Multi-diamond cutting tool assembly for creating microreplication tools

Abstract

In one embodiment, a cutting tool assembly used for creating grooves in a microreplication tool is described. The cutting tool assembly includes a mounting structure and multiple diamonds mounted in the mounting structure. For example, first and second tool shanks having first and second diamond tips can be positioned in the mounting structure such that a cutting location of a diamond cutting tip of the first tool shank is a defined distance from a cutting location of a diamond cutting tip of the second tool shank. The defined distance may correspond to an integer number of pitch spacings, and may be accurate to within a tolerance of less than approximately 10 microns.

1 . A cutting tool assembly comprising: 
 a mounting structure;    a first tool shank mounted in the mounting structure, the first tool shank defining    a first diamond tip that corresponds to a first groove to be created in a work piece; and    a second tool shank mounted in the mounting structure, the second tool shank defining a second diamond tip that corresponds to a second groove to be created in the work piece,    wherein the first and second tool shanks are positioned in the mounting structure such that a cutting location of the first diamond tip is a defined distance from a cutting location of the second diamond tip, the defined distance being accurate to a tolerance of less than approximately 10 microns.    
     
     
         2 . The cutting tool assembly of  claim 1 , wherein the defined distance corresponds to an integer number of pitch spacings, wherein each of the pitch spacings defines a distance between two adjacent features to be created in the work piece.  
     
     
         3 . The cutting tool assembly of  claim 2 , wherein the first and second tool shanks are positioned in the mounting structure such that the cutting location of the first diamond tip is approximately one pitch spacing from the cutting location of the second diamond tip.  
     
     
         4 . The cutting tool assembly of  claim 2 , wherein the pitch spacing is less than approximately 1000 microns.  
     
     
         5 . The cutting tool assembly of  claim 4 , wherein the pitch spacing is less than approximately 100 microns.  
     
     
         6 . The cutting tool assembly of  claim 5 , wherein the pitch spacing is less than approximately 10 microns.  
     
     
         7 . The cutting tool assembly of  claim 6 , wherein the pitch spacing is less than approximately 1 micron.  
     
     
         8 . The cutting tool assembly of  claim 1 , wherein an aspect ratio of a cutting height of the first diamond tip relative to a cutting width of the first diamond tip is greater than approximately 1 to 1.  
     
     
         9 . The cutting tool assembly of  claim 8 , wherein the aspect ratio is greater than approximately 2 to 1.  
     
     
         10 . The cutting tool assembly of  claim 1 , wherein the first and second diamond tips define cutting widths of less than approximately 200 microns.  
     
     
         11 . The cutting tool assembly of  claim 1 , wherein at least one of the diamond tips defines a substantially straight side wall.  
     
     
         12 . The cutting tool assembly of  claim 1 , wherein at least one of the diamond tips defines an undercut side wall.  
     
     
         13 . The cutting tool assembly of  claim 1 , wherein at least one of the diamond tips defines a side wall that defines an obtuse angle relative to an adjacent surface of the mounting structure.  
     
     
         14 . The cutting tool assembly of  claim 1 , wherein the cutting tool assembly is a flycutting assembly configured to be rotated about an axis perpendicular to a cutting direction of the diamond tips, wherein the first and second tool shanks are mounted in the mounting structure on opposing sides of the mounting structure.  
     
     
         15 . The cutting tool assembly of  claim 1 , where the defined distance is less than a width associated with either of the first and second tool shanks.  
     
     
         16 . The cutting tool assembly of  claim 1 , wherein the first and second tool shanks are mounted in the mounting structure on a common side of the mounting structure.  
     
     
         17 . The cutting tool assembly of  claim 1 , further comprising a securing mechanism for securing the first tool shank in the mounting structure relative to the second tool shank.  
     
     
         18 . The cutting tool assembly of  claim 1 , wherein a shape of the first diamond tip is substantially different from a shape of the second diamond tip.  
     
     
         19 . The cutting tool assembly of  claim 1 , wherein the first and second diamond tips are shaped to create grooves in a microreplication tool that correspond to features to be created in a microreplicated structure.  
     
     
         20 . The cutting tool assembly of  claim 19 , wherein the microreplicated structure comprises a mechanical fastener that defines a self-mating profile.  
     
     
         21 . The cutting tool assembly of  claim 19 , wherein the microreplicated structure comprises an optical film.  
     
     
         22 . The cutting tool assembly of  claim 21 , wherein a shape of the first diamond tip is substantially different from a shape of the second diamond tip, and wherein the first diamond tip defines a first optical characteristic to be created in the optical film and the second diamond tip defines a second optical characteristic to be created in the optical film.  
     
     
         23 . The cutting tool assembly of  claim 1 , further comprising a third tool shank mounted in the mounting structure, the third tool shank defining a third diamond tip that corresponds to a third groove to be created in the work piece, wherein a cutting location of the third tip is a second defined distance from the cutting location of the second diamond tip, the second defined distance being accurate to a tolerance of less than approximately 10 microns.  
     
     
         24 . The cutting tool assembly of  claim 1 , wherein the defined distance is accurate to within a tolerance of less than approximately 1 micron.  
     
     
         25 . A diamond tooling machine used for creating grooves in a work piece comprising: 
 a cutting tool assembly including: 
 a mounting structure;  
 a first tool shank mounted in the mounting structure, the first tool shank defining a first diamond tip that corresponds to a first groove to be created in the work piece; and  
 a second tool shank mounted in the mounting structure, the second tool shank defining a second diamond tip that corresponds to a second groove to be created in the work piece, wherein the first and second tool shanks are positioned in the mounting structure such that a cutting location of the first diamond tip is a defined distance from a cutting location of the second diamond tip, the defined distance being accurate to a tolerance of less than approximately 10 microns; and  
   an apparatus to receive the cutting tool assembly and to control positioning of the cutting tool assembly relative to the work piece.    
     
     
         26 . The diamond tooling machine of  claim 25 , wherein the machine is a fly-cutting machine the rotates the cutting tool assembly about an axis, and wherein the apparatus includes a drive train coupling the mounting structure to a motor.  
     
     
         27 . A cutting tool assembly comprising: 
 a mounting structure;    a first tool shank mounted in the mounting structure, the first tool shank defining a first diamond tip that corresponds to a first groove to be created in the work piece;    a second tool shank mounted in the mounting structure, the second tool shank defining a second diamond tip that corresponds to a second groove to be created in the work piece; and    means for securing the first and second tool shanks in the mounting structure such that a cutting location of the first diamond tip is a defined distance from a cutting location of the second diamond tip, the defined distance being accurate to a tolerance of less than approximately 10 microns.    
     
     
         28 . A flycutting tool assembly configured to be rotated about an axis to cut grooves in a microreplication tool comprising: 
 a mounting structure;    a first tool shank mounted in a first side of the mounting structure, the first tool shank defining a first diamond tip that corresponds to a first groove to be created in the microreplication tool; and    a second tool shank mounted in the mounting structure on a second side of the mounting structure opposite the first side, the second tool shank defining a second diamond tip that corresponds to a second groove to be created in the work piece, wherein the first and second tool shanks are positioned in the mounting structure such that a cutting location of the first diamond tip is a defined distance from a cutting location of the second diamond tip, the defined distance being accurate to a tolerance of less than approximately 10 microns.    
     
     
         29 . The flycutting tool assembly of  claim 28 , where the defined distance is less than a width associated with either of the first and second tool shanks.  
     
     
         30 . The flycutting tool assembly of  claim 28 , wherein the defined distance corresponds to an integer number of pitch spacings, wherein a pitch spacing defines a distance between two adjacent features to be created in a work piece.  
     
     
         31 . The flycutting tool assembly of  claim 30 , wherein the first and second tool shanks are positioned in the mounting structure such that the cutting location of the first diamond tip is approximately one pitch spacing from the cutting location of the second diamond tip.  
     
     
         32 . The flycutting tool assembly of  claim 28 , wherein a shape of the first diamond tip is substantially different from a shape of the second diamond tip.  
     
     
         33 . The flycutting tool assembly of  claim 28 , wherein the defined distance is accurate to within a tolerance of less than approximately 1 micron.  
     
     
         34 . A method comprising: 
 defining a pitch spacing for a microreplication tool;    creating a cutting tool assembly by positioning first and second tool shanks in a mounting structure such that a cutting location of a first diamond tip associated with the first tool shank is a defined distance from a cutting location of a second diamond tip associated with the second tool shank, the defined distance corresponding to an integer number of pitch spacings, wherein the defined distance is accurate to within a tolerance of less than approximately 10 microns.    
     
     
         35 . The method of  claim 34 , further comprising creating a microreplication tool using the cutting tool assembly.  
     
     
         36 . The method of  claim 34 , further comprising creating microreplicated structures using the microreplication tool.  
     
     
         37 . The method of  claim 34 , wherein positioning first and second tool shanks includes adjusting a position of the tool shanks relative to one another under a tooling microscope in response to positioning feedback.  
     
     
         38 . The method of  claim 37 , wherein the defined distance is accurate to within a tolerance of less than approximately 1 micron.