# US 2014/0151935 A1 · Fluid application method for improved roll-to-roll pattern formation

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- Number: US 2014/0151935 A1
- Document ID: US20140151935A1
- Status: Published application
- Kind: A1
- Application number: 14/094,516
- Filed: 2013-12-02
- Published: 2014-06-05
- Earliest claimed: 2012-11-30
- Assignees: MicroContinuum, Inc.
- Applicants: Microcontinuum, Inc.
- Inventors: W. Dennis Slafer
- Web page: https://patentgrep.com/patent/US20140151935A1

## CPC

- B29C 35/0888: {using transparant moulds}
- B29C 35/10: for articles of indefinite length
- B29C 59/046: {for layered or coated substantially flat surfaces}
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

Methods, apparatus and systems are disclosed by which patterned layers can be formed in a roll-to-roll process using a variable and programmable means for applying liquids and solutions used in the patterning process.

## Claims

### Claim 1

A continuous roll-to-roll method for forming a desired pattern on a flexible substrate of desirable length, the method comprising:
a. providing a rotary-shaped template surface comprising a 3D relief in a roll-to-roll embossing process;
b. providing a substrate upon whose surface a pattern complementary that of said relief surface is formed;
c. providing a means for applying a fluid selectively in relationship to the 3D relief pattern of said template;
d. contacting together said substrate and said rotary-shaped template with the intervening selectively applied fluid; and
e. solidifying the relief pattern formed by said fluid,
f. by use of a continuous roll-to-roll process, removing the substrate containing the selective relief pattern from the rotary template surface.

### Claim 2 (depends on 1)

The method of claim 1 in which the fluid is a radiation-curable monomer.

### Claim 3 (depends on 1)

The method of claim 1 in which the fluid is a polymer-softening solvent.

### Claim 4 (depends on 1)

The method of claim 1 in which the fluid is an etchant.

### Claim 5 (depends on 1)

The method of claim 1 in which the fluid applicator is an array of fluid applicators.

### Claim 6 (depends on 1)

The method of claim 1 in which the fluid applicator comprises multiple rows of applicator arrays.

### Claim 7 (depends on 5)

The method of claim 5 in which the fluid applicator comprises an ink jet head array.

### Claim 8 (depends on 6)

The method of claim 6 in which rows of applicator arrays dispense different fluids.

### Claim 9 (depends on 8)

The method of claim 8 in which the fluids differ in physico-chemical properties.

### Claim 10 (depends on 9)

The method of claim 9 in which the differing property is viscosity.

### Claim 11 (depends on 8)

The method of claim 8 in which the fluids are different solvents.

### Claim 12 (depends on 1)

The method of claim 1 in which the dispensers are controlled by computer.

### Claim 13 (depends on 12)

The method of claim 12 in which the fluid is dispensed in a pre-defined pattern.

### Claim 14 (depends on 13)

The method of claim 13 in which the pattern is a specific relationship to the template pattern.

### Claim 15 (depends on 12)

The method of claim 12 in which electronic and/or optical means are used to synchronize the fluid application.

### Claim 16 (depends on 7)

The method of claim 7 in which the ink jet nozzles can dispense variable fluid volumes.

### Claim 17 (depends on 13)

The method of claim 13 in which deposition at template seams or defects is avoided.

### Claim 18 (depends on 1)

The method of claim 1 in which the 3D relief pattern of the rotary template is formed by an opaque metal layer on a transparent cylindrical substrate in the form of a rotary photomask.

### Claim 19 (depends on 18)

The method of claim 18 in which radiation exposure through the rotary photomask is used to solidify the applied fluid.

### Claim 20 (depends on 19)

The method of claim 19 in which the fluid is a radiation-curable monomer.

### Claim 21 (depends on 1)

The method of claim 1 in which the fluid is applied to the substrate.