Device for processing a three dimensional structure into a substrate

Abstract

A device and method for processing a substrate, wherein a flexible force absorbing means is provide in at least a part of a tool plan and / or a reaction plan, so as to locally absorbing the forces applied by the planes. The flexible force absorbing mean having spring-like properties such that it is adapted to be elastically deformed when the tool plan and the reaction plan are pressed against each other.

Description

FIELD OF THE INVENTION [0001] This invention relates generally to a device and a process for processing a substrate, e.g. forming a three-dimensional structure, nanostructure, hologram or similar relief diffraction pattern into a substrate by use of a re-configurable mould. BACKGROUND OF THE INVENTION [0002] Various techniques for cutting and forming a substrate exist. Cutting is done in different ways e.g. punching. Normally the cutting machine is provided with co-operating edges used to cut the material. Especially when cutting fine geometry's where allowable variations in the tolerances are relatively small, the tool with the cutting edges need to be renewed or renovated often, due to tear and ware of the tool. This makes the process relatively expensive. [0003] Various casting techniques for forming microstructure surfaces exist. Typically a mould holds a liquid resin on the substrate during curing of the resin whereby the resin forms the microstructure. The mould may be provide...

AI Technical Summary

Benefits of technology

[0011] The flexible force absorbing means is adapted to equalise the pressure along the core and / tool, so that possible sporadic unevenness along the length of the core and / or tool do not result in a higher local pressure in the area of the unevenness, as the force absorbing means will absorb / equalise such high pressure.

[0023] Preferably, the flexible force absorbing means are provided so that the flexibility may be changed. According to an embodiment of the invention, the flexible force absorbing means are provided in the form of a resilient adhesive tape attached to the surface of the tool plan and / or to the surface of the reaction plan forming a force absorbing layer of the device. The resiliency and thus the capability of the device to take up tolerances may easily be changed e.g. by changing the type of adhesive tape or the thickness of the adhesive tape.

[0026] Preferably, the flexible force absorbing layer is provided in the multiple layer construction between the core and the tool. This embodiment is advantageous, as the absorbing layer then absorbs all sporadic unevenness along the entire length of the core and / or tool.

[0037] The adhesive layer of the tape may be provided with a permanent adhesion so that it will be possible to reuse the tape and to refit the shims to the flexible layer, which will make refitting easier and faster. Thus, the invention provides a much more flexible device, as the tool can be changed very easy.

[0051] Due to this device, it is possible to control a processing of a substrate held by a bearing material in an easy way, and where a deformation of the bearing material (or core material) is avoided due to the use of the flexible force absorbing layer, e.g. the double sided adhesive tape.

Problems solved by technology

Especially when cutting fine geometry's where allowable variations in the tolerances are relatively small, the tool with the cutting edges need to be renewed or renovated often, due to tear and ware of the tool.

This makes the process relatively expensive.

In order to create visible distortion in the diffraction pattern, the tolerances must be low and accordingly, the cost for making a mould is relatively high.

The moulds have to be replaced after a number of moulding cycles, as the moulds are incorporated e.g. in rotational drums for mass replication of holograms, the costs for replacing moulds being high.

Only very small displacements of the mould in relation to the substrate during the casting will reduce the quality of the cast.

However, when casting in non-liquid materials such as directly in steel plates or similar ‘hard’ substrates, the rigidity disables the machine to take up tolerances occurring in the substrate.

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