Embossing Mold Composite for Accurate Microstructure Transfer

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Solution Overview

Problem

Existing methods for transferring embossed structures, particularly in the micrometer and nanometer range, suffer from inadequate replication accuracy, loss of modulation depth, and poor separation of the embossing mold from the cured coating, often requiring aging and leading to decreased mold filling and adhesion issues.

Innovation Solution

A method involving a composite of a substrate and a partially embossed, partially cured radiation-curable coating composition, comprising specific weight percentages of crosslinkable polymers, reactive diluents, photoinitiators, and additives, allows for high replication accuracy and successful transfer of microstructures and nanostructures without loss of modulation, with improved adhesion and separation characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional embossing methods are used to transfer microstructures and nanostructures, then the embossed structures can be formed on the coating surface, but the replication accuracy deteriorates and modulation depth is lost

Engineering Contradiction:

Improvereplication accuracyVSAvoidmold filling quality

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies parameter changes by optimizing the coating composition ratios (crosslinkable polymer 1-45 wt%, reactive diluent 40-95 wt%, photoinitiator 0.01-15 wt%) and curing conditions to achieve complete mold filling and high replication accuracy without loss of modulation depth

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining specific crosslinkable polymers with reactive diluents and photoinitiators in defined proportions to create a coating composition that achieves both complete mold filling and high replication accuracy

Inventive Principle:

Principle #40Composite materials

2Productivity

If the embossing mold is used repeatedly, then productivity increases, but the separation between mold and cured coating deteriorates

Engineering Contradiction:

Improvereusability of embossing moldVSAvoidseparation quality

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by adjusting the chemical composition parameters of the coating to achieve optimal adhesion and separation characteristics, allowing the mold to be reused multiple times while maintaining easy separation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent enables the embossing mold to function as a reusable tool that maintains its separation characteristics across multiple cycles, eliminating the need for frequent replacement or complex cleaning procedures

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If aging is allowed to improve separation, then separation quality improves, but the time required for production increases

Engineering Contradiction:

Improveseparation qualityVSAvoidproduction cycle time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent applies preliminary action by formulating the coating composition with predetermined optimal ratios of crosslinkable polymer, reactive diluent, and photoinitiator that immediately provide good separation characteristics upon curing, eliminating the need for aging time

Inventive Principle:

Principle #10Preliminary action

4Strength

If the coating composition is modified to improve adhesion, then adhesion quality improves, but the replication accuracy deteriorates

Engineering Contradiction:

Improveadhesion strengthVSAvoidreplication accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by precisely controlling the weight percentages of crosslinkable polymer (1-45 wt%), reactive diluent (40-95 wt%), and photoinitiator (0.01-15 wt%) to achieve the optimal balance between adhesion strength and replication accuracy

Inventive Principle:

Principle #35Parameter changes

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

The method enables high-quality replication of embossed structures over large areas with improved mold filling and separation, allowing for reusable embossing molds that maintain replication quality independent of aging, with enhanced adhesion and separation properties.

Implementation Method 1

the coating composition (C1a) is a radiation-curable coating composition

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS20250368830A1Method for transferring an embossed structure to the surface of a coating, and composite employable as embossing mold

Publication Date: 2025.12.04 BASF COATINGS GMBH

AI summary

Disclosed herein is a method for transferring an embossed structure to at least a part of a surface of a coating composition (C2a) using a composite (S1C1) including a substrate (S1) and an at least partially embossed and at least partially cured coating (C1) upon following steps (1), (2-i) and (3-i) or (2-ii) and (3-ii), and also at least step (4) and optionally step (5-i) or (5-ii), where the coating composition (C1a) is a radiation-curable coating composition of defined constitution and the composite (S1C1) is used as embossing mold (e2) of an embossing tool (E2).