METHOD OF FABRICATING MICRO STRUCTURED SURFACES WITH ELECTRICALLY CONDUCTIVE PATTERNS
A method comprises forming a first pattern on a first flat surface and forming an inverse of the pattern on a second flat surface. The method further comprises attaching the second flat surface to a roller to produce an embossing tool and applying pressure between the embossing tool and a substrate thereby forming a second pattern in the substrate. The substrate is coated with a radiation curable resin material. The method also comprises transferring ink to the substrate, the ink containing a catalyst, and coating the substrate with the second pattern in an electroless plating bath. The first pattern alternatively may be formed on a sleeve which is then attached to a drum/roller.
1 . A method, comprising:
forming a first pattern on a first flat surface;
forming an inverse of the pattern on a second flat surface;
attaching the second flat surface to a ropier to produce an embossing tool;
applying pressure between the embossing tool and a substrate thereby forming a second pattern in the substrate, wherein the substrate is coated with a radiation curable resin material; and
coating the substrate with the second pattern in an electroless plating bath.
2 . The method of claim 1 wherein the radiation curable resin material does not include an organometallic compound and the method further comprises transferring a catalyst-based ink onto the substrate before coating the substrate in the electroless plating bath.
3 . The method of claim 1 further comprising transferring a catalyst-based ink onto the substrate before coating the substrate in the electroless plating bath.
4 . The method of claim 1 , wherein the radiation curable resin material comprises an organometallic compound.
5 . The method of claim 1 further comprising curing the substrate with the second pattern to produce a cured structure on the substrate,
6 . The method of claim 5 wherein coating the substrate comprises coating the cured structure on the substrate.
7 . The method of claim 1 further comprising applying pressure between the embossing tool and the substrate.
8 . A method, comprising:
forming a first pattern on a first flat surface;
forming an inverse of the pattern on a second flat surface;
attaching the second flat surface to a roller to produce an embossing tool;
applying pressure between the embossing tool and a substrate thereby forming a second pattern in the substrate, wherein the substrate is coated with a radiation curable resin material;
transferring ink to at least a portion of the substrate, said ink containing a catalyst; and
coating the substrate with the second pattern in an electroless plating bath.
9 . The method of claim 8 wherein the radiation curable resin material does not include an organometallic compound.
10 . The method of claim 8 further comprising curing the substrate.
11 . A method, comprising:
creating a photomask;
applying the photomask to a flexographic plate;
exposing the photomask and flexographic plate to radiation to produce a printing plate based on said flexographic plate; and
transferring a catalyst-based ink to the printing plate.
12 . The method of claim 11 further comprising transferring ink from the printing plate to a film.
13 . The method of claim 12 further comprising curing said film.
14 . The method of claim 13 further comprising coating the film in an electroless plating bath.
15 . The method of claim 11 wherein applying the photomask to the flexographic plate comprises laminating the photomask to the flexographic plate.
16 . A method, comprising forming a first pattern on a sleeve;
mounting said sleeve around a drum thereby forming an embossing tool;
applying pressure between the embossing tool and a substrate thereby forming a second pattern in the substrate, wherein the substrate is coated with a radiation curable resin material; and
coating the substrate with the second pattern in an electroless plating bath.
17 . The method of claim 16 wherein mounting said sleeve around said drum comprising creating a temperature differential between said sleeve and drum.