Roll-to-roll method and system for micro-replication of a pattern of large relief three-dimensional microstructures

An apparatus for replicating three-dimensional microstructures from a master pattern of microstructures onto a continuous rolling substrate band of curable adhesive-coated flexible planar material;

• the apparatus comprising:
• an image drum having said master pattern of microstructures on a peripheral surface;
• a nip roller positioned in proximate parallel relation to said image drum;
• said adhesive-coated material being wrapped partially about said image drum and between said nip roller and said image drum with said adhesive in an uncured liquid state before said nip roller and in a curing and cured state beyond said nip roller;
• a source of ultraviolet radiation positioned for curing said adhesive-coated material beyond said nip roller;
• and
• said uncured wrap of said material about said image drum being along a selected angle of between 5° and 70°, said curing and cured wrap of said material about said image drum being along a selected angle of more than 90°.

A method of replicating three-dimensional microstructures from an image drum having a master pattern of microstructures onto a continuous rolling substrate band of curable adhesive-coated flexible planar material;

• the method comprising the steps of:
• a) positioning a nip roller in proximate parallel relation to said image drum;
• b) rolling said adhesive-coated material between said nip roller and said image drum with said adhesive in an uncured liquid state, said adhesive-coated material being wrapped on said image drum through a selected angle of from 5° to 70° prior to reaching said nip roller;
• c) applying a sufficient amount of liquid adhesive to said material to form a self-metering reservoir of said liquid adhesive between said material and said image drum prior to said nip roller;
• d) wrapping said adhesive-coated material around said image drum through a selected angle exceeding 90° beyond said nip roller;
• and
• e) applying ultraviolet radiation to said adhesive-coated material beyond said nip roller to cure said adhesive.

An apparatus for replicating three-dimensional microstructures from a master pattern of microstructures onto a continuous rolling substrate band of curable adhesive-coated flexible planar material;

• the apparatus comprising:
• an image drum having said master pattern of microstructures on a peripheral surface;
• a nip roller positioned in proximate parallel relation to said image drum;
• said adhesive-coated material being wrapped partially about said image drum and between said nip roller and said image drum with said adhesive in an uncured liquid state before said nip roller and in a curing and cured state beyond said nip roller;
• a sufficient amount of liquid adhesive applied to said material to form a self-metering reservoir of liquid adhesive between said material and said image drum prior to said nip roller;
• a source of ultraviolet radiation positioned for curing said adhesive-coated material beyond said nip roller;
• and
• said uncured wrap of said material about said image drum being along a selected angle of between 5° and 70°, said curing and cured wrap of said material about said image drum being along a selected angle of more than 90°.

A method of replicating a master elliptical diffuser microstructure pattern located on an image drum onto a continuous rolling substrate band of curable-adhesive coated flexible planar material, the method comprising the steps of:

• an image drum having said master pattern of microstructures on a peripheral surface;
• a nip roller positioned in proximate parallel relation to said image drum;
• said adhesive-coated material being wrapped partially about said image drum and between said nip roller and said image drum with said adhesive in an uncured liquid state before said nip roller and in a curing and cured state beyond said nip roller;
• a sufficient amount of liquid adhesive applied to said material to form a self-metering reservoir of liquid adhesive between said material and said image drum prior to said nip roller;
• a source of ultraviolet radiation positioned for curing said adhesive-coated material beyond said nip roller;
• and
• said uncured wrap of said material about said image drum being along a selected angle of between 5° and 70°, said curing and cured wrap of said material about said image drum being along a selected angle of more than 90°.

A roll-to-roll web-based method of replicating a three-dimensional microstructure pattern from an image drum onto a cured adhesive;

• the method comprising the steps of:
• a) positioning a nip roller in proximate parallel relation to said image drum;
• b) forming a looped belt between said nip roller and said image drum, said belt being partially wrapped about said image drum through a selected wrap angle of from 5° to 70° prior to said nip roller;
• c) applying an uncured liquid adhesive between said belt and said image drum in sufficient quantity to form a self-metering reservoir of said liquid adhesive for flowing onto said image drum and said microstructure pattern;
• d) curing said adhesive on said image drum;
• and
• e) releasing said cured adhesive from said image drum, said cured adhesive having a replicated version of said microstructure pattern.