Methods for embossing and embossed articles formed thereby

Abstract

A method for manufacturing an embossed surface including a polymer composition having reactive moieties and a first glass transition temperature T g1 . The method includes embossing the surface a temperature T emb ; and raising the first glass transition temperature T g1 of the embossed polymeric surface to a second glass transition temperature T g2 such that T g2 >T emb . In another embodiment, a method for improving the release of a polymeric surface from an embossing tool includes incorporating one or more of fluorine atoms, silicon atoms, or siloxane segments into the backbone of polymer. The methods are particular suited for direct patterning of photoresists, fabrication of interdigitated electrodes, and fabrication of data storage media.

1 . An article comprising a surface, wherein the surface comprises a polymer composition having a first glass transition temperature (T g1 ), and wherein the article is formed by: 
 embossing the surface at temperature T emb ; and    altering the T g1  of the surface polymer composition to provide a second glass transition temperature (T g2 ), wherein the altering is during embossing, after embossing, or both during and after embossing.    
     
     
         2 . The article of  claim 1 , wherein the polymer composition comprises a thermoplastic polymer, a thermoset polymer, a blend comprisig a thermoplastic polymer, a blend comprising a thermoset polymer, or a blend comprising a thermoplastic polymer and a thermoset polymer.  
     
     
         3 . The article of  claim 2 , wherein the polymer is a thermoplastic selected from the group consisting of polyvinyl chloride, polyolefins, polyethylene, chlorinated polyethylene, polypropylene, polyesters, polyethylene terephthalate, polybutylene terephthalate, polycyclohexylmethylene terephthalate, polyamides, polysulfones, hydrogenated polysulfones, polyimides, polyether imides, polyether sulfones, polyphenylene sulfides, polyether ketones, polyether ether ketones, ABS resins, polystyrenes, hydrogenated polystyrenes, syndiotactic and atactic polystyrenes, polycyclohexyl ethylene, styrene-co-acrylonitrile, styrene-co-maleic anhydride, polybutadiene, polyacrylates, polymethylmethacrylate, methyl methacrylate-polyimide copolymers, polyacrylonitrile, polyacetals, polycarbonates, polyphenylene ethers, ethylene-vinyl acetate copolymers, polyvinyl acetate, liquid crystal polymers, ethylene-tetrafluoroethylene copolymer, aromatic polyesters, polyvinyl fluoride, polyvinylidene fluoride, polyvinylidene chloride, polytetrafluoroethylene, and combinations comprising at least one of the foregoing thermoplastics.  
     
     
         4 . The article of  claim 2 , wherein the polymer is a thermoplastic blend selected from the group consisting of acrylonitrile-butadiene-styrene/nylon, polycarbonate/acrylonitrile-butadiene-styrene, acrylonitrile butadiene styrene/polyvinyl chloride, polyphenylene ether/polystyrene, polyphenylene ether/nylon, polysulfone/acrylonitrile-butadiene-styrene, polycarbonate/thermoplastic urethane, polycarbonate/polyethylene terephthalate, polycarbonate/polybutylene terephthalate, thermoplastic elastomer alloys, nylon/elastomers, polyester/elastomers, polyethylene terephthalate/polybutylene terephthalate, acetal/elastomer, styrene-maleic anhydride/acrylonitrile-butadiene-styrene, polyether etherketone/polyethersulfone, polyimide/polysiloxane, polyetherimide/polysiloxane, polyethylene/nylon, polyethylene/polyacetal, and combinations comprising at least one of the foregoing blends of thermoplastic polymers.  
     
     
         5 . The article of  claim 2 , wherein the polymer is a thermoset selected from the group consisting of epoxys, phenolics, alkyds, polyesters, polyurethanes, silicone polymers, mineral filled silicones, bis-maleimides, cyanate esters, vinyl, benzocyclobutene polymers, and combinations comprising at least one of the foregoing thermosetting polymers.  
     
     
         6 . The article of  claim 1 , wherein the polymer is selected from the group consisting of polyimides, polyetherimides, copolymers of polyimides, copolymers of polyetherimides, and blends comprising at least one of the foregoing polymers.  
     
     
         7 . The article of  claim 6 , wherein the polymer comprises reactive moieties selected from the group consisting of vinyl substituted aromatic monoamines, polyfunctional alkenyl aromatic monomers, acryloyl monomers, sulfides, toluidines, ethynyl groups, ethyl groups, ethenyl groups, epoxies, fluoroolefins, alkoxysilanes, and combinations comprising at least one of the foregoing reactive moieties.  
     
     
         8 . The article of  claim 6 , wherein T g2  is greater than T emb , wherein T g2  is greater than T g1 , or wherein T g2  is greater than T emb  and T g1 .  
     
     
         9 . The article of  claim 6 , wherein the polymer comprises a reactive plasticizer having the structural formula A-R-A wherein A is a reactive functionality selected from the group consisting of vinyl substituted aromatic monoamines, polyfunctional alkenyl aromatic monomers, acryloyl monomers, sulfides, toluidines, ethynyl groups, ethyl groups, ethenyl groups, epoxies, fluoroolefins, alkoxysilanes, and combinations comprising at least one of the reactive functionalities and R is a monomeric or oligomeric polyimide repeat unit shown in the formula (XVIII)  
       
         
           
           
               
               
           
         
         wherein Y is —O— or a group of the formula —O- Z- O— wherein the divalent bonds of the —O— or the —O- Z- O— group are in the 3,3′, 3,4′, 4,3′, or the 4,4′ positions, and wherein Z comprises divalent radicals of formula (III)  
         
           
             
             
                 
                 
             
           
         
         wherein n is an integer from 0 to about 5 and Ar is an aromatic group comprising reactive diamines.  
       
     
     
         10 . The article of  claim 6 , wherein the polymer comprises a reactive plasticizer selected from the group having the structural formula XIXa, XIXb, XIXc,  
       
         
           
           
               
               
           
         
       
       or combinations comprising at least one of XIXa, XIXb, XIXc, wherein R is an aromatic moiety having about 36 to about 60 carbon atoms.  
     
     
         11 . The article of  claim 6 , wherein the polymer comprises about 0.1 to about 30 wt. % reactive moieties, based on the total weight of the polymer.  
     
     
         12 . An embossed polymer surface formed by a process comprising: 
 embossing a surface comprising a polymer and a plasticizer having reactive moieties; and    reacting the reactive moieties to increase the glass transition temperature of the embossed polymer surface.    
     
     
         13 . The embossed polymer surface of  claim 12 , wherein the amount of reactive plasticizer is effective to raise the glass transition temperature of the polymer after reaction to reast the glass transition temperature  
     
     
         14 . The embossed polymer surface of  claim 12 , wherein the polymer surface comprises a thermoplastic selected from the group consisting of polyimides, polyetherimides, copolymers of polyimides, copolymers of polyetherimides, blends of polyimides with perfluorocarbons, blends of polyetherimides with perfluorocarbons and combinations comprising at least one of the foregoing thermoplastics.  
     
     
         15 . The embossed polymer surface of  claim 12 , wherein the polymer comprises reactive moieties selected from the group consisting of vinyl substituted aromatic monoamines, polyfunctional alkenyl aromatic monomers, acryloyl monomers, sulfides, toluidines, ethynyl groups, ethnyl groups, ethenyl groups, epoxies, fluoroolefins, alkoxysilanes, and combinations comprising at least one of the foregoing reactive moieties.  
     
     
         16 . An embossed polymer surface formed by: 
 embossing a surface comprising the reaction product of m-phenylenediamine and a dianhydride; and    treating the embossed polymer to increase the glass transition temperature of the embossed polymer.    
     
     
         17 . The embossed polymer surface of  claim 16 , wherein the dianhydride is selected from the group consisting of bisphenol A dianhydride, 4,4′-oxydiphthalic anhydride, hexafluoroisopropylidene diphthalic anhydride, and combinations comprising at least one of the foregoing dianhydrides.  
     
     
         18 . The embossed polymer surface of  claim 16 , wherein the reaction product is the reaction product of m-phenylenediamine, a dianhydride, and a terminated siloxane, the reaction product of m-phenylenediamine, a dianhydride, and polyamic acid.  
     
     
         19 . The embossed polymer surface of  claim 17 , further comprising a reactive plasticizer.