APPARATUS AND PROCESS FOR REPLICATING A TEXTURE

Abstract

A process is for replicating a texture. A method continuously produces a flex stamp and applies the flex stamp in texturing a resin by combination of a roll-to-plate and a plate-to-roll process. An apparatus is suited for the continuous process.

Claims

1. Method for continuously replicating a texture comprising the steps of: a. providing a substrate, b. providing a first resin to the substrate, c. texturing the first resin by an imprint texture applying a roll-to-plate process, d. consolidating the first resin, with steps a to d being repeated as often as replications of the texture are needed, prior to the replicating process the steps of:  i. providing a master with a texture to be replicated with the textured surface of the master having a surface free energy of at most 35 mN/m,  ii. providing a second resin to the master,  iii. providing a carrier,  iv. bringing the master and carrier in contact with the second resin in between for texturing the second resin by applying a plate-to-roll process,  v. consolidating the second resin to obtain the imprint texture of step c, are carried out; and while carrying out step c, the substrate is moving in the a same plane as the master while carrying out step iv.

2. The method of claim 1, wherein step b is carried out by providing the first resin to the imprint texture and afterwards bringing the imprint texture with the first resin in contact with the substrate and/or the second resin is provided to the master by providing the second resin to the carrier and afterwards bringing the carrier with the resin in contact with the master.

3. The method of claim 1, wherein the consolidating of the first resin and the second resin is carried out under the same thermal and/or radiation conditions.

4. The method of claim 1, wherein the master is treated with an anti-stick agent prior to being provided.

5. The method of claim 1, wherein the steps of texturing the first resin as well as the step of texturing the second resin have an imprint speed of between 0.05 m/min and 20 m/min.

6. The method of claim 1, wherein the first resin and the second resin are independently selected from a polymer type selected from the group consisting of: epoxides, thiols, polyvinyl resins, acrylates, methacrylates, polyethers, fluorinated acrylates, fluorinated methacrylates, fluorinated polyethers, siloxanes, siloxane-acrylates or blends thereof.

7. The method of claim 1, wherein the roll-to-plate process and the plate-to-roll process are carried out using a same at least one roller.

8. The method of claim 1, wherein the imprint texture is part of a flexible stamp.

9. The method of claim 7, wherein the at least one roller is moved by the carrier.

10. The method claims 9 wherein the carrier and/or the flexible stamp are contacting at least one second roller and the carrier and/or the flexible stamp are in frictional contact with different rollers at a same time.

11. An apparatus for replicating a texture comprising: i) at least a first flexible rectangular sheet of material having a front surface and a rear surface, ii) at least one roller mounted in a mount, iii) sliding means for sliding goods through the apparatus, iv) a gap between the sliding means and the at least one roller, v) at least one driven belt connected with the flexible rectangular sheet of material and capable of moving the flexible sheet of material with the rear surface over the roller and the front surface 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 and/or means for exerting pressure.

12. The apparatus of claim 11, wherein the means to adjust the gap comprises a spindle, a wedge, a motor, a hydraulic system or pneumatic system.

13. The apparatus according to claim 11, wherein the means to exert pressure comprises a hydraulic system, a pneumatic cylinder, a spindle, a wedge, a spring, and/or a linear motor.

14. A flexible stamp with a textured surface obtained in a method according to claim 1.

15. The method of claim 1, wherein the steps of texturing the first resin as well as the step of texturing the second resin have an imprint speed of between 0.1 m/min and 10 m/min.

16. The method of claim 7, wherein the at least one roller is moved by the carrier by frictional contact.

Description

DESCRIPTION OF FIGURES

[0060] The figures show the process according to the application carried out in an apparatus according to the invention. The apparatus comprises a first roller 10, a second roller 11 and guidance rollers 12, a driven belt 7 with a carrier 3 connected to the belt and a UV lamp 4. The first roller is mounted in a mount (13) and equipped with means to adjust the size of the gap (14) as well as means to exert pressure on the roller (15). Furthermore, the apparatus comprises a conveyor belt 8 which is equipped with third lower rollers 8.

[0061] FIG. 1 shows the process of the application on its very beginning with a master 1 with a texture on its surface and a second resin 2 being provided to the master is conveyed on the conveyor belt 9 into the apparatus. A first substrate 5 with a layer of first resin 6 on its surface is conveyed after the master 1.

[0062] FIG. 2 shows a later step of the process according to the application where the master 1 has already left the apparatus. The second resin has been transferred from its surface onto the carrier where it has turned into a consolidated second resin 2A forming an imprint texture. The carrier 3 and the imprint texture 2A together form a flexible stamp. A first substrate 5 with a layer of first resin 6 on its surface is approaching the apparatus while a second substrate 5′ with a layer of first resin on top is conveyed after the first substrate 5.

[0063] FIG. 3 shows an even later step of the process according to the application where the first substrate 5 has left the apparatus with a consolidated and textured layer of first resin 6A on its surface. The second substrate 5′ with a layer of first resin 6 on its surface is approaching the apparatus. Behind the second substrate 5′ a third substrate 5″ with a layer of first resin on its surface is conveyed to the apparatus.