Methods for forming microstructures on a substrate using a mold

Abstract

In a method of making a microstructured assembly, a substantially uniform coating of a curable material is formed on a substrate with the coating defining a leading edge. The coating is contacted with a mold starting at the leading edge to form in the curable material a plurality of barrier regions connected by intervening land regions. The curable material is cured and the mold is removed. Optionally, the coating includes a binder. Such a coating can optionally be debinded. In addition, the coating can be fired to form ceramic microstructures.

1 . A method of making a microstructured assembly, the method comprising: 
 forming a substantially uniform coating of a curable material comprising a ceramic material and a fugitive binder on a substrate;    contacting the coating with a mold that is substantially optically clear to curing radiation, thereby forming in the curable material a plurality of barrier regions connected by intervening land regions such that curable material is between the mold and the substrate;    radiation curing the curable material at least through the mold;    removing the mold; and    firing the curable material thereby forming fused microstructures wherein the firing substantially burns out the fugitive binder such that the microstructures are substantially free of carbon residue.    
     
     
         2 . The method of  claim 1 , wherein forming a substantially uniform coating comprises forming the coating of the curable material on the substrate with a thickness that varies by no more than 5%.  
     
     
         3 . The method of  claim 1 , wherein contacting the coating comprises unrolling the mold while contacting the coating starting at the leading edge of the coating.  
     
     
         4 . The method of  claim 3 , wherein removing the mold comprises rolling the mold onto a receiving element.  
     
     
         5 . The method of  claim 1 , wherein the intervening land regions have a substantially uniform center thickness.  
     
     
         6 . The method of  claim 1 , further comprising a plurality of electrodes disposed on the substrate.  
     
     
         7 . The method of  claim 6 , further comprising aligning the land regions with the plurality of electrodes disposed on the substrate.  
     
     
         8 . The method of  claim 7 , wherein aligning the land regions comprises stretching the mold to align the land regions with the plurality of electrodes.  
     
     
         9 . The method of  claim 1 , wherein the coating defines a coating area that is smaller than a surface area of the substrate.  
     
     
         10 . The method of  claim 1 , wherein the coating defines at least two individual coating areas.  
     
     
         11 . The method of  claim 1 , wherein the microstructured assembly comprises a display.  
     
     
         12 . A method of making a microstructured assembly, the method comprising: 
 disposing a curable material on a substrate having a first end, wherein the curable material comprises a ceramic material and a fugitive binder;    contacting the curable material with a mold that is substantially optically clear to curing radiation, starting at the first end and proceeding at a substantially uniform contact speed and applying a substantially uniform contact pressure such that curable material is between the mold and the substrate;    forming the curable material, using the mold, into a plurality of barrier regions connected by intervening land regions, wherein the land regions have a substantially uniform center thickness;    radiation curing the curable material at least through the mold;    removing the mold; and    firing the curable material thereby forming fused microstructures wherein the firing substantially burns out the fugitive binder such that the microstructures are substantially free of carbon residue.    
     
     
         13 . The method of  claim 12 , wherein disposing a curable material on a substrate comprises disposing the curable material on the substrate as a substantially uniform coating.  
     
     
         14 . A method of making a microstructured assembly, the method comprising: 
 forming a substantially uniform coating of a curable material, the coating defining a leading edge and defining a coating area that is smaller than a surface area of the substrate, wherein the curable material comprises a ceramic material and a fugitive binder;    contacting the coating with a mold, wherein the mold is substantially optically clear to curing radiation, starting at the leading edge, the mold forming the curable material into a plurality of barrier regions connected by intervening land regions without substantially enlarging the coating area such that curable material is between the mold and the substrate;    radiation curing the curable material at least through the mold;    removing the mold; and    firing the curable material thereby forming fused microstructures wherein the firing substantially burns out the fugitive binder such that the microstructures are substantially free of carbon residue.    
     
     
         15 . The method of  claim 14 , wherein the microstructured assembly comprises a display.