Making imprinted multi-layer biocidal particle structure
View Patent ↗A method of making a multi-layer biocidal structure includes providing a support and locating a first curable layer on the support, the first curable layer including dispersed multiple biocidal particles. A second curable layer is located on the first curable layer; the multiple biocidal particles are dispersed within only the first curable layer. The first curable layer and the second curable layer are imprinted in a single step with an imprinting stamp having a structure with a depth greater than the thickness of the second curable layer. The first curable layer and the second curable layer are cured in a single step to form a first cured layer and a second cured layer. The imprinting stamp is removed.
1. A method of making a multi-layer biocidal structure, comprising:
providing a support;
providing a first curable layer on the support, the first curable layer including dispersed multiple biocidal particles;
providing a second curable layer on the first curable layer, wherein multiple biocidal particles are dispersed within only the first curable layer;
imprinting the first curable layer and the second curable layer in a single step with an imprinting stamp having a structure that forms microscopic indentations in the first curable layer and the second curable layer corresponding to a magnitude of the indentations having a depth greater than the thickness of the second curable layer;
curing the first curable layer and the second curable layer in a single step to form a first cured layer and a second cured layer; and
removing the imprinting stamp.
2. The method of claim 1 , wherein the first curable layer includes a first cross-linkable material, the second curable layer includes a second cross-linkable material, and the step of curing cross links the first cross-linkable material to the second cross-linkable material.
3. The method of claim 2 , wherein the first cross-linkable material is the same material as the second cross-linkable material.
4. The method of claim 1 , wherein providing the first curable layer includes coating or laminating a first curable material on or over the support.
5. The method of claim 1 , wherein providing the second curable layer includes coating or laminating a second curable material on or over the first curable layer.
6. The method of claim 1 , further including forming a dispersion of biocidal particles in a first curable material and then providing the first curable material on or over the support to form the first curable layer.
7. The method of claim 1 , wherein the second curable layer is thinner than the first curable layer.
8. The method of claim 1 , wherein the second curable layer is thinner than a mean or median diameter of the particles.
9. The method of claim 1 , wherein the second curable layer is thicker than a mean or median diameter of the particles.
10. The method of claim 1 , wherein the first cured layer has a different color than the second cured layer.
11. The method of claim 1 , wherein the depth of the indentations is between 0.5 microns and 50 microns.
12. The method of claim 1 , wherein the depth of the indentations is between 0.5 microns and 10 microns.
13. The method of claim 1 , wherein the depth of the indentations is between 0.5 microns and 5 microns.
14. The method of claim 1 , wherein the depth of the indentations is between 0.5 microns to 2 microns.