Vacuum-formed roll sleeves and methods of making and using same

Abstract

The vacuum formed roll sleeve (100, 700, 800) comprises a body (119, 818, 819) including a mold wall portion (120, 820) disposed between a molding surface (110, 1210, 710, 810) and at least one vacuum surface (130, 830). The molding surface (110, 1210, 710, 810) has a molded recessed feature and has first openings (112, 812) disposed at a first predetermined location (134). Each first opening (112, 812) is spaced from the at least one vacuum surface (130, 830) by a respective minimum thickness (135, 835). The at least one vacuum surface (130, 830) has a second opening (132, 832) disposed at a second predetermined location (134). The first openings (112, 812) are fluidly connected to the second openings (132, 832) by conduits (140, 840), at least some of which are longer than a minimum thickness (135, 835) between the first openings (112, 812) and the vacuum surface (130, 830), respectively. The vacuum formed roll sleeves (100, 700, 800) are configured such that at least a partial vacuum can be applied to the first openings (112, 812) through the conduits (140, 840) fluidly connected to the first openings (112, 812). The vacuum formed roll sleeves (100, 700, 800) are mountable to a backup roll (737). Methods of making and using the vacuum formed sleeves are also disclosed.

Description

[Background technology]

[0001] Vacuum forming roll sleeves are used in applications where it is desired to draw material into intimate contact with a forming surface. Such tools facilitate the removal of air trapped between the material and the forming surface by providing vacuum channels that open at the forming surface. In many cases, the design of vacuum forming roll sleeves is complex, time consuming, and expensive. For example, the manufacture of a single tool can take months and cost hundreds of thousands of dollars. Summary of the Invention

[0002] The present disclosure provides a vacuum-formed roll sleeve that can be produced using rapid prototyping design and manufacturing methods that can reduce design time (e.g., from months to weeks) and reduce manufacturing costs many times over. Thus, vacuum-formed roll sleeve designs that would be difficult or impossible to produce using other manufacturing methods can be rapidly designed and manufactured. If adjustments are desired, they are relatively easy to design and manufacture based on the original design template. Vacuum-formed roll sleeves are useful in processes such as continuous casting extrusion and continuous thermoforming, for example.

[0003] Vacuum formed roll sleeves according to the present disclosure can be manufactured in a monolithic form or in a modular form having multiple components assembled together to form a vacuum roll, in some embodiments, a modular frame allows for one or more vacuum formed roll sleeve sections to be quickly replaceable during pauses in a manufacturing run.

[0004] In one aspect, the present disclosure provides a vacuum formed roll sleeve, the vacuum formed roll sleeve comprising: a body including a mold wall portion disposed between a molding surface and at least one vacuum surface, the vacuum forming roll sleeve comprising: the molding surface has a molded recessed feature, the molding surface has first openings disposed at first predetermined locations, each first opening spaced apart from at least one vacuum surface by a respective minimum thickness; the at least one vacuum surface having a second opening disposed at a second predetermined location; the first opening is fluidly connected to the second opening by a conduit; At least some of the conduits are longer than a minimum thickness between the first opening and a vacuum surface to which they are fluidly connected; a vacuum forming roll sleeve configured to be capable of applying at least a partial vacuum to the first opening through a conduit fluidly connected to the first opening; A vacuum formed roll sleeve can be attached to the backup roll.

[0005] In another aspect, the present disclosure provides a method of making a vacuum formed roll sleeve according to the present disclosure, the method comprising using additive manufacturing techniques to produce a vacuum formed roll sleeve according to a predetermined design.

[0006] In yet another aspect, the present disclosure provides a method of using a vacuum formed roll sleeve according to the present disclosure, the method comprising: introducing a molten thermoplastic polymer onto a forming surface of a vacuum forming roll sleeve while applying a vacuum to at least one vacuum surface; Separating the molded article from the molding surface under conditions in which the molded article has a contoured surface that is a substantial inverse of at least a portion of the molding surface.

[0007] In yet another aspect, the present disclosure provides a method of using a vacuum formed roll sleeve according to the present disclosure, the method comprising: contacting the thermoplastic polymer film with a forming surface of a vacuum forming roll sleeve while applying a vacuum to at least one vacuum surface; Separating the molded film from the molding surface under conditions where the molded film has a contoured surface that is a substantial inverse of at least a portion of the molding surface.

[0008] As used herein, "Opening" means allowing access to an aperture or conduit.

[0009] "Conduit" means a hollow channel for conveying a gas between at least two openings.

[0010] The features and advantages of the present disclosure will be further understood by considering the detailed description and the appended claims. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is an exemplary schematic perspective view of a vacuum-formed roll sleeve 100 according to one embodiment of the present disclosure. [Diagram 2] 2 is a schematic enlarged partial cross-sectional view of the vacuum-formed roll sleeve 100 taken along line 2-2 of FIG. 1. [Diagram 3] 3 is a schematic enlarged partial cross-sectional view of the vacuum-formed roll sleeve 100 taken along line 3-3 of FIG. 1. [Figure 4A] FIG. 1 is a schematic end view of a vacuum formed roll sleeve 100 as viewed from end 111a. [Figure 4B] 1 is a schematic end view of the vacuum formed roll sleeve 100 as viewed from end 111b. [Diagram 5] 2 is a schematic enlarged partial cross-sectional view of the vacuum-formed roll sleeve 100 taken along line 2-2 of FIG. 1. [Figure 6] 2 is a schematic enlarged view of region 6 of FIG. 1 showing the underside of the vacuum formed roll sleeve 100. FIG. [Figure 7] FIG. 1 is a schematic diagram of an extrusion vacuum forming process according to the present disclosure. [Figure 8] FIG. 8 is an exemplary schematic perspective view of a vacuum formed roll sleeve 800 according to one embodiment of the present disclosure. [Figure 9] FIG. 8 is a schematic partial cutaway perspective view of a vacuum formed roll sleeve 800. [Figure 10]10 is a schematic enlarged partial cross-sectional view of a vacuum-formed roll sleeve 800 taken along line 10-10 of FIG. 8. [Figure 11A] FIG. 8 is a schematic end view of a vacuum formed roll sleeve 800 as viewed from end 811a. [Figure 11B] FIG. 8 is a schematic end view of the vacuum formed roll sleeve 800 as viewed from end 811b. [Figure 12] FIG. 12 is a schematic diagram of a protruding feature 1200. [Figure 13] FIG. 2 is a schematic perspective view of a portion of a vacuum process roll sleeve or expiratory airflow sample collection device made using the process described herein. [Figure 14] FIG. 2 is a schematic perspective view of a portion of a vacuum process roll sleeve or expiratory airflow sample collection device made using the process described herein.

[0012] Repeat use of reference characters in the specification and drawings is intended to represent the same or similar features or elements of the present disclosure. It is to be understood that those skilled in the art can devise numerous other modifications and embodiments that are within the scope and spirit of the principles of the present disclosure. The figures may not be drawn to scale. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] 1-6 show one exemplary embodiment of a vacuum formed roll sleeve 100 according to the present disclosure. Referring now to FIG. 1, the vacuum formed roll sleeve 100 comprises a molding surface 110, which is the radially outermost surface of the vacuum formed roll sleeve 100, and a back surface 125, which is the radially innermost surface. A body 119 comprises a mold wall portion 120 (see FIG. 3) disposed between the molding surface 110 and a vacuum surface 130. Vacuum inlet ports 114 (see again FIG. 3) are spaced circumferentially about first and second identical ends (111a, 111b; see also FIGS. 4A and 4B) of the vacuum formed roll sleeve 100. Threaded sockets 116 are alternately positioned with the vacuum inlet ports 114 to allow for attachment (e.g., with screws 798) of a vacuum seal ring 765 as shown in FIG. 7.

[0014] 2-5, and in particular FIG. 5, molding surface 110 has molded recessed features 118 and first openings 112 disposed at first predetermined locations. Molding surface 110 includes local maxima 117 and local minima 113. Each first opening 112 is spaced from vacuum surface 130 by a respective minimum thickness 135 (i.e., the minimum radial displacement between first opening 112 and vacuum surface 130 for each particular conduit 140 having second opening 132). While the particular embodiment illustrated has a relatively simple design, this aspect of the disclosure can be very important when highly topographically structured molding surfaces are used.

[0015] The vacuum surface 130 has a second opening 132 disposed at a second predetermined location 134. The first opening 112 is fluidly connected to the second opening 132 by a conduit 140. The vacuum formed roll sleeve 100 is configured such that at least a partial vacuum can be applied to the first openings 112 through respective conduits 140 fluidly connected to the first openings 112.

[0016] 6, the vacuum surface 130 and the vacuum manifold walls 133, both of which form part of the back surface 125, seal the vacuum formed roll sleeve 100 to the backup roll when the vacuum formed roll sleeve 100 is attached thereto (see FIG. 7), thereby forming a vacuum manifold (not shown). Support ridges 165, which help maintain the dimensional stability of the vacuum formed roll sleeve in use, have a top that is flush with the vacuum manifold walls. Vacuum troughs 172 help maintain a sufficient vacuum in the portions of the vacuum manifold remote from each vacuum inlet port 114.

[0017] The vacuum formed roll sleeve can be attached to a backup roll that can be used in a vacuum forming process or a similar continuous roll thermoforming process, such as the vacuum extrusion process shown in Figure 7. The two processes are similar, except that vacuum extrusion uses an extruded polymer melt curtain, whereas the continuous roll thermoforming process uses a softened (but not melted) polymer film.

[0018] In either process, the vacuum formed roll sleeve 700 is mounted on a rotatable backup roll 737. The backup roll 737 may be expandable (e.g., a hydraulically pressurized backup roll) to ensure a snug frictional engagement between the vacuum formed roll sleeve and the backup roll. Other methods for fastening the vacuum formed roll sleeve to the backup roll may be used (e.g., mechanically interlocking ridges / slots, mechanical fasteners, or adhesives that tightly engage corresponding structures on the backup roll). In use, the vacuum formed roll sleeve rotates about a common axis by driving the backup roll. In use, an external vacuum source may be applied to the vacuum port, thereby evacuating the vacuum manifold to promote contact between the molten or softened polymer and the molding surface.

[0019] In FIG. 7, this is accomplished by connecting the port 767 of the hollow vacuum shoe 722 to an external vacuum (not shown). As the vacuum formed roll sleeve 100 rotates, the vacuum inlet port 796 in contact with the hollow vacuum shoe is exposed to a vacuum, which in turn evacuates one of the vacuum manifolds and draws a polymer melt curtain 777 from the extruder 775 against the molding surface 110 of the vacuum formed roll sleeve 100 and into its recessed features (not shown). As each vacuum inlet port is exposed to atmospheric pressure beyond the hollow vacuum shoe 722, normal pressure is returned to each vacuum manifold. The hollow vacuum shoe 722 and hollow pressure shoe 724 (which typically overlap at either end of the rotatable backup roll 737) are mounted to an external frame (not shown) and configured to form a seal with vacuum seal rings 765 that are attached to either end of the vacuum formed roll sleeve 700 by screws 798.

[0020] The polymer may be cooled, for example, by at least one of cooling a backup roll or blowing air against the molded polymer. Once the polymer is cooled, it becomes dimensionally stable and is eventually passed through hollow pressure shoe 724. Hollow pressure shoe 724 operates similarly to hollow vacuum shoe 722, except that a positive gas (e.g., air) pressure is applied to pressure port 769 to facilitate separation of molded polymer film 779 from molding surface 710 by forcing gas through an associated first opening (not shown) through a fluidly connected conduit (not shown).

[0021] 8-11B illustrate another embodiment of an exemplary vacuum formed roll sleeve 800 according to the present disclosure.

[0022] 8, the vacuum formed roll sleeve 800 includes a molding surface 810, which is the radially outermost surface of the vacuum formed roll sleeve 800, and a back surface 825, which is the radially innermost surface. A body 818 includes a mold wall portion 820 (see FIG. 9) disposed between the molding surface 810 and the vacuum surface 830. Vacuum inlet ports 814 (see again FIG. 9) are spaced circumferentially about the same first and second ends (811a, 811b) of the vacuum formed roll sleeve 800 shown in FIGS. 11A and 11B. Threaded sockets 816 are alternately positioned with the vacuum inlet ports 814 to allow for attachment (e.g., with screws 798) of a vacuum seal ring 765 as shown in FIG. 7.

[0023] Referring again to FIG. 9, support posts 865 within the vacuum manifold 872, which are integrally formed with the body 819, help maintain the dimensional stability of the vacuum formed roll sleeve 800 during use.

[0024] 10, the molding surface 810 has a molded recess feature 818 and a first opening 812 disposed at a first predetermined location. Each first opening 812 is spaced from a vacuum surface 830 by a respective minimum thickness 835 (i.e., a minimum radial displacement between the first opening 812 and the vacuum surface 830). The vacuum surface 830 is disposed within a body 819 of the vacuum forming roll sleeve 800. The body 819 includes a mold wall portion 820 disposed between the molding surface 810 and the vacuum surface 830. The vacuum surface 830 has a second opening 832 disposed at a second predetermined location. The first openings 812 are fluidly connected to the second openings 832 by respective conduits 840 (see FIG. 9).

[0025] The vacuum formed roll sleeve 800 is configured such that at least a partial vacuum can be applied to the first openings 812 through respective conduits 840 fluidly connected to the first openings 812, thereby also applying at least a partial vacuum to a vacuum manifold 856 in fluid communication with the vacuum inlet port 814.

[0026] Regardless of the embodiment selected, the first and second openings may have any size and / or shape (e.g., circular, oval, square, triangular, rectangular, or trilobal). Typically, the openings have a cross-sectional area large enough that a vacuum can be drawn to bring the softened or molten polymer adjacent the first opening into intimate contact with the molding surface, although this is not a requirement. Preferably, the openings are small enough that the softened or molten polymer does not significantly penetrate into their respective associated conduits under intended process conditions.

[0027] Similarly, the first openings are typically arranged according to a predetermined pattern, with most or all of the recessed features having one or more first openings disposed therein, preferably including their most recessed locations. Additional first openings disposed at other locations on the molding surface can help hold the molded article in contact with the molding surface (e.g., during cooling) until it is desired to separate the molded article from the molding surface, thereby retaining its molded shape.

[0028] The conduits may connect the first and second openings on a one-to-one basis, a one-to-many (i.e., at least two) basis, a many-to-one basis, or any combination thereof. A one-to-one relationship between the first and second openings and each conduit is general. The conduits may have any internal configuration so long as they terminate in at least one first opening and at least one second opening, and fluidly connect at least one first opening to at least one second opening. For example, the conduits may be radially oriented, inclined (i.e., oblique to the radial orientation), straight, arcuate, convoluted, unbranched, branched, or combinations thereof.

[0029] At least 20 percent, at least 30 percent, at least 40 percent, at least 50 percent, or even at least 60 percent of the conduits may be longer than the minimum thickness of the mold wall portion at each first opening, although this is not a requirement. For a distance from at least one vacuum surface, the molding surface includes a plurality of local maxima and minima. In some embodiments, at least a majority of the minima have one of the first openings located proximate to the minima, although this is not a requirement.

[0030] The vacuum formed roll sleeves described herein can be used to form a wide variety of shapes and devices within the formed film. One exemplary device that can be formed using the vacuum formed roll sleeves and methods of use thereof is described in U.S. Patent Application Publication Nos. 63 / 199226, filed December 15, 2020, 63 / 200058, filed February 12, 2021, 63 / 227498, filed July 30, 2021, 63 / 200901, filed April 2, 2021, 63 / 227519, filed July 30, 2021, 63 / 273300, filed October 29, 2021, and 63 / 272000, filed May 23, 2021. No. 63 / 202140 filed on May 28, 2021, No. 63 / 227534 filed on July 30, 2021, No. 63 / 200958 filed on April 6, 2021, No. 63 / 203831 filed on August 2, 2021, No. 63 / 201981 filed on May 21, 2021, No. 63 / 202143 filed on May 28, 2021, No. 63 / 227608 filed on July 30, 2021, No. 63 / 201983 filed on May 21, 2021, No. 63 / 227529 filed on July 30, 2021, No. 63 / 260828 filed on September 1, 2021, No. 63 / 203441 filed on July 22, 2021, No. 63 / 203442 filed on July 22, 2021, No. 63 / 306273 filed on February 3, 2022, No. 63 / 136723 filed on January 13, 2021, No. 63 / 148195 filed on February 11, 2021, No. 63 / 222745 filed on July 16 ... No. 63 / 224242 filed on July 21, 2020, No. 63 / 237909 filed on August 27, 2021, No. 63 / 255363 filed on October 13, 2021, No. 63 / 283075 filed on November 24, 2021, No. 63 / 287911 filed on December 9, 2021, No. 63 / 142874 filed on January 28, 2021, No. 63 / 158153 filed on March 8, 2021, No. 63 / 051116 filed on July 13, 2020 (nowand WO 63 / 029974, filed May 26, 2020 (now published as WO 2021242907), each of which is incorporated herein by reference in its entirety. This type of sample collection device generally includes a porous sample collection medium disposed within a device housing and along an airflow channel defined by the device housing. A user can exhale into the sample collection device to load the porous sample collection medium with a sample of the exhaled airstream to form a loaded porous sample collection medium. In some embodiments, fluid passes through the porous sample collection medium (e.g., a metered dose of fluid), carrying away pathogens or viruses that may be bound to the porous sample collection medium. The fluid can then be analyzed.

[0031] In some embodiments, the housing includes a first element and a second element that cooperate to define an air flow path. In some embodiments, the first element and the second element of the housing are removably coupled to one another. In alternative embodiments, the first element and the second element are permanently coupled to one another such that they cannot be separated without being destroyed or deformed. The first element and the second element may be coupled by any suitable mechanism. For example, the first element and the second element may be coupled by a bayonet coupling, an interference fit, a snap fit, or a threaded coupling. In one embodiment, the first element and the second element are coupled by a bayonet coupling. When configured for a bayonet coupling, the first element may include one or more protrusions and the second element may include one or more corresponding grooves configured to receive and guide the one or more protrusions. Alternatively, the one or more protrusions may be on the second element and the one or more grooves may be on the first element.

[0032] The first piece has a proximal end and an opposing distal end. The proximal end may form a mouthpiece. The second piece has a proximal end and an opposing distal end. The first and second pieces may be coupled to one another.

[0033] According to an exemplary embodiment, the housing has a central longitudinal axis. An airflow channel extends through both the first element and the second element. The airflow channel may extend along the central longitudinal axis. One or both of the first element and the second element may include a tubular, quadrilateral, rectangular, or cylindrical body. When the first element and the second element are joined, the tubular, quadrilateral, rectangular, or cylindrical body may be coaxial.

[0034] In some embodiments, one of the first piece or the second piece may also include any suitable mechanism for coupling with a sample collection tube. For example, one of the ends of the first piece or the second piece may be configured for a bayonet coupling, an interference fit, a snap fit, or a screw coupling. Many commercially available sample collection tubes or test tubes have a threaded top for attaching a cap. The tube coupling end of the second element may be configured to couple with the threads of the sample collection tube. The tube coupling end of the second element may include an internal thread configured to couple with the external threads of the sample collection tube. The tube coupling end of the second element may include two or more different threads with different configurations (e.g., sizes, thread spacing, or thread angles) for attachment to different types or sizes of sample collection tubes. In some embodiments, the tube coupling end of the second element is configured for an interference fit with the sample collection tube. To facilitate the interference fit, the tube coupling end may include a protrusion sized to be received inside the sample collection tube.

[0035] One exemplary implementation is shown in Figures 13 and 14. Figure 13 shows a first molded film 1300 including a row of spaced apart first pieces of housing 1310 which when mated with a second piece of housing form a sample collection device of the type described in the above-listed applications. The first piece 1310 in Figure 13 is generally rectangular in shape and includes an elongated rectangular insert or well 1320 into which a lateral or vertical flow assay (LFA or VFA, respectively) may be placed. Thus, the depth of the insert or well should be at least twice the thickness of the LFA or VFA.

[0036] 14 shows a second molded film 1400 including a row of spaced apart second pieces of housing 1410 which, when mated with the second piece of housing, form a sample collection device of the type described in the above-listed applications. The second piece 1410 includes an exhalation aperture 1420 through which a user can exhale and an indicator aperture 1430 through which a user can see the results of the test. The second piece may also include a liquid receiving aperture 1440 through which liquid can enter the housing or liquid can enter the housing through the exhalation aperture 1420.

[0037] The vacuum formed roll sleeve may be made by any suitable technique. In many cases additive manufacturing (AM) techniques are preferred and / or necessary. In such cases, the body of the vacuum formed roll sleeve is often of unitary construction, although this is not a requirement.

[0038] In typical additive manufacturing, an object is produced by depositing successive layers of material, which may include, for example, organic polymers (e.g., cross-linked polymers or thermoplastics), metals, or ceramics.

[0039] Common to additive manufacturing techniques is the use of computers, three-dimensional (3D) modeling software (also known as Computer Aided Design (CAD)), machine equipment, and additive materials. Once a CAD sketch is generated, the AM equipment reads the data from the CAD file and stacks or adds successive layers of liquid, powder, sheet material, etc. to produce the 3D object. Additive manufacturing techniques include, for example, vat photopolymerization, material extrusion, powder bed fusion bonding, material jet printing, binder jet printing, directed energy deposition, and sheet lamination.

[0040] Of these, vat polymerization has been found to be particularly applicable to vacuum formed roll sleeve manufacturing. Vat polymerization uses a vat of liquid photopolymer resin from which the model is built, layer by layer. Ultraviolet (UV) light is used to cure or harden the resin as needed, while a platform moves the workpiece downwards as each new layer is cured. Regardless of the method selected, vacuum formed roll sleeves (and their forming surfaces) contain individual, bonded layers of material that are generally evident on closer inspection.

[0041] In this process, a photopolymerizable liquid is used to form an object, so there is no structural support from the material during the build phase, unlike powder-based methods where support comes from unbound materials. In such cases, it is often necessary to add support structures. The photopolymerizable liquid is cured using a process of photopolymerization, where light (e.g., ultraviolet and / or visible light) is directed across the surface of the resin using motorized mirrors. When the resin comes into contact with the light, it polymerizes and hardens to form a crosslinked organic polymer, typically a crosslinker acrylic polymer.

[0042] A typical general process is as follows: 1. The build platform is lowered one thin layer thickness below the top of the vat of photopolymerizable liquid. 2.UV light hardens the resin layers according to a predetermined pattern. The platform continues to move downwards, building additional layers on top of the previous ones. 3. After completion or multiple cycles the object is produced, the photopolymerizable liquid is drained from the vat and the object is removed.

[0043] Specific types of vat photopolymerization include stereolithography (SLA), digital light processing (DLP), continuous liquid interface production (CLIP), and daylight polymer processing (DLP).

[0044] During the SLA manufacturing process, a concentrated beam of ultraviolet light or laser is focused onto the surface of a vat filled with liquid photopolymer. The beam or laser is focused to create each layer of the desired 3D object by crosslinking monomers or decomposing the polymer.

[0045] The DLP process uses a digital projector screen to flash one image of each layer across the entire platform at once. Because the projector is a digital screen, the image for each layer is made up of square pixels, resulting in layers being made up of tiny rectangular bricks called voxels. With DLP, each entire layer is exposed at once, rather than being written with a laser, allowing faster print times to be achieved for some parts.

[0046] CLIP vat photopolymerization technology uses a tank of resin as the base material. A portion of the vat bottom is transparent to ultraviolet light, and is therefore called the window. A beam of ultraviolet light is shone through the window, illuminating a precise cross-section of the object. The light solidifies (photopolymerizes) the resin. The object rises slowly enough to allow the resin to flow underneath the object and maintain contact with the bottom of the object. Below the resin is an oxygen-permeable membrane, which creates a dead zone. This persistent liquid interface prevents the resin from adhering to the window, which means it prevents photopolymerization between the window and the object being produced. Unlike standard SLA, the 3D printing process is continuous and is claimed to be up to 100 times faster than commercial 3D printing methods.

[0047] Instead of using a laser or projector to harden the polymer, the DPP manufacturing process uses a liquid crystal display (LCD).

[0048] Suitable materials and techniques are known in the art and are available, for example, from additive manufacturing equipment suppliers. Contract manufacturers can also manufacture parts when provided with an appropriate digital CAD file of the part to be made.

[0049] In embodiments using vat polymerization, the resulting article generally comprises a crosslinked organic polymer. If material extrusion is used, the article may comprise a thermoplastic organic polymer. Of the two, crosslinked organic polymers are generally more suitable for vacuum forming roll sleeve manufacturing since they are not thermoplastic and are more susceptible to thermal deformation.

[0050] Examples of polymerizable materials suitable for use in batch polymerization include methacrylate and / or acrylate monomers such as polyethylene glycol diacrylate (PEGDA), triethylene glycol dimethacrylate (TEGDMA), biphenol A-glycidyl methacrylate (Bis-GMA), trimethylolpropane triacrylate (TTA), soft aliphatic urethane dimethacrylate (UDMA) having the structural formula: [ka] Bisphenol A ethoxylate diacrylate (Bis-EDA) having the following structural formula: [ka] where n is an integer equal to or greater than 1. Useful free radical polymerization photoinitiators are well known in the art and include, for example, 2-hydroxy-2-methyl-1-phenyl-propan-1-one, 2,2-dimethoxy-2-phenylacetophenone, phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide, 2-hydroxy-2-methyl-1-phenylpropan-1-one, and ethyl(2,4,6-trimethylbenzoyl)phenylphosphinate.

[0051] Other polymerization systems include thiol-ene and thiol-yne polymerization systems, as well as cationically polymerizable epoxy monomer systems.

[0052] Further details regarding vat polymerization are known and are described, for example, in "Photopolymerization in 3D printing" by Bagheri et al., ACS Applied Polymer Materials, 2019, vol. 1, pp. 591-611 and "A Review of Vat Photopolymerization Technology: Materials, Applications, Challenges, and Future Trends of 3D Printing" by Pagac et al., Polymers, 2021, vol. 13, pp. 598-618 and references contained therein.

[0053] In one embodiment, a CAD template for a vacuum formed roll sleeve can be generated. In such cases, a regularly spaced array of radially oriented conduits is often used. In the CAD template, all design elements are present except for the absence of features on the forming surface. Once the desired structure is applied to the forming surface, the software can reposition the first opening to correspond to a local minimum on the forming surface. This can significantly reduce the CAD design time required to generate a new roll.

[0054] Preferably, the vacuum formed roll sleeve is constructed with its ends standing up, either as a monolith or as modular sections that can be assembled to form the entire roll, thus reducing or eliminating the need for support structures.

[0055] Advantageously, additive manufacturing can be used to produce complex internal features such as vacuum manifolds, supports, conduits, and molding surfaces (e.g., molding surfaces with overhanging features). Overhanging features typically prevent access to the portion of the molding surface directly beneath them and are difficult to create using traditional techniques such as carving. An example of an overhanging feature is shown in FIG. 12, where feature 1200 is a radial extension of a portion of molding surface 1210.

[0056] The preceding description is intended to enable one skilled in the art to practice the disclosure as set forth in the claims and is not to be construed as limiting the scope of the disclosure, which is defined by the claims and all equivalents thereof.

Claims

1. 1. A vacuum forming roll sleeve comprising a body including a mold wall portion disposed between a forming surface and at least one vacuum surface, the molding surface has a molded recessed feature, the molding surface has first openings disposed at first predetermined locations, each first opening spaced apart from the at least one vacuum surface by a respective minimum thickness; the at least one vacuum surface having a second opening disposed at a second predetermined location; the first opening is fluidly connected to the second opening by a conduit; At least some of the conduits are each longer than the minimum thickness between the first opening and the vacuum surface; the vacuum forming roll sleeve is configured to be capable of applying at least a partial vacuum to the first opening through the conduit fluidly connected to the first opening; The vacuum-formed roll sleeve is attachable to a backup roll. Vacuum formed roll sleeve.

2. 2. The vacuum formed roll sleeve of claim 1, further comprising at least one vacuum manifold in fluid communication with the at least one vacuum surface, each of the at least one vacuum manifold comprising at least one vacuum port disposed at at least one end of the vacuum formed roll sleeve and fluidly connected to the at least one vacuum manifold, the at least one vacuum manifold being disposed within the vacuum formed roll sleeve.

3. 2. The vacuum formed roll sleeve of claim 1, further comprising a back surface opposite the molding surface, the at least one vacuum surface forming a portion of the back surface, a raised portion of the back surface surrounding the at least one vacuum surface and forming at least one vacuum manifold in fluid communication with the at least one vacuum surface when the vacuum formed roll sleeve is attached to the backup roll, and at least one vacuum port disposed at at least one end of the vacuum formed roll sleeve and fluidly connected to the at least one vacuum manifold.

4. The vacuum formed roll sleeve of any one of claims 1 to 3, wherein at least 20 percent of the conduits are longer than the minimum thickness of the mold wall portion at each of the first openings.

5. The vacuum formed roll sleeve of any one of claims 1 to 4, wherein at least 50 percent of the conduits are longer than the minimum thickness of the mold wall portion at each of the first openings.

6. The vacuum formed roll sleeve of any one of claims 1 to 4, wherein at least 60 percent of the conduits are longer than the minimum thickness of the mold wall portion at each of the first openings.

7. The vacuum formed roll sleeve of any one of claims 1 to 6, wherein at least some of the conduits are straight.

8. The vacuum formed roll sleeve of any one of claims 1 to 7, wherein at least some of the conduits are not straight.

9. A vacuum formed roll sleeve according to any one of claims 1 to 8, wherein at least some of the conduits are unbranched.

10. A vacuum formed roll sleeve according to any one of claims 1 to 9, wherein at least some of the conduits are branched.

11. The vacuum formed roll sleeve of any one of claims 1 to 10, wherein the forming surface includes a protruding feature.

12. The vacuum formed roll sleeve of any one of claims 1 to 11, wherein the vacuum formed roll sleeve comprises an organic polymer.

13. 13. The vacuum formed roll sleeve of claim 12, wherein the organic polymer is crosslinked.

14. A vacuum formed roll sleeve according to any one of claims 1 to 13, wherein at least the forming surface comprises bonded individual layers of material.

15. 15. The vacuum formed roll sleeve of claim 1, wherein the forming surface includes a plurality of local maxima and minima for a distance from the at least one vacuum surface, at least a majority of the minima having one of the first openings disposed proximate to the minima.

16. A method for producing a vacuum formed roll sleeve according to any one of claims 1 to 15, comprising using additive manufacturing techniques to produce said vacuum formed roll sleeve according to a predetermined design.

17. 17. The method of claim 16, wherein the additive manufacturing technique is selected from the group consisting of vat photopolymerization, material extrusion, powder bed fusion, material jet printing, binder jet printing, directed energy deposition, and sheet lamination.

18. introducing a molten thermoplastic polymer onto the forming surface of the vacuum forming roll sleeve while applying a vacuum to the at least one vacuum surface; separating the molded article from the molding surface under conditions in which the molded article has a contoured surface that is a substantial inverse of at least a portion of the molding surface; A method for using the vacuum-formed roll sleeve according to any one of claims 1 to 15, comprising:

19. 20. The method of claim 18, further comprising the step of cooling the molded article to at least a temperature at which the molded article is dimensionally stable prior to the step of separating the molded article from the molding surface.

20. 20. The method of claim 18 or 19, further comprising the step of forcing gas from some of the conduits through some of the first openings during the step of separating the molded article from the molding surface.

21. contacting a thermoplastic polymer film with the molding surface of the vacuum forming roll sleeve while applying a vacuum to the at least one vacuum surface; separating the molded film from the molding surface under conditions where the molded film has a contoured surface that is a substantial inverse of at least a portion of the molding surface; A method for using the vacuum-formed roll sleeve according to any one of claims 1 to 15, comprising:

22. 22. The method of claim 21, further comprising the step of cooling the molded film to at least a temperature at which the molded film is dimensionally stable prior to the step of separating the molded film from the molding surface.

23. 23. The method of claim 21 or 22, further comprising the step of forcing gas from some of the conduits through some of the first openings during the step of separating the molded article from the molding surface.

24. The use of any one of claims 21 to 23, wherein the cast film comprises one or more portions of a sample collection device.

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