Method and apparatus for seamless microreplication using an expandable mold
Assignee3M Innovative Properties Company
InventorsDavid J. Lundin, Kevin M. Eliason
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Abstract
An apparatus and method for seamless closed mold microreplication using a one-piece expandable mold are disclosed. The apparatus includes an expandable mold having a plurality of microstructured features on the inner surface thereof. The apparatus also includes a means for elastically expanding the mold in order to remove the finished molded article. The expandable mold may be used to make seamless articles having microstructured features, such as an illumination device comprising a fiber core having a plurality of microstructured light extraction structures on the surface thereof.
Claims10
A method for microreplication using a one-piece mold comprising the steps of:
- providing an expandable, hollow, one-piece mold having an interior with an interior surface including a plurality of microstructured features thereon, the interior being accessible through an opening in the mold;
- filling the interior of the mold with a curable material;
- curing the curable material inside the mold to thereby form an illumination device, wherein the step of curing the curable material to form the illumination device substantially replicates the plurality of microstructured features of the interior surface of the mold onto the illumination device;
- and
- elastically expanding the mold to thereby separate the illumination device from the mold.
A method of molding a seamless illumination device, the method comprising the steps of:
- providing an expandable, hollow, one-piece mold having an interior with an interior surface including a plurality of microstructured features thereon, the interior being accessible through an opening in the mold;
- filling the interior of the mold with a curable material;
- curing the curable material inside the mold to form a cured material;
- elastically expanding the mold;
- and
- removing the cured material from the mold, the cured material forming the illumination device having a replica of the microstructured features.
Dependencies are inferred from the claim text.