Structured thermal transfer donors
View Patent ↗A laser induced thermal imaging (LITI) donor film having a substrate, a light-to-heat conversion layer overlaying the substrate, and a transfer layer overlaying the light-to-heat conversion layer. A surface of the transfer layer includes microstructured or nanostructured features, in a continuous or discontinuous pattern, embossed or otherwise imparted in the transfer layer. The features provide break points to assist in release and transfer of portions of the transfer layer to a permanent receptor in a pattern defined by the features.
1. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate; and
a transfer layer overlaying the light-to-heat conversion layer, wherein a surface of the transfer layer includes a plurality of microstructured or nanostructured features extending into the transfer layer, and wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
placing the LITI donor film against a surface of a permanent receptor such that the transfer layer is in contact with the surface of the receptor; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor in a pattern defined by the features.
2. The method of claim 1 , wherein the providing step includes forming the microstructured or nanostructured features as a continuous pattern.
3. The method of claim 1 , wherein the providing step includes forming the microstructured or nanostructured features as a discontinuous pattern.
4. The method of claim 1 , wherein the microstructured or nanostructured features form a first pattern in the transfer layer, wherein the surface of the receptor has a structure forming a second pattern substantially matching the first pattern, and wherein the placing step includes substantially aligning the first pattern with the second pattern.
5. The method of claim 1 , wherein the transferring step includes transferring fusible elements to the permanent receptor, and further including the step of fusing the fusible elements subsequent to the transferring step.
6. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate; and
a transfer layer overlaying the light-to-heat conversion layer, wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
placing the LITI donor film against a surface of a permanent receptor, wherein a surface of the permanent receptor includes a tool having a plurality of microstructured or nanostructured features extending away from a surface of the tool and wherein the transfer layer is in contact with the microstructured or nanostructured features of the tool; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor having the tool in a pattern defined by the features.
7. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate; and
a transfer layer overlaying the light-to-heat conversion layer, wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
etching perforations or separations in the transfer layer;
placing the LITI donor film against a surface of a permanent receptor such that the transfer layer is in contact with the surface of the receptor; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor in a pattern defined by the perforations or separations.
8. The method of claim 7 , wherein the transfer layer comprises a light emitting material.
9. The method of claim 8 , wherein the transfer layer comprises a phosphor.
10. The method of claim 7 , wherein the transfer layer comprises a semiconducting material.
11. The method of claim 10 , wherein the semiconducting material is light emitting.
12. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate;
a release layer overlaying the light-to-heat conversion layer; and
a transfer layer overlaying the release layer, wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
etching perforations or separations in the transfer layer;
placing the LITI donor film against a surface of a permanent receptor such that the transfer layer is in contact with the surface of the receptor; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor in a pattern defined by the perforations or separations.
13. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate;
a release layer overlaying the light-to-heat conversion layer; and
a transfer layer overlaying the release layer, wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
etching perforations or separations in the transfer layer;
applying an adhesive layer to the transfer layer;
placing the LITI donor film against a surface of a permanent receptor such that the transfer layer is in contact with the surface of the receptor; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor in a pattern defined by perforations or separations.
14. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate; and
a transfer layer overlaying the light-to-heat conversion layer, wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
etching perforations or separations in the transfer layer;
applying an adhesive layer to the transfer layer;
placing the LITI donor film against a surface of a permanent receptor such that the transfer layer is in contact with the surface of the receptor; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor in a pattern defined by perforations or separations.
15. A method of fabricating a microstructured or nanostructured article, comprising:
providing a laser induced thermal imaging (LITI) donor film, comprising:
a substrate;
a light-to-heat conversion layer overlaying the substrate; and
a perforated or separated transfer layer overlaying the light-to-heat conversion layer, wherein the transfer layer comprises an inorganic material, an organometallic material, or a multicomponent transfer unit;
etching perforations or separations in the transfer layer;
placing the LIII donor film against a surface of a permanent receptor such that the transfer layer is in contact with the surface of the receptor; and
selectively transferring at least a portion of the transfer layer to the surface of the permanent receptor in a pattern defined by the perforations or separations.