Differentially Patterned Microstructured Articles via Masked Irradiation
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Solution Overview
Problem
Conventional methods for replicating patterns on surfaces are limited, requiring different molding tools for each pattern configuration and being costly and time-consuming.
Innovation Solution
A method using radiation curable resins and patterned irradiation techniques, such as masked light-emitting diodes or lasers, to create microstructured articles with differentially patterned regions without modifying the molding tool, allowing for various patterns to be replicated from a single tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional replication methods are used with different molding tools for each pattern configuration, then manufacturing precision is maintained, but device complexity and production cost increase
Solution Approach 1:
A single molding tool with microstructured surface is used to replicate multiple different patterns by varying the irradiation conditions (patterned vs. non-patterned, different wavelengths, different exposure times). This multi-functional approach eliminates the need for multiple specialized molding tools while maintaining pattern replication precision through controlled radiation curing of the composition.
Solution Approach 2:
The invention changes the irradiation parameters (pattern configuration, wavelength, intensity, exposure time) to generate different patterns from the same molding tool. By adjusting these parameters, the same microstructured tool can produce various patterns including transparent, translucent, and opaque regions with different optical and mechanical properties.
2Adaptability or versatility
If different molding tools are used for different pattern configurations, then pattern diversity is achieved, but productivity decreases due to tool changes and setup time
Solution Approach 1:
The single multi-functional molding tool can produce diverse patterns without requiring physical tool changes or reconfiguration. The tool maintains constant contact with the composition while the irradiation parameters are dynamically adjusted to create different patterns, significantly improving production speed and eliminating setup time associated with tool changes.
Solution Approach 2:
The invention introduces dynamic control of the irradiation system to adapt the patterning process in real-time. By dynamically adjusting the irradiation pattern, wavelength, and exposure parameters during the curing process, the system can switch between different pattern configurations without physical tool changes, enhancing both versatility and productivity.
3Adaptability or versatility
If multiple molding tools are used for different patterns, then optical property differentiation is achieved, but manufacturing cost increases
Solution Approach 1:
The single molding tool approach eliminates the need to manufacture, store, and maintain multiple specialized tools for different optical patterns. The same tool produces articles with varied optical properties (transparent, translucent, opaque regions) by controlling the irradiation parameters, significantly reducing manufacturing costs while maintaining full versatility.
Solution Approach 2:
Instead of creating multiple physical tools, the invention uses light patterns (optical copies) to define the different regions in the cured composition. The irradiation pattern acts as a template that copies the desired pattern configuration into the material without requiring a physical mold for each pattern type.
4Adaptability or versatility
If patterned irradiation is applied to create differentially cured regions, then functional differentiation is achieved, but process complexity increases
Solution Approach 1:
The invention uses a mask or patterned irradiation source as an intermediary to translate complex pattern requirements into controlled radiation exposure. This intermediary component simplifies the overall system by providing a straightforward method to create differentially cured regions without requiring complex multi-axis positioning or multiple irradiation sources.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the rapid and cost-effective production of microstructured articles with diverse optical, mechanical, or adhesive properties by varying the irradiation patterns, expanding the range of possible patterns without tool modification.
Implementation Method 1
exposing the radiation curable resin to a first, patterned irradiation to provide a correspondingly patterned partially cured resin comprising at least one first region and at least one second region, wherein the at least one first region is irradiated by the first, patterned irradiation and the at least one second region is not irradiated by the first, patterned irradiation
Implementation Method 2
exposing both the at least one first region and the at least one second region to a second irradiation to provide an article having a microstructured surface and a differentially cured pattern therein
Data Source
Figure 1A~1C
Figure 1D~1F
Figure 2
AI summary
Methods for making differentially pattern cured microstructured articles are disclosed, using a molding tool having a microstructured surface, a patterned irradiation to generate irradiate and non-irradiated regions in a radiation curable resin. Different combinations of molding tools and patterned irradiation provide numerous variants of differentially pattern cured microstructured articles without requiring costly modification of the molding tools.