Roll-to-roll embossing tools and processes
View Patent ↗The invention is directed to a polymer shim and a roll-to-roll process for its manufacture.
1. A process for the preparation of a first generation metal mold which process comprises:
a) forming a polymer shim in a roll continuously on a web;
b) cutting off any defects from the polymer shim and joining the remaining polymer shim which is substantially free of defects;
c) coating a conductive seed layer over the joined polymer shim; and
d) electroforming the first generation metal mold.
2. The process of claim 1 wherein said polymer shim is formed from a composition comprising a thermoplastic polymer.
3. The process of claim 1 wherein said polymer shim is formed from a composition comprising a multifunctional monomer or oligomer.
4. The process of claim 1 wherein said conductive seed layer is a thin layer of silver, nickel or nickel-chrome.
5. The process of claim 4 wherein said conductive seed layer is a thin layer of silver.
6. The process of claim 1 wherein said conductive seed layer is coated by sputtering, physical or chemical vapor deposition, evaporation or electroless plating by reduction reaction.
7. The process of claim 1 wherein said electroforming is performed with a nickel layer.
8. The process of claim 5 further comprising a passivation treatment of the surface of the silver coating.
9. The process of claim 1 wherein said first generation metal mold is flat.
10. The process of claim 1 wherein said first generation metal mold is in the shape of a cylinder.
11. The process of claim 1 further comprising surface treating the polymer shim after step (b).
12. The process of claim 1 further comprising polishing the first generation metal mold.
13. The process of claim 1 wherein the thermoplastic polymer is plasticized by a plasticizer or solvent.
14. The process of claim 11 wherein said surface treating is corona treating, plasma treating, or UV radiating.