Deflection member having suspended portions and process for making same

摘要

A deflection member comprising a patterned framework having a web-side and a backside opposite to the web-side and forming an X-Y plane. The framework comprises a plurality of bases extending from the X-Y plane in a Z-direction perpendicular to the X-Y plane, and a plurality of suspended portions laterally extending from the plurality of bases to form void spaces between the X-Y plane and the suspended portions. The deflection member can comprise a reinforcing element joined to the plurality of bases and positioned between the web-side and at least a portion of the backside of the framework. A process for making the deflection member comprises curing a coating of a liquid photosensitive resin supported by a forming surface through a mask having a pattern of transparent and opaque regions. The opaque regions comprise regions having first opacity and regions having second opacity less than the first opacity. The transparent regions leave coating's areas corresponding thereto unshielded to allow said areas to cure through the entire thickness of the coating, thereby forming the bases. The opaque regions having the first opacity shield first areas of the coating to preclude curing thereof through the entire thickness of the coating. The opaque regions having the second opacity partially shield second areas of the coating to allow them to cure through a predetermined second thickness less than the entire thickness of the coating, thereby forming the suspended portions. The mask can have a gradient opacity that gradually changes in at least one direction to cause the coating to cure though a differential thickness. The mask can also have a three-dimensional topography pattern therein to imprint the coating.