Adhesives having a 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.

1 . An adhesive article comprising a continuous adhesive layer having a first major surface and a second major surface, said first major surface comprising: 
 (a) a plurality of lands;    (b) a plurality of protrusions that extend above the lands; and    (c) a plurality of channels between the lands,    wherein the width of the protrusions varies.    
   
   
       2 . The adhesive article of  claim 1  wherein the protrusions comprise a non-adhesive material.  
   
   
       3 . The adhesive article of  claim 2  wherein the non-adhesive material is a polymer.  
   
   
       4 . The article of  claim 1 , wherein the channels are interconnected.  
   
   
       5 . The article of  claim 1 , wherein the channels define a square grid.  
   
   
       6 . The article of  claim 1 , wherein the channels define a series of hexagons.  
   
   
       7 . The article of  claim 1 , wherein the channels are substantially parallel to each other.  
   
   
       8 . The article of  claim 1 , wherein the channels occupy about 1% to about 65% of the total area of the first major surface of the adhesive layer.  
   
   
       9 . The article of  claim 1 , wherein the channels occupy about 2% to about 50% of the total area of the first major surface of the adhesive layer.  
   
   
       10 . The article of  claim 1 , wherein the channels occupy about 3% to about 40% of the total area of the first major surface of the adhesive layer.  
   
   
       11 . The article of  claim 1 , wherein the channels occupy about 4% to about 30% of the total area of the first major surface of the adhesive layer.  
   
   
       12 . The article of  claim 1 , wherein the channels occupy about 5% to about 15% of the total area of the first major surface of the adhesive layer.  
   
   
       13 . The article of  claim 1 , wherein the channels extend below the lands to a depth of about 3 μm to less than about 45 μm.  
   
   
       14 . The article of  claim 1 , wherein the channels extend below the lands to a depth of about 5 μm to about 30 μm.  
   
   
       15 . The article of  claim 1 , wherein the channels extend below the lands to a depth of about 6 μm to about 20 μm.  
   
   
       16 . The article of  claim 1 , wherein the protrusions occupy about 1% to about 70% of the total area of the first major surface of the adhesive layer.  
   
   
       17 . The article of  claim 1 , wherein the protrusions occupy about 2% to about 25% of the total area of the first major surface of the adhesive layer.  
   
   
       18 . The article of  claim 1 , wherein the protrusions occupy about 3% to about 15% of the total area of the first major surface of the adhesive layer.  
   
   
       19 . The article of  claim 1 , wherein the protrusions extend above the lands to a height of about 4 μm to about 200 μm.  
   
   
       20 . The article of  claim 1 , wherein the protrusions extend above the lands to a height of about 8 μm to about 100 μm.  
   
   
       21 . The article of  claim 1 , wherein the protrusions extend above the lands to a height of about 10 μm to about 300 μm.  
   
   
       22 . The article of  claim 1 , wherein the protrusions extend above the lands to a height of about 5 μm to about 9 μm.  
   
   
       23 . The article of  claim 1 , wherein the protrusions extend above the lands to a height of about 3 μm to about 10 μm.  
   
   
       24 . The article of  claim 1 , wherein the adhesive layer comprises a pressure sensitive adhesive.  
   
   
       25 . The article of  claim 24 , wherein the pressure sensitive adhesive is tacky at room temperature.  
   
   
       26 . The article of  claim 1 , wherein the adhesive layer has a thickness of at least about 5 μm.  
   
   
       27 . The article of  claim 1 , wherein the adhesive layer has a thickness of about 20 μm to about 50 μm.  
   
   
       28 . The article of  claim 1 , further comprising a release liner having a first major surface contacting the first major surface of the adhesive layer.  
   
   
       29 . A release article comprising a first major surface and a second major surface, the first major surface comprising 
 (a) a plurality of lands,    (b) a plurality of depressions, and    (c) a plurality of ridges between the lands,    wherein the width of the depressions varies.    
   
   
       30 . The article of  claim 29 , wherein the depressions contain a non-adhesive material.  
   
   
       31 . The article of  claim 30  wherein the non-adhesive material is a polymer.  
   
   
       32 . The article of  claim 1 , further comprising a backing on the second major surface of the adhesive layer.  
   
   
       33 . The article of  claim 32 , wherein the backing has (i) a first major surface on the second major surface of the adhesive layer and (ii) a second major surface, wherein the second major surface of the backing comprises a graphic image.  
   
   
       33 . The article of  claim 32 , wherein the backing is selected from the group consisting of foils, metallic plates, ceramic plates, polymeric films, vibration damping materials, reflective sheeting, retroreflecting sheeting, and combinations thereof.  
   
   
       34 . The article of  claim 32 , wherein the backing comprises a polymeric film.  
   
   
       35 . The article of  claim 33 , wherein the polymeric film is selected from the group consisting of polyesters, polyolefins, polyvinyl chloride, and combinations thereof.  
   
   
       36 . The article of  claim 35 , wherein the backing comprises polyvinyl chloride.