Formation of pattern replicating tools
AssigneeMicroContinuum, Inc.
InventorW. Dennis Slafer
Life of this patent
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Abstract
Systems, methods, and apparatus are disclosed for making patterning tools from one or more discrete elements. Such tools can have one or more “seams” or joints where the individual elements abut which can limit the tools' performance and utility in roll-to-roll manufacturing. Methods are described herein for producing “near-seamless” tools, that is, tools having seams that exhibit minimum disruption of the tool pattern and thus improved material produced by such tools. The patterning tools can be cylindrical and/or closed in shape.
Claims13
A cylindrical shell tool system for configuring a shell tool having two or more segments, the tool being configured to hold pattern parts each having a three-dimensional relief pattern having features of under a micron in size for embossing, the shell tool system comprising:
- a plurality of pattern parts each having a desired three-dimensional relief pattern having desired features of under a micron in size, wherein the desired features are configured for embossing, wherein the plurality of pattern parts is configured with one common seam between adjacent pairs of the pattern parts, wherein each discrete pattern part is rectangular and has a length and width, and wherein the three-dimensional relief patterns of corresponding pattern parts are aligned across a common seam that is linear and traverses the entire length or width, respectively, of each of the pattern part of adjacent pairs of pattern parts;
- a multi-segment shell including multiple segments, wherein each segment is configured for adjustment along a cylinder axis for pattern alignment of the relief patterns of adjacent pattern parts without disruption of the relief pattern between parts;
- and
- a precision dovetail slide configured between two of the multiple segments, wherein the dovetail slide is configured and arranged to allow sliding engagement of the two segments.
A cylindrical shell tool system for configuring a shell tool having two or more segments, the tool being configured to hold pattern parts each having a three-dimensional relief pattern having features of under a micron in size for embossing, the shell tool system comprising:
- a plurality of pattern parts each having a desired three-dimensional relief pattern having desired features of under a micron in size, wherein the desired features are configured for embossing, wherein the plurality of pattern parts is configured with one common seam between adjacent pairs of the pattern parts, wherein each discrete pattern part is rectangular and has a length and width, and wherein the three-dimensional relief patterns of corresponding pattern parts are aligned across a common seam that is linear and traverses the entire length or width, respectively, of each of the pattern part of adjacent pairs of pattern parts, wherein each pattern part is joined directly or indirectly to the adjacent element across a common seam;
- a multi-segment shell including multiple segments, wherein each segment is operative for adjustment along a cylinder axis for pattern alignment of the relief patterns of adjacent pattern parts without disruption of the relief pattern between parts;
- and
- a precision mechanical slide configured between two of the multiple segments, wherein the precision mechanical slide is operative to allow sliding engagement of the two segments.
Dependencies are inferred from the claim text.