Equipment and process for duplicating textures

Abstract

The present invention relates to a process for replicating textures. A method is disclosed for the continuous production of flexible stamps and their application to texturing resins by combining roll-to-plate and plate-to-roll processes. Additionally, an apparatus suitable for the continuous process is disclosed.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for replicating textures and a product obtained using the process according to the present application.

Background Art

[0002] The use of functional texturing layers on devices is an important topic. The intelligent use of such layers can improve the performance of products, reduce costs, or improve the visual appearance. For example, using a diffuser layer on a display enables the use of a thinner LED backlight concept and illuminates the display from the side. Other possibilities for new cutting-edge technologies are to incorporate functional texturing layers into solar panels to improve their efficiency or into organic light-emitting diode (OLED) lighting panels to extract more light.

[0003] Functionally textured layers can be fabricated using UV imprinting. In this process, the substrate, the stamp, or both are coated with lacquer (also called resin or resist). After pressing the stamp with the lacquer in between onto the substrate, the textured lacquer hardens into a solid phase. The hardening method may be by heat or by the use of UV light. This technique was already described in U.S. Patent No. 4,128,369 in 1978. Further pioneering research was conducted by Chou in 1995. He demonstrated that textures below 25 nm could be replicated at high throughput for mass production by using a rigid stamp (U.S. Patent No. 5,772,905 or article by Stephen Y. Chou, Peter R. Krauss, and Preston J. Renstrom (Appl. Phys. Lett. 67 (1995) 3114-3116)). Subsequently, the use of rollers was demonstrated to replicate textures by applying pressure to either a rigid stamp or a curved thin metal sheet (article Hua Tan, Andrew Gilbertson, Stephen Y. Chou, J. Vac. Sci. Technol., B 16 (1998) 3926-3928).

[0004] Many institutions and companies have continued this research, resulting in different techniques. In the semiconductor industry, plate-to-plate imprinting is applied by using rigid stamps in combination with the transfer process, materials, and precise positioning, as described in U.S. Patent No. 6,334,960, U.S. Patent Application Publication No. 2004 / 0065976, and U.S. Patent No. 8,432,548. Roll-to-roll imprinting techniques, as described in U.S. Patent No. 8,027,086, for example, use texturized rollers in combination with a flexible substrate to texturize foil or film in a continuous process.

[0005] As mentioned above, the plate-to-plate technique is designed to accurately imprint fine textures (feature sizes less than 100 nm) on a uniform, flat wafer with high positional accuracy and wafer-scale precision. However, as described in Chinese Patent Application Publication No. 103235483, this technique is difficult to scale to larger areas. By using roll-to-roll technology, textured foils can be continuously produced at high production speeds. The textured foils can be used as substrates for flexible applications or laminated onto rigid substrates. However, the latter incurs the additional cost of an intermediate adhesive layer to adhere the textured flexible foil to the rigid substrate or product. Therefore, a third new technique, direct roll-to-plate imprinting, has been developed. This allows a functional textured layer to be directly applied to a separate substrate without the use of auxiliary films with an additional intermediate adhesive layer of tens to hundreds of microns in thickness. Unlike plate-to-plate technology, the imprint may be produced by using a textured roller or by using a textured foil, also known as a flexible stamp, wound onto a roller.

[0006] Unlike most rigid stamps and imprint rollers, which are generally made from metal, flexible stamps typically have a shorter lifespan due to their lower resistance to mechanical stress caused by the softness of the polymer material that constitutes them. Flexible stamps are also exposed to radiation and / or thermal stress, as they typically come into contact with lacquer or resin during the curing or solidification process, which shortens the lifespan of their chemical structure. Compared to rigid stamps and imprint rollers, which are usually made of metal and have a more or less infinite lifespan, this necessitates that flexible stamps be replaced more frequently. This implies that flexible stamps must be produced more frequently, and therefore there is a need for a rapid and efficient process for their production.

[0007] Typically, flexible stamps are produced by replicating a texture from a rigid master, which may be made of a wear-resistant material such as metal, glass, or quartz. This master is typically coated with a resin with a carrier placed on top, and this resin is cured thermally or by UV light. The cured and textured resin layer is then separated from the master and further processed by additional steps, for example, to improve its mechanical properties and reduce adhesive interaction with the lacquer used in the imprint process. After this processing, the textured resin layer may become part of a flexible stamp, which can be assembled into a device and used for roll-to-plate imprinting of rigid substrates.

[0008] Compared to imprint processes using rigid stamps or imprint rollers, roll-to-plate processes are time-consuming due to the need to frequently produce flexible stamps. The use of flexible stamps requires know-how to produce them, equipment to produce the stamps, and then applying the flexible stamps for imprinting to the product imprint process and equipment. This limits the applications of roll-to-plate processes using flexible stamps to areas where, for example, plate-to-plate or roll-to-roll processes are not feasible due to substrate size. [Overview of the project] [Problems that the invention aims to solve]

[0009] An object of the present invention disclosed herein is to make roll-to-plate imprinting with flexible stamps more efficient by providing an alternative technique for producing flexible stamps that can also be used in conjunction with apparatus suitable only for carrying out roll-to-plate imprinting processes. [Means for solving the problem]

[0010] The objective is solved by a method for continuously replicating a texture, comprising the steps of: providing a substrate; providing a first resin to the substrate; texturing the first resin with an imprint texture by applying a roll-to-plate process; and solidifying the first resin, wherein the steps are repeated whenever the replication of the texture is required, the method comprising: providing a master having the texture to be replicated prior to the replication process, wherein the texturing surface of the master has a surface free energy of up to 35 mN / m; providing a second resin to the master; providing a carrier; bringing the master and carrier into contact with the second resin between them by applying a plate-to-roll process for texturing the second resin; and solidifying the second resin to obtain an imprint texture used for texturing the first resin, further characterized in that, while the step of texturing the first resin is being performed, the substrate is moving in the same plane as the master while the step of bringing the carrier and master into contact with the second resin is being performed.

[0011] Throughout this application, the term “continuously” means that a method for producing a product can deliver multiple products without interrupting the process. With respect to an apparatus for carrying out a production process, “continuously” means that the apparatus can perform the method multiple times in succession without stopping. Furthermore, “continuously” may mean that the apparatus can perform the method multiple times in succession without the need to adjust the curing method, without the need to adjust the direction of operation of the apparatus, or without the need for additional process modules, such as a firing station, a non-adhesive coating station, or a flexible stamp storage rack.

[0012] Texture duplication means that a texture present on a first surface is transferred to a second surface without altering or damaging the first surface. In the context of this application, texture is any kind of three-dimensional structure present on the first surface. The term “texture” does not relate to molecular properties of the surface, including features such as color or adhesion behavior. The term “texture” refers to a surface texture, or possibly a surface topology, that includes random or periodically structured deviations from an ideal, perfectly flat plane. Another expression for those skilled in the art is relief texture. Texture may be in the micrometer or nanometer range. Texture may have optical properties and, depending on its size range, may be called optical micron or nanotexture. Texture may have tactile properties. Texture may be a flat surface.

[0013] Throughout this application, the term “imprint texture” is used for textures used to create a texture on a substrate. In the sense of the process as used in this application, this means that an imprint texture is the inverse of a texture on a substrate, and therefore an opening in a texture is a raised area in an imprint texture, and a raised area in a texture is an opening in an imprint texture. Thus, an imprint texture is analogous to the texture of a traditional seal that is pressed into molten wax or lacquer.

[0014] In the replication method according to this application, the texture of the first surface can be transferred to one or more second surfaces by an intermediate imprint texture, which is the inverse of the texture to be replicated. The replicated texture on the second surface has different properties from the texture on the first surface. The three-dimensional structures on the first and second surfaces will be the same, but the three-dimensional structure on the second surface may be made of a different material than the three-dimensional structure on the first surface. Throughout the remainder of this application, the first surface will be referred to as the "master," and the second surface as the "substrate."

[0015] The substrate for the imprint process may be any material that can be coated with the first resin and can withstand the pressure of the roll-to-plate process. Furthermore, the substrate material is required to be compatible with the first resin. In one embodiment, the substrate may be a rigid plate. In one embodiment, the substrate may be a glass plate. In one embodiment, the substrate may be a metal plate. In one embodiment, the substrate may be a resin plate. In one embodiment, the substrate may be a plate made from a composite material. In one embodiment, the substrate may be a plastic sheet or plastic foil.

[0016] The substrate is coated with a first resin. This first resin can be applied by different methods, such as spin coating, dispensing coating, slot die coating, screen printing, gravure printing, slit coating, or inkjet printing. Alternatively, instead of applying the first resin to the substrate, the first resin can be applied to an imprint texture and transferred to the substrate by the imprint texture. In one embodiment, the first resin can be solidified by applying heat and / or UV light. In one embodiment, the first resin exhibits low adhesion to the material of the imprint texture. In one embodiment, the first resin may be a polymer containing monomers and / or oligomers, such as epoxides, thiols, polyvinyl resins, acrylates, methacrylates, polyethers, vinyl ethers, acrylic urethanes, polyesters, fluorinated acrylates, fluorinated methacrylates, fluorinated polyethers, siloxanes, siloxane-acrylates, or mixtures thereof. In one embodiment, the first resin may contain an active agent for initiating solidification, such as a radical initiator, a cationic initiator, or an anionic initiator. Suitable initiators are known to those skilled in the art. Possible radical initiators are azo compounds such as azobisisobutyronitrile, peroxides such as dibenzoyl peroxide or peroxodisulfate, phosphine oxides such as diphenylphosphine oxide, aromatic ketones such as 1-hydroxycyclohexylphenyl ketone or 2-hydroxy-2-methylpropiophenone, or Norish type II initiators such as methylbenzoyl formate. Possible cationic and anionic initiators are benzenesulfonic acid esters, alkylsulfonium salts, or photobase generators, e.g., triphenylsulfonium (cation), tetrafluoroborate, or 2-nitrobenzyl cyclohexylcarbamate (anion). Depending on the initiator, solidification may be initiated either thermally or by, for example, UV radiation.

[0017] A first layer of resin on a substrate is texturized by an imprint texture, which is guided and pressure is applied by a roller. Therefore, when the texture is transferred from the roller to a separate plate, this process is called a "roll-to-plate process".

[0018] The first resin solidifies while in contact with the imprinted texture. The term "solidification" means that a liquid or viscous material is exposed to conditions that initiate a chemical reaction within the resin, thereby resulting in the formation of a solid material, for example, through polymerization. This type of material change is also known to those skilled in the art by the term "curing."

[0019] To solidify the first resin, all solidification techniques known to those skilled in the art, such as thermal solidification or radiation solidification, may be used. Depending on the selected solidification technique, the first resin may contain a radical initiator, a cationic initiator, or an anionic initiator. Thermal solidification may be carried out by heating the first resin to a temperature at which the radical initiator or cationic initiator decomposes to form radicals or cations capable of initiating a polymerization reaction. Heating may be carried out in a furnace or, for example, by a source of infrared radiation. Radiation solidification is carried out by exposing the first resin to visible light or ultraviolet radiation. Exposure to light causes the radical initiator or cationic initiator to decompose and release radicals or cations capable of initiating a polymerization reaction. Radiation solidification requires a radiation source, such as a lamp or UV lamp. The radiation from the radiation source must be able to penetrate the medium surrounding the first resin, meaning that either or both of the substrate or imprint texture must be transparent to the radiation from the radiation source.

[0020] After the first resin has solidified, the imprint texture is separated from the solidified resin. The solidified resin adheres to the substrate, forming a texturized layer on the substrate which is the opposite image of the imprint texture. As those skilled in the art will understand, in the roll-to-plate process, the depressions of the imprint texture are transferred as raised areas within the texturized resin.

[0021] The steps of providing the substrate, providing the first resin to the substrate, texturing the substrate with the imprint texture, and solidifying the first resin may be performed whenever texture replication is required. The upper limit of the repetition of the steps is the mechanical life of the imprint texture, and the imprint texture must be replaced if it is damaged or shows signs of wear that otherwise affect the imprint result.

[0022] A master is typically a rigid, flat, planar plate made of a durable material. In one embodiment, the master may be made of a metal such as steel, nickel, copper, or aluminum. In one embodiment, the master may be silicon, quartz, or glass. In one embodiment, the master may be a plastic foil or a plastic sheet. The master has a texture to be replicated using the method according to the present invention. The texture to be replicated can be engraved on the surface of the master by any engraving technique such as milling. Other master processing techniques include, but are not limited to, laser ablation, grayscale lithography, waferscale lithography, and etching.

[0023] To facilitate the separation of the carrier having the imprinted texture from the master, the master may be treated with a non-adhesive agent before being supplied to the plate-to-roll process. Possible non-adhesives may be low-viscosity silicone oils, paraffin oils, fatty oils, fatty acids, siloxanoic acids or fluorinated phosphonic acids, or aliphatic silanes, siloxanesilanes or fluorinated silanes. For the plate-to-roll process to be carried out properly, it is necessary that the non-adhesive agent and the second resin do not mix with each other. However, the non-adhesive agent may remain on the surface of the imprinted texture formed by solidifying the second resin, giving it non-adhesive properties, and they may be useful for carrying out the roll-to-plate process because they facilitate the separation of the imprinted texture from the solidified first resin. The non-adhesive agent may be applied by any technique known in the art, such as printing, spin coating, spray coating, dipping, kiss-roll or vapor deposition.

[0024] The textured surface of the master may have a surface free energy of up to 35 mN / m. In one embodiment, the surface free energy of the textured surface of the master is up to 25 mN / m or up to 15 mN / m.

[0025] A second resin is provided to a master before carrying out the plate-to-roll process according to the present invention. In one embodiment, the second resin can be solidified by applying heat and / or radiation. In one embodiment, the second resin exhibits low adhesion to the master material. In one embodiment, the second resin may be a polymer containing monomers and / or oligomers, such as epoxides, thiols, polyvinyl resins, acrylates, methacrylates, polyethers, vinyl ethers, acrylic urethanes, polyesters, fluorinated acrylates, fluorinated methacrylates, fluorinated polyethers, siloxanes, siloxane-acrylates, or mixtures thereof. In one embodiment, the second resin may contain an active agent for initiating solidification, such as a radical initiator, a cationic initiator, or an anionic initiator. Suitable radical initiators are known to those skilled in the art. Possible radical initiators include azo compounds such as azobisisobutyronitrile, peroxides such as dibenzoyl peroxide or peroxodisulfate, phosphine oxides such as diphenylphosphine oxide, aromatic ketones such as 1-hydroxycyclohexylphenyl ketone or 2-hydroxy-2-methylpropiophenone, or Norish type II initiators such as methylbenzoyl formate. Possible cationic and anionic initiators include benzenesulfonic acid esters, alkylsulfonium salts, or photobase generators, such as triphenylsulfonium (cation), tetrafluoroborate, or 2-nitrobenzyl cyclohexylcarbamate (anion). Depending on the initiator, solidification may be initiated either thermally or by, for example, UV radiation. The second resin may have inherent non-adherent properties. This means that the resin requires no post-treatment after curing and is ready to use itself to produce imprints. Non-adhesion properties are achieved through the correct combination of low surface free energy materials (e.g., perfluoropolyether (PFPE) monomers, perfluorinated monomers, silicone monomers and / or aliphatic monomers, among others), process conditions, and master material.The inherent non-adhesive properties of the second resin may be either compatible with the master material or compatible with the non-adhesive coating of the master.

[0026] In the context of the present application, the carrier may be a flexible rectangular sheet of material, such as a foil, laminate or cloth. The carrier may have a front side and a back side. In one embodiment, the carrier is a foil comprising polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyimide or glass. In one embodiment, the carrier may be a laminate of several foils of the same or different polymeric materials, or a laminate of a plastic foil and a thin glass panel or a thin metal sheet. In one embodiment, the dimensions of the carrier are selected so as to be able to completely cover the area of the master to be textured, for example both the width and the length of the carrier are at least the same as the width and the length of the area to be textured within the master. In one embodiment, the width and the length of the carrier are greater than the width and the length of the master. If the first resin and / or the second resin are cured by light or UV radiation, the carrier may be transparent to visible and / or UV radiation. If the first resin and / or the second resin are thermally cured, it is required that the mechanical properties of the carrier do not change at the curing temperature.

[0027] The carrier contacts a second resin layer on the master. This second resin can be applied by different methods, such as spin coating, dispensing coating, slot die coating, screen printing, gravure printing, slit coating, or inkjet printing. Instead of applying the second resin to the master, the second resin can also be applied to the carrier, and then the second resin can be supplied to the master when the carrier and master come into contact. The carrier contacts the second resin so that the carrier covers the layer of second resin on the master, the master is positioned beneath the carrier, and the second resin solidifies while the layer of second resin is positioned between the carrier and the master. The surface of the carrier in contact with the resin may be the front surface. Since the master is a plate and the carrier can be guided by rollers, the process of bringing the carrier into contact with the second resin is called a "plate-to-roll" process. The second resin solidifies while in contact with both the master and the carrier, so it adheres to the carrier simultaneously and takes over the image of the master and the opposite image during solidification, so that, for example, a depression on the master becomes a bulge in the solidified resin. In this way, an imprint texture for the roll-to-plate process is formed. Thus, the plate-to-roll process is analogous to the formation of a dental impression, in which the opposite image is pressed into a soft material, which after solidification serves as a mold for forming a dental model, such as a plaster cast. The fundamental difference between the imprint texture according to this application and a dental impression is that the imprint texture is intended to produce one more imprint result.

[0028] To solidify the second resin, any solidification technique known to those skilled in the art may be used, such as thermal solidification or radiation-induced solidification. Depending on the selected solidification technique, the second resin may contain a radical initiator, a cationic initiator or an anionic initiator. Thermal solidification may be carried out by heating the second resin to a temperature at which the radical initiator or cationic initiator decomposes to form radicals capable of initiating a polymerization reaction. The heating may be carried out in a furnace or by, for example, a source of infrared radiation. Solidification by radiation is carried out by exposing the second resin to light by means of ultraviolet radiation. By exposure to light, the radical initiator, cationic initiator or anionic initiator decomposes and releases radicals, cations or anions respectively capable of initiating a polymerization reaction. For radiation-induced polymerization, a source of radiation such as a lamp or a UV lamp is required. It is further necessary that the radiation from the source of radiation can penetrate the medium surrounding the second resin, which means that either or both of the master or the carrier must be transparent to the radiation from the source of radiation.

[0029] After solidification of the second resin, the carrier and the layer of solidified second resin adhering thereto are separated from the master. <*

[0030] In embodiments of the method of the present invention, the solidification of the first resin and the solidification of the second resin may be carried out using the same thermal and / or radiation conditions. This requires that the first resin and the second resin may contain the same or similar radical initiator. By solidifying the first resin and the second resin using the same thermal or radiation conditions, the structure of the apparatus for carrying out the process according to the present invention can be simplified, and the process itself can be made particularly efficient. It may only require, for example, one lamp, UV lamp, furnace, or infrared radiation source, and when changing from a plate-to-roll process to a roll-to-plate process, it may not be necessary to change the process parameters of the lamp, UV lamp, furnace, or infrared radiation source, such as wavelength, intensity, and / or even temperature. Furthermore, there is no need to wait for adaptation to changed parameters such as temperature.

[0031] In one embodiment, the process of texturing the first resin and the process of texturing the second surface have an imprint speed of 0.05 m / min to 10 m / min. In another embodiment, the process of texturing the first resin and the process of texturing the second resin have an imprint speed of 0.1 m / min to 5 m / min. If the process of texturing the first resin and the process of texturing the second resin can be performed at the same imprint speed, then the method according to the present invention can be implemented particularly efficiently because there is no need to change the process parameters when switching from the process of texturing the first resin to the process of texturing the second resin, or vice versa. This allows for a simple structure for the apparatus that implements the method according to the present invention.

[0032] The roll-to-plate process and the plate-to-roll process may be carried out using at least one identical roller. At least one identical roller may be part of an apparatus capable of carrying out both the plate-to-roll process and the roll-to-plate process. At least one roller may have a cylindrical shape. At least one roller may be made from any suitable material known to those skilled in the art, such as metal, particularly steel; ceramic material, such as porcelain; glass; rubber; or polymer material. At least one roller may be equipped with means for heating or cooling the surface of at least one roller. At least one roller may be equipped with means for applying a return force. The surface of at least one roller may be smooth. The surface of at least one roller may be textured.

[0033] In one embodiment, there is no fixed connection between the imprint texture and the roller. Even if the imprint texture is not fixed to the roller, the roller may apply pressure to the imprint texture and guide it.

[0034] The imprint texture used in the roll-to-plate process may be part of a flexible stamp. In particular, the flexible stamp may comprise a carrier obtained in the plate-to-roll process and a solidified second resin. The flexible stamp may be produced in the plate-to-roll process and used in the roll-to-plate process. The flexible stamp may be in contact with at least one roller. The flexible stamp does not require further processing between the plate-to-roll process and the roll-to-plate process according to the present invention. After the completion of the plate-to-roll process according to the present invention, the flexible stamp may be immediately ready for use in the roll-to-plate process according to the present invention. It is not necessary to remove the flexible stamp from the apparatus between the plate-to-roll process and the roll-to-plate process according to the present invention, thereby allowing both the plate-to-roll process and the roll-to-plate process to be carried out in a single apparatus. This means that, from a procedural standpoint, the process for replicating textures according to the present invention may be carried out in such a way that the master and the substrate can be provided to the process in the same way, in the same direction, and in the same orientation, without the need to create any differences between them. In one embodiment, the master and the substrate move within the same plane. Literally speaking, there may be no difference between the master and the substrate in the apparatus for carrying out the process according to the present invention, and the apparatus can operate with exactly the same procedural parameters regardless of whether the master is provided for a plate-to-roll process or the substrate is provided for a roll-to-plate process.

[0035] In one embodiment, the carrier and the imprinted texture together form a flexible stamp. In one embodiment, contact between the carrier and / or flexible stamp on one side and at least one roller on the other side is by friction. In one embodiment, contact between the carrier and / or flexible stamp on one side and at least one roller on the other side is by adhesion. In one embodiment, contact between the carrier and / or flexible stamp on one side and at least one roller on the other side is by contact between the texture on the back surface of the carrier and / or flexible stamp and the texture on the roller. The texture on the back surface of the carrier and / or flexible stamp and the texture on the roller may correspond to each other in the form of gears. In one embodiment, at least one roller may be moved by the carrier and / or flexible stamp.

[0036] The carrier and / or flexible stamp may be in contact with at least one driven belt. This contact may be made using, for example, tape, screws, clamps and / or rope. The belt may form a loop. The belt may be connected to one or more driven pulleys that move the belt. The moved belt may move the flexible stamp and / or carrier.

[0037] The carrier and / or flexible stamp may be in contact with at least one second roller. The carrier and / or flexible stamp may be in contact with different rollers simultaneously. The functions achieved by the first and second rollers during the imprint process may be different. In one embodiment, both at least one first roller and at least one second roller apply pressure to the carrier and / or flexible stamp.

[0038] If the master and the substrate have the same thickness, the process for replicating the texture according to the present invention may be carried out using prior art equipment designed to perform only roll-to-plate processes.

[0039] The present invention further relates to an apparatus for replicating texture, comprising: at least a first flexible rectangular sheet of material having a front side and a back side; at least one roller mounted on a mount; a sliding means suitable for sliding an article through the apparatus; a gap between the sliding means and the at least one roller; and at least one driven belt connected to the flexible rectangular sheet of material, which is capable of moving the back side of the flexible rectangular sheet of material on the roller and moving the front side between the roller and the sliding means, wherein the mount comprises means for adjusting the gap between the sliding means and the at least one roller.

[0040] In one embodiment, means for changing the size of the gap and / or means for applying pressure can change the size of the gap while the device is operating, meaning that the size of the gap can be changed without having to stop the device or even partially disassemble it.

[0041] In one embodiment, means for changing the size of the gap and / or means for applying pressure can change the size of the gap by 10 mm.

[0042] In one embodiment, the gap is suitable for both the master and the substrate of the process according to the present invention to pass through.

[0043] A flexible rectangular sheet of material may function as a carrier used to carry out the method for replicating textures according to the present invention. According to the method, the carrier may become part of a flexible stamp during a plate-to-roll process and may be used to replicate a structure in a roll-to-plate process.

[0044] In one embodiment, the sliding means may be capable of moving or transporting a master or substrate by the method according to the present invention under at least one roller. This allows the sliding means to apply counterpressure to at least one upper roller during the imprint process. In one embodiment, the sliding means is a conveyor belt with counterpressure rollers. In one embodiment, the sliding means is a plate that slides under at least one roller, applying counterpressure to a master and / or substrate placed on this plate.

[0045] In one embodiment, the sliding means may be capable of moving both the master and the substrate of the process according to the present invention under at least one roller.

[0046] Means for adjusting the size of the gap and / or for applying pressure may be a movable stage, which, in combination with a sliding means or with a lower third roller that moves below or above the plate, moves at least one roller.

[0047] In one embodiment, the means for adjusting the size of the gap and / or for applying pressure may comprise at least one screw. In one embodiment, the screw is a spindle.

[0048] In another embodiment, the means for adjusting the size of the gap and / or for applying pressure is a wedge, which is optionally moved laterally by a screw or spindle.

[0049] In one embodiment, means for adjusting the size of the gap and / or for applying pressure may include a hydraulic cylinder.

[0050] In one embodiment, means for adjusting the size of the gap and / or for applying pressure may include a pneumatic cylinder.

[0051] In one embodiment, means for adjusting the size of the gap and / or means for applying pressure may include a linear motor.

[0052] While adjusting the gap size and applying pressure can be done simultaneously, in one embodiment, these are applied separately.

[0053] As is known to those skilled in the art, the thicknesses of the master and substrate may differ, and different substrates imprinted with the same imprint pattern may have different thicknesses. The use of masters and substrates of different thicknesses is not possible with prior art apparatus. Therefore, setting different gaps almost certainly requires readjusting the pressure, and this can be linked to a means for applying pressure.

[0054] As far as clearance adjustment is concerned, and since the rollers are mounted on roller shaft holders (or rotor mounts), the mounts can move up and down to change the clearance between the rollers and the conveyor belt. Typically, this is done by a spindle, wedge, motor, hydraulic system, or pneumatic system.

[0055] Regarding pressure regulation, in some embodiments, counter pressure can be used, which means the counter pressure that the substrate faces as it passes over the roller. The substrate pushes the roller upwards. The (counter) roller pressure pushes the roller downwards. This can be achieved by springs, spindles, motors, pneumatic systems, hydraulic systems, etc.

[0056] This application also relates to products having a textured surface obtained by the method of this application. For example, the product may be a tactile layer or a light management layer for solar, display, biomedical, architectural, or lighting applications. [Brief explanation of the drawing]

[0057] [Figure 1]This figure shows the first process of the present invention, in which a master having a texture on its surface and provided with a second resin is transported into the apparatus on a conveyor belt. [Figure 2] This figure shows the subsequent steps in the process according to the present invention, after Master 1 has already passed through the apparatus. [Figure 3] This figure shows a further subsequent step in the process according to the present invention, in which the first substrate 5 has passed through the apparatus with a layer of solidified and textured first resin 6A on its surface. [Modes for carrying out the invention]

[0058] The drawings show a process according to the present invention as carried out in an apparatus according to the present invention. The apparatus comprises a first roller 10, a second roller 11, a guide roller 12, a driven belt 7 to which a carrier 3 is connected, and a UV lamp 4. The first roller is mounted (13) and includes means (14) for adjusting the size of the gap and means (15) for applying pressure to the roller. Furthermore, the apparatus comprises a conveyor belt 9 having a lower third roller 8.

[0059] Figure 1 shows the initial process of the present invention, in which a master 1 having a textured surface and provided with a second resin 2 is transported into the apparatus on a conveyor belt 9. A first substrate 5 having a layer of the first resin 6 on its surface is transported behind the master 1.

[0060] Figure 2 shows the subsequent steps of the process according to the present invention after the master 1 has already passed through the apparatus. The second resin is transferred from the surface of the master onto the carrier. The second resin becomes solidified second resin 2A, forming an imprint texture. The carrier 3 and the imprint texture 2A form a flexible stamp with each other. The first substrate 5, having a layer of the first resin 6 on its surface, is approaching the apparatus, while the second substrate 5', having a layer of the first resin on its upper surface, is being transported behind the first substrate 5.

[0061] Figure 3 shows a further subsequent step in the process according to the present invention, in which the first substrate 5 has passed through the apparatus with a layer of solidified and textured first resin 6A on its surface. A second substrate 5', also having a layer of the first resin 6 on its surface, is approaching the apparatus. Behind the second substrate 5', a third substrate 5'', also having a layer of the first resin on its surface, is being transported toward the apparatus.

Claims

1. A method for continuously duplicating textures, a. The step of providing substrates (5), (5'), and (5''), b. The step of providing the first resin (6) to the substrate, c. The first resin is texturized by applying a roll-to-plate process to create an imprint texture (2A), d. A step of solidifying the first resin (6A), Includes, Steps a) through d) are repeated each time the texture needs to be duplicated, Prior to the replication process, i. A step of providing a master (1) having a texture to be duplicated, wherein the texturing surface of the master has a maximum surface free energy of 35 mN / m, ii. The step of providing the second resin (2) to the master, iii. Steps to provide a career (3), iv. To texturize the second resin (2), a plate-to-roll process is applied to bring the master (1) and the carrier (3) into contact with the second resin (2) between them; v. The step of solidifying the second resin to obtain the imprint texture (2A) of step c), The following was implemented: Furthermore, the method is characterized in that, while step c) is being performed, the substrate is moving in the same plane as the master while step iv) is being performed.

2. Step b) is performed by providing the first resin to the imprint texture, then bringing the imprint texture having the first resin into contact with the substrate, and / or providing the second resin to the carrier, then bringing the carrier having the resin into contact with the master, thereby providing the second resin to the master, according to claim 1.

3. The method according to claim 1 or 2, wherein the solidification of the first resin (6) and the second resin (2) is carried out under the same thermal and / or radiation conditions.

4. The method according to any one of claims 1 to 3, wherein the master (1) is treated with a non-adhesive agent before being provided.

5. The method according to any one of claims 1 to 4, wherein the steps of texturing the first resin (6) and texturing the second resin (2) have an imprint speed of 0.05 m / min to 20 m / min, more preferably 0.1 m / min to 10 m / min.

6. The method according to any one of claims 1 to 5, wherein the first resin (6) and the second resin (2) are independently selected from polymer types, such as epoxides, thiols, polyvinyl resins, acrylates, methacrylates, polyethers, fluorinated acrylates, fluorinated methacrylates, fluorinated polyethers, siloxanes, siloxane-acrylates, or mixtures thereof.

7. The method according to any one of claims 1 to 6, wherein the roll-to-plate process and the plate-to-roll process are carried out using the same at least one roller (10).

8. The method according to any one of claims 1 to 7, wherein the imprint texture (2A) is part of a flexible stamp.

9. The method according to claim 8, referencing claim 7, wherein the carrier (3) and / or the flexible stamp is in contact with at least one second roller (11), and the carrier (3) and / or the flexible stamp are in frictional contact with different rollers simultaneously.

10. A device for duplicating textures, i) At least a first flexible rectangular sheet of material having a front surface and a back surface, ii) At least one roller (10) attached to the mount (13), iii) A sliding means suitable for sliding an article through the device, iv) The gap between the sliding means and the at least one roller (10), v) At least one driven belt connected to a flexible rectangular sheet of the material, which can move the back side of the flexible rectangular sheet of the material on the roller and move the front side between the roller (10) and the sliding means, Equipped with, The mount comprises means (14) for adjusting the gap between the sliding means and the at least one roller, and / or means (15) for applying pressure.

11. The apparatus according to claim 10, wherein the means for adjusting the gap includes a spindle, a wedge, a motor, a hydraulic system, or a pneumatic system.

12. The apparatus according to claim 10, wherein the means (15) for applying pressure includes a hydraulic system, a pneumatic cylinder, a spindle, a wedge, a spring and / or a linear motor.

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