microstructured surface substantially the same as the eventual barrier ribs;
- providing a polymerizable resin composition in at least recesses of the microstructured surface of the polymeric transfer mold;
- stacking a support comprising a flexible polymeric film onto the polymeric transfer mold;
- curing the polymerizable resin composition;
- and
- removing the cured polymerizable resin composition together with the support from the polymeric transfer mold, thereby forming a flexible mold comprising a support and shape-imparting layer having an inverse pattern of the eventual barrier ribs;
- wherein the polymeric transfer mold is reused at least 5 times.
A flexible mold comprising a shape-imparting layer comprising the reaction product of a polymerizable composition comprising at least one urethane (meth)acrylate oligomer and
- a) at least 20 wt-% of a (meth)acryl monomer having a weight average molecular weight of at least 300 g/mole;
- or
- b) at least one (meth)acryl monomer having a weight average molecular weight of at least 350 g/mole.
A flexible mold comprising a shape-imparting layer comprising the reaction product of a polymerizable composition comprising at least one urethane (meth)acrylate oligomer and at least one (meth)acryl monomer wherein
- a) the urethane (meth)acrylate oligomer has a weight average molecular weight ranging from 1000 g/mole to 3500 g/mole and the (meth)acryl monomer has a solubility parameter of at least 19 [MJ/m3]1/2;
- or
- b) the polymerizable composition comprises at least 60 wt-% of urethane (meth)acrylate oligomer having a weight average molecular weight ranging from 4500 g/mole to 50,000 g/mole and greater than 25 wt-% of (meth)acryl monomer having a solubility parameter of at least 20 [MJ/m3]1/2;
- or
- c) the (meth)acryl monomer comprises at least one (meth)acryl monomer having a solubility parameter of at least 21 [MJ/m3]1/2.
Dependencies are inferred from the claim text.