Digital Mold Texturizing Methods, Materials, and Substrates
AssigneeIkonics Corporation
InventorsToshifumi Komatsu, Jeremy Peterson, Alexander Gybin
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Abstract
Methods, materials, and systems for texturizing mold surfaces is disclosed. In one method and system of the invention, a first step involves generating a graphics file of a desired texture pattern. The graphics file is subsequently output to an ink jet printer, which is configured to print using an acid-etch resist ink. The acid-etch resist ink is formulated to provide optimal properties for ink-jet printing, while also providing excellent acid-etch resist and superior handling properties. The acid-etch resist ink is printed onto a sheet of a carrier substrate that allows the acid-etch resist to be transferred to a mold surface, after which the mold surface is etched with a strong acid.
Claims37
A method of creating a texturized surface, the method comprising:
- generating a graphics file;
- sending the graphics file to an ink jet printer;
- printing the graphics file in an acid-etch resist composition onto a substrate material;
- transferring the acid-etch resist composition onto a surface to be texturized;
- and
- etching the surface using an acid.
An ink-jetable acid-etch resist, the ink-jetable acid-etch resist comprising:
- from 10 to 50 percent by weight of a tackifier;
- from 20 to 90 percent by weight of one or more reactive monomers;
- and
- a photoinitiator.
A multi-layer ink receptive substrate, the ink-receptive substrate comprising:
- a micro-porous ink receptive layer;
- a degradable binder layer;
- and
- a carrier layer;
- wherein the degradable binder layer is positioned intermediate the micro-porous ink receptive layer and the insoluble carrier layer.
A multi-layer ink receptive substrate, the ink-receptive substrate comprising:
- an ink receptive layer comprising at least 50 percent by weight of porous alumina;
- a degradable binder layer comprising at least 25 percent by weight polyvinyl alcohol;
- and
- a substantially water-insoluble carrier layer;
- wherein the degradable binder layer is positioned intermediate the micro-porous ink receptive layer and the insoluble carrier layer.
A method of forming an acid-resist pattern, the method comprising:
- providing a multi-layer ink receptive substrate, the ink-receptive substrate comprising a micro-porous ink receptive layer;
- a degradable binder layer;
- and
- a carrier layer, wherein the degradable binder layer is positioned intermediate the micro-porous ink receptive layer and the insoluble carrier layer;
- depositing an acid-resistant ink-jetted UVuv-curable material onto the multi-layer ink receptive substrate;
- at least partially curing the acid-resistant ink-jetted UVuv-curable material;
- and
- transferring the acid-resistant ink-jetted UVuv-cured material to a substrate to be etched.
Dependencies are inferred from the claim text.