Electroform, methods of making electroforms, and products made from electroforms

Abstract

In one embodiment, the method for making a product comprises: contacting a surface of the electroform with a solution having a pH of less than or equal to 6, applying a cathodic current to the electroform, applying a product material to the electroform, curing the product material, and removing the cured material from the electroform to form the product.

1 . A method for making a product from an electroform, comprising: 
 contacting a surface of the electroform with a solution having a pH of less than or equal to 6, wherein the surface comprises features to be replicated;    applying a cathodic current to the electroform;    applying a product material to the electroform;    curing the product material; and    removing the cured material from the electroform to form the product.    
     
     
         2 . The method of  claim 1 , wherein the pH is less than or equal to about 5.  
     
     
         3 . The method of  claim 1 , wherein the pH is about 2 to about 5.  
     
     
         4 . The method of  claim 1 , wherein the cathodic current is applied at a current density of about 1 ASF to about 60 ASF.  
     
     
         5 . The method of  claim 4 , wherein the current density is about 2 ASF to about 30 ASF.  
     
     
         6 . The method of  claim 5 , wherein the current density is about 2 ASF to about 10 ASF.  
     
     
         7 . The method of  claim 1 , wherein, after the product has been removed, further comprising contacting the surface with a caustic media.  
     
     
         8 . The method of  claim 7 , wherein the caustic media has a pH of greater than or equal to about 8.  
     
     
         9 . The method of  claim 8 , wherein the pH is about 8 to about 14.  
     
     
         10 . The method of  claim 9 , wherein the pH is about 12 to about 14.  
     
     
         11 . The method of  claim 7 , further comprising rinsing the electroform with deionized water and applying a cathodic current to the electroform.  
     
     
         12 . The method of  claim 1 , wherein the product comprises microstructures and/or nanostructures.  
     
     
         13 . The method of  claim 1 , wherein the electroform comprises nickel.  
     
     
         14 . The method of  claim 1 , wherein the product material comprises an acrylate.  
     
     
         15 . The method of  claim 14 , wherein curing the product material comprises ultraviolet curing of the product material.  
     
     
         16 . The method of  claim 1 , wherein applying a product material further comprises pressing the product material into the electroform with a backing film.  
     
     
         17 . The method of  claim 16 , wherein the backing film is selected from the group consisting of polycarbonate, polyester, and so forth, as well as reaction products comprising at least one of the foregoing, and combinations comprising at least one of the foregoing.  
     
     
         18 . A product formed from the method of  claim 1 , wherein the product has microstructures with nanoscale resolution.  
     
     
         19 . The product of  claim 18 , wherein the product is a film.  
     
     
         20 . A light management article comprising the film of  claim 19 .  
     
     
         21 . The article of  claim 20 , wherein the article is a backlight computer display.