Method of molding simple or complex micro and/or nanopatterned features on both planar or non-planar molded objects and surfaces and the molded objects produced using same

摘要

The present invention is a method that (i) allows for creating micro and/or nanostructures on either planar or non-planar three-dimensional surfaces in a single molding step, and (ii) allows for the molded production of complex high-aspect ratio micro and/or nanostructures including but not limited to cylinders, conical structures, low aspect-ratio channels, bumps, or posts. An example of such a complex structure are high aspect ratio pillars with enlarged “mushroom-shaped” or undercut tips which demonstrate enhanced, repeatable adhesion and shear strength on a variety of substrates when compared with other micro and/or nanostructures and unstructured materials. The mold of such a material requires an “undercut” feature that cannot be produced using typical micro/nano-molding processing techniques.

主权项

1. A method for making a negative mold having a mold surface with negative microscale and/or nanoscale patterned features on a tool surface of a molding tool to generate a molded product with replicate microscale and/or nanoscale patterned features, the method comprising the steps of:
providing a base material with actual patterned features selected from a group consisting of microscale features, nanoscale features, and microscale and nanoscale features, providing a backing material, liquid tool insert material, and the molding tool; attaching the base material with actual patterned features to the backing material to form a product; adding the liquid tool insert material to the tool surface of the molding tool; pressing the actual patterned features of the product into the liquid tool insert material and allowing the liquid tool insert material to cure; and removing the product from the molding tool to form the negative mold having the mold surface with the negative patterned features of the actual patterned features.