Adhesives having microreplicated topography and methods of making and using same

Abstract

Adhesives having a microreplicated topography are prepared from contacting a microembossed pattern to a layer of adhesive. When an adhesion interface is established between the layer of adhesive and a supporting substrate, the topography of the adhesive surface controls the performance of the adhesion interface. Articles having microreplicated adhesive surfaces are also disclosed that have an advantage of providing microchannels for fluid egress for an effective period of time. Multiple microembossed patterns produce microreplicated adhesive surfaces having both microchannels for fluid egress and pegs for improved adhesive properties.

What is claimed is:  
     
         1 . A method of controlling the topography of an adhesive surface, comprising: 
 contacting a microembossed pattern to a layer of adhesive and forming a microreplicated adhesive surface, such that when an adhesion interface is established between the layer of adhesive and a supporting substrate, the topography of the adhesive surface controls the performance of the adhesion interface between that adhesive and the supporting substrate.    
     
     
         2 . The method according to  claim 1 , wherein the contacting step is selected from the group consisting of casting techniques, coating techniques, and compressing techniques.  
     
     
         3 . The method according to  claim 2 , wherein the casting technique comprises using a tool having a microembossed pattern.  
     
     
         4 . The method according to  claim 2 , wherein the coating technique comprises coating an adhesive onto a release liner having a microembossed pattern.  
     
     
         5 . The method according to  claim 2 , wherein the compressing technique comprises passing through a nip roll to compress pressure sensitive adhesive against a release liner.  
     
     
         6 . The method according to  claim 3 , wherein the microembossed pattern on the tool is formed by etching, photolithography, stereolithography, micromachining, knurling, scoring or cutting.  
     
     
         7 . The method according to  claim 1 , wherein the surface is at least one major surface.  
     
     
         8 . The method according to  claim 1 , further contacting a major, opposing surface of the adhesive.  
     
     
         9 . The method according to  claim 1 , wherein the microembossed pattern resides on a release liner.  
     
     
         10 . The method according to  claim 1 , wherein the microembossed pattern resides on a tape backing.  
     
     
         11 . The method according to  claim 1 , wherein the microembossed pattern is a multiple microembossed pattern.  
     
     
         12 . The method according to  claim 1 , wherein rheology of the adhesive retains the microreplicated adhesive surface for an effective period of time.  
     
     
         13 . The method according to  claim 1 , further comprising the step of contacting the microreplicated adhesive surface to the supporting substrate to provide controlled fluid egress from the interface between the adhesive surface and the supporting substrate.  
     
     
         14 . The method according to  claim 11 , wherein different types of materials are introduced into recesses of differing depths of the multiple microembossed pattern.  
     
     
         15 . An article comprising a layer of adhesive having an interconnected microreplicated adhesive surface.  
     
     
         16 . The article according to  claim 15 , wherein the microreplicated adhesive surface has a complex pattern of differing depths or heights.  
     
     
         17 . The article according to  claim 15 , wherein different types of materials reside on the microreplicated adhesive surface.  
     
     
         18 . The article according to  claim 15 , wherein rheology of the adhesive retains the microreplicated adhesive surface for an effective period of time.  
     
     
         19 . The article according to  claim 15 , further comprising a supporting substrate and an interface between the supporting substrate and the microreplicated adhesive surface, wherein the microreplicated adhesive surface controls fluid egress from the interface.  
     
     
         20 . The article according to  claim 15 , wherein the layer further comprises a major, opposing microreplicated adhesive surface.  
     
     
         21 . An article comprising a layer of adhesive having an microreplicated adhesive surface formed from at least two microembossed patterns.  
     
     
         22 . The article according to  claim 21 , wherein the microreplicated adhesive surface has a complex pattern of differing depths or heights.  
     
     
         23 . The article according to  claim 21 , wherein different types of materials reside on the microreplicated adhesive surface.  
     
     
         24 . The article according to  claim 21 , wherein rheology of the adhesive retains the microreplicated adhesive surface for an effective period of time.  
     
     
         25 . The article according to  claim 21 , further comprising a supporting substrate and an interface between the supporting substrate and the microreplicated adhesive surface, wherein the microreplicated adhesive surface controls fluid egress from the interface.  
     
     
         26 . The article according to  claim 21 , wherein the layer further comprises a major, opposing microreplicated adhesive surface.  
     
     
         27 . A method of using a release liner having a microembossed pattern, comprising the steps of: 
 (a) contacting the microembossed pattern to a layer of adhesive and    (b) forming a microreplicated adhesive surface.