Apparatus for embossing a flexible substrate with a pattern carried by an optically transparent compliant media

Abstract

An apparatus for embossing a flexible substrate with an optically transparent compliant media is disclosed. The complaint media includes an optically transparent imprint stamp with an imprint pattern therein. The flexible substrate is coated with a photopolymer material. The compliant media can be connected with an optically transparent belt material to form an embossing belt or connected with an optically transparent cylinder to from an embossing drum. A coated side of the flexible substrate is urged into contact with the imprint stamp and the imprint pattern is embossed in the photopolymer material and an ultraviolet light passing through the compliant media contemporaneously cures the photopolymer material during the embossing.

1 - 16 . (canceled)  
     
     
         17 . An embossing apparatus, comprising: 
 a flexible substrate including a coated side and a base side;    a coating unit for depositing a photopolymer material having a first thickness on the coated side;    an embossing drum comprising an optically transparent cylinder and an optically transparent complaint media connected with the cylinder, the compliant media including an optically transparent imprint stamp having an imprint pattern therein;    a drive unit for imparting a drive motion to the embossing drum and the flexible substrate;    a plurality of transport rollers connected with the base side and operative to conformally wrap the coated side over a portion of the embossing drum so that the embossing drum imparts a tension in the flexible substrate and the tension generates a pressure between the flexible substrate and the embossing drum,    the drive motion is operative to transport the coated side over the embossing drum and to urge the imprint stamp and the coated side into contact with each other so that the imprint pattern is embossed in the photopolymer material and forms a replicate pattern in the photopolymer material; and    an ultraviolet light source for irradiating the replicate pattern with an ultraviolet light through the cylinder and the imprint stamp, the irradiating occurring contemporaneously with the embossing of the replicate pattern.    
     
     
         18 . The embossing apparatus as set forth in  claim 17 , wherein the flexible substrate is opaque to the ultraviolet light.  
     
     
         19 . The embossing apparatus as set forth in  claim 17 , wherein the ultraviolet light source has a position relative to the embossing drum selected from the group consisting of a position inside of the embossing drum and a position outside of the embossing drum.  
     
     
         20 . The embossing apparatus as set forth in  claim 17 , wherein the ultraviolet light source comprises a UVA ultraviolet light source.  
     
     
         21 . The embossing apparatus as set forth in  claim 17 , wherein the ultraviolet light includes a wavelength from about 300.0 nanometers to about 400.0 nanometers.  
     
     
         22 . The embossing apparatus as set forth in  claim 17 , wherein the coating unit comprises a coater selected from the group consisting of a Gravure coater,.a MICRO GRAVURE COATER, and a Slotdie coater.  
     
     
         23 . The embossing apparatus as set forth in  claim 17 , wherein the first thickness is in a range from about 0.05 micrometers to about 2.0 micrometers.  
     
     
         24 . The embossing apparatus as set forth in  claim 17 , wherein at least one of the transport rollers is connected with the drive unit and the drive unit is operative to rotate the transport roller to impart the drive motion to the embossing drum and the flexible substrate.  
     
     
         25 . The embossing apparatus as set forth in  claim 17  and further comprising: 
 a supply reel for carrying the flexible substrate and for dispensing the flexible substrate to the coating unit.    
     
     
         26 . The embossing apparatus as set forth in  claim 17  and further comprising: 
 a takeup reel for collecting the flexible substrate after the flexible substrate has been embossed and cured.    
     
     
         27 . The embossing apparatus as set forth in  claim 26 , wherein the takeup reel is connected with the drive unit and the drive unit is operative to rotate the takeup reel to collect the flexible substrate and to impart the drive motion to the embossing drum and the flexible substrate.  
     
     
         28 . The embossing apparatus as set forth in  claim 17 , wherein the compliant media comprises an optically transparent silicone-based elastomer material that is laminated to an optically transparent transfer adhesive layer.  
     
     
         29 . The embossing apparatus as set forth in  claim 28 , wherein the optically transparent silicone-based elastomer material is a material selected from the group consisting of Polydimethyl Siloxane, SYLGARD 182, SYLGARD 183, SYLGARD 184, and SYLGARD 186.  
     
     
         30 . The embossing apparatus as set forth in  claim 28 , wherein the optically transparent transfer adhesive layer is an ARclear DEV-8932 optically clear silicone adhesive.  
     
     
         31 . The embossing apparatus as set forth in  claim 17 , wherein the optically transparent cylinder is made from a material selected from the group consisting of a glass, a plastic, and quartz.  
     
     
         32 . The embossing apparatus as set forth in  claim 17 , wherein the ultraviolet light source further includes a reflector for focusing the ultraviolet light at a point where the imprint stamp is urged into contact with the coated surface so that the photopolymer material is not cured before the imprint pattern is embossed in the photopolymer material.