Methods and materials for fabricating laminate nanomolds and nanoparticles therefrom
A laminate nanomold includes a layer of perfluoropolyether defining a cavity that has a predetermined shape and a support layer coupled with the layer of perfluoropolyether. The laminate can also include a tie-layer coupling the layer of perfluoropolyether with the support layer. The tie-layer can also include a photocurable component and a thermal curable component. The cavity can have a broadest dimension of less than 500 nanometers.
1. A system for making a laminate mold, comprising:
a patterned master defining structures configured to receive a curable material;
a support layer configured to mate with the patterned master and conform the curable material with the structures of the patterned master; and
a curing device configured to cure the curable material such that the curable material substantially retains a mirror image of the structures of the patterned master, wherein after removal of the patterned master the combined support layer and cured material have a modulus of at least 200 times the modulus of the cured curable material without the support layer.
2. The system of claim 1 , wherein the support layer comprises a roller configured to engage the curable material with the patterned master.
3. The system of claim 2 , wherein the patterned master and mated support layer engage the roller in conformal contact.
4. The system of claim 1 , wherein the cured curable material has a thickness less than 75 micrometers.
5. The system of claim 1 , wherein the structures have a width to height aspect ratio of less than 50:1.
6. The system of claim 1 , wherein the structures have a width to height aspect ratio of less than 20:1.
7. The system of claim 1 , wherein the curable material comprises a fluoropolymer.
8. The system of claim 1 , wherein the curable material comprises a poly(dimethylsiloxane).
9. The system of claim 1 , further comprising a composition configured to be deposited on the mirror image of the structures of the patterned master in the cured curable material to form particles.
10. A system for making a laminate mold, comprising:
a patterned master defining structures configured to receive a curable material;
a support layer configured to mate with the patterned master and conform the curable material with the structures of the patterned master; and
a curing device configured to cure the curable material such that the curable material substantially retains a mirror image of the structures of the patterned master, wherein after removal of the patterned master the combined support layer and cured material have a modulus of at least 1000 Mpa.
11. The system of claim 10 , wherein the support layer comprises a roller configured to engage the curable material with the patterned master.
12. The system of claim 11 , wherein the patterned master and mated support layer engage the roller in conformal contact.
13. The system of claim 10 , wherein the cured curable material has a thickness less than 75 micrometers.
14. The system of claim 10 , wherein the structures have a width to height aspect ratio of less than 50:1.
15. The system of claim 10 , wherein the curable material comprises a fluoropolymer.
16. The system of claim 10 , wherein the curable material comprises a poly(dimethylsiloxane).
17. The system of claim 10 , further comprising a composition configured to be deposited on the mirror image of the structures of the patterned master in the cured curable material to form particles.
18. A system for making a laminate mold, comprising:
a patterned master defining structures configured to receive a curable material;
a support layer configured to mate with the patterned master and conform the curable material with the structures of the patterned master;
a curing device configured to cure the curable material such that the curable material substantially retains a mirror image of the structures of the patterned master, wherein after removal of the patterned master the combined support layer and cured material have a modulus of at least 1000 Mpa; and
a composition configured to be deposited on the mirror image of the structures of the patterned master in the cured curable material to form particles.
19. The system of claim 18 , wherein the support layer comprises a roller configured to engage the curable material with the patterned master.
20. The system of claim 18 , wherein the curable material is selected from a fluoropolyether or a poly(dimethylsiloxane).