Methods for making microstructured polymer substrates
Assignee3M Innovative Properties Company
InventorsClyde D. Calhoun, David C. Koskenmaki, James G. Berg, Jennifer M. Aamodt
Life of this patent
Estimating the term…
Abstract
A unitary polymer substrate having a plurality of microfibers projecting from a surface is provided. The presence of the microfibers greatly increases the surface area and can impart a cloth-like feel to the surface. The projecting microfibers may have a variety of forms, including frayed-end microfibers, tapered microfibers, microfibers having an expanded cross-sectional shape, and microfibers having a very high aspect ratio. A number of methods of producing unitary polymer structures with a plurality of projecting microfibers are also provided.
Claims24
A method of producing a unitary polymer substrate having a napped surface, said method comprising:
- providing a template surface comprising a release material and having a plurality of microdepressions therein, said microdepressions have a non-release surface therein;
- laminating a thermoplastic polymer substrate to the template surface such that a portion of the thermoplastic polymer enters into the plurality of microdepressions;
- and
- delaminating the thermoplastic polymer substrate from the template surface while maintaining a surface of the thermoplastic polymer substrate in a sufficiently softened state such that a plurality of microfibers are generated on the thermoplastic polymer surface prior to debonding of the thermoplastic polymer substrate from the template surface.
A method of producing a unitary polymer substrate having a napped surface comprising:
- providing a template surface comprising a release material and having a plurality of microdepressions therein;
- laminating a surface of a thermoplastic polymer substrate to the template surface such that a portion of the thermoplastic polymer enters into the plurality of microdepressions;
- and
- delaminating the thermoplastic polymer surface from the template surface while maintaining the thermoplastic polymer surface in a sufficiently softened state such that a plurality of microfibers are generated on the thermoplastic polymer surface prior to debonding of the thermoplastic polymer surface from the template surface;
- wherein
- the providing step comprises providing a template surface comprising a release material and having a plurality of microdepressions therein, wherein the microdepressions have a non-release surface therein,
- the laminating step comprises laminating the polymer substrate to the template surface to form microprojections on the polymer substrate, each microprojection being bonded to one of the microdepression non-release surfaces;
- and
- the delaminating step comprises delaminating the polymer substrate from the template surface while maintaining the polymer substrate in a sufficiently softened state such that the microprojections are stretched into microfibers before debonding from the non-release surfaces.
A method of producing a unitary polymer substrate having a napped surface comprising:
- providing a resilient template surface comprising a release material and having a plurality of microdepressions therein, wherein the resilient template surface comprises a polymer foam;
- laminating a surface of a thermoplastic polymer substrate to the template surface such that a portion of the thermoplastic polymer enters into the plurality of microdepressions;
- and
- delaminating the thermoplastic polymer surface from the template surface while maintaining the thermoplastic polymer surface in a sufficiently softened state such that a plurality of microfibers are generated on the thermoplastic polymer surface prior to debonding of the thermoplastic polymer surface from the template surface.
A method of producing a unitary polymer substrate having a napped surface, said method comprising:
- providing a resilient template surface having a plurality of undercut-shaped microdepressions therein, the resilient template surface comprising an open cell foam;
- laminating a thermoplastic polymer substrate to the resilient template surface such that a portion of the thermoplastic polymer enters into the plurality of undercut-shaped microdepressions;
- and
- delaminating the thermoplastic polymer substrate from the resilient template surface while maintaining a surface of the thermoplastic polymer substrate in a sufficiently softened state such that a plurality of microfibers are generated on the thermoplastic polymer surface prior to debonding of the thermoplastic polymer substrate from the resilient template surface.
A method of producing a unitary polymer substrate having a napped surface, said method comprising:
- providing a resilient template surface having a plurality of microdepressions therein;
- laminating a surface of a thermoplastic polymer substrate to the resilient template surface such that a portion of the thermoplastic polymer enters into the plurality of microdepressions;
- and
- delaminating the thermoplastic polymer surface from the resilient template surface while maintaining the thermoplastic polymer surface in a sufficiently softened state such that a plurality of microfibers are generated on the thermoplastic polymer surface prior to debonding of the thermoplastic polymer surface from the resilient template surface,
- wherein the providing step comprises providing a resilient template surface comprising a screen laminated to a surface of a non-release substrate, the screen having an outer surface formed from a release material.
Dependencies are inferred from the claim text.