Methods of using nanostructured transfer tape and articles made therefrom

Abstract

A method of making patterned structured solid surfaces is disclosed that includes filling a structured template with backfill material to produce a structured transfer film and laminating the structured transfer film to a receptor substrate. The receptor substrate comprises a patterned adhesion promotion layer. The template layer is capable of being removed from the backfill layer while leaving at least a portion of the structured surface of the backfill layer substantially intact. The backfill layer can include at least two different materials, one of which can be an adhesion promotion layer. In some embodiments the backfill layer includes a silsesquioxane such as polyvinyl silsesquioxane. The structured transfer film is a stable intermediate that can be covered temporarily with a release liner for storage and handling.

1 . A method of making patterned structured solid surfaces comprising:
 filling a structured template with backfill material to produce a structured transfer film; and   laminating the structured transfer film to a receptor substrate,   
       wherein the receptor substrate comprises a patterned adhesion promotion layer. 
     
     
         2 . A method of making patterned structured solid surfaces according to  claim 1 , further comprising removing the structured template layer, thereby leaving patterned structured backfill material on the receptor substrate. 
     
     
         3 . A method of making patterned structured solid surfaces according to  claim 1 , wherein the backfill comprises a silsesquioxane. 
     
     
         4 . A method of making patterned structured solid surfaces according to  claim 1 , wherein the structured transfer film is temporarily laminated to a release liner. 
     
     
         5 . A method of making patterned structured solid surfaces according to  claim 1 , wherein the receptor substrate comprises glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite. 
     
     
         6 . A method of making structured solid surfaces comprising:
 filling a structured template with backfill material to produce a structured transfer film, wherein the backfill material comprises a silsesquioxane;   laminating the structured transfer film to a receptor substrate,   curing the sample, and   removing the structured template layer, thereby leaving structured backfill material on the receptor substrate.   
     
     
         7 . A method of making structured solid surfaces according to  claim 6 , wherein the structured transfer film is temporarily laminated to a liner. 
     
     
         8 . A method of making structured solid surfaces according to  claim 6 , where the receptor comprises substrate glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite. 
     
     
         9 . A method of making structured solid surfaces comprising:
 filling a structured template with backfill material to produce a structured transfer film;   laminating the structured transfer film to a receptor substrate,   patternwise curing the backfill material to produce cured areas and uncured areas in the structured transfer film;   removing the structured template allowing the uncured areas to reflow; and   blanket curing the structured template.   
     
     
         10 . A method of making patterned structured solid surfaces according to  claim 9 , further comprising removing the structured template layer, thereby leaving patterned structured backfill material on the receptor substrate. 
     
     
         11 . A method of making patterned structured solid surfaces according to  claim 9 , wherein the backfill comprises a silsesquioxane. 
     
     
         12 . A method of making patterned structured solid surfaces according to  claim 9 , wherein the structured transfer film is temporarily laminated to a release liner. 
     
     
         13 . A method of making patterned structured solid surfaces according to  claim 9 , wherein the receptor substrate comprises glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite. 
     
     
         14 . A method of making patterned structured solid surfaces according to  claim 9 , wherein patternwise curing comprises photocuring through a photomask. 
     
     
         15 . A method of making patterned structured solid surfaces according to  claim 9 , wherein patternwise curing comprises using a rastered laser. 
     
     
         16 . A method of making patterned structured solid surfaces according to  claim 9 , wherein allowing the uncured areas to reflow further comprises applying heat. 
     
     
         17 . A method of making structured solid surfaces comprising:
 filling a structured template with backfill material to produce a structured transfer film;   patternwise curing the backfill material;   laminating the structured transfer film to a receptor substrate;   removing the structured template layer; and   blanket curing the structured template layer.   
     
     
         18 . A method of making patterned structured solid surfaces according to  claim 17 , wherein the patternwise curing is performed in an oxygen environment. 
     
     
         19 . A method of making patterned structured solid surfaces according to  claim 17 , wherein one or more layers are applied over the pattern cured backfilled transfer tape before lamination to increase adhesion of the backfilled layer to the receptor substrate. 
     
     
         20 . A method of making patterned structured solid surfaces according to  claim 17 , wherein the backfill comprises a silsesquioxane. 
     
     
         21 . A method of making patterned structured solid surfaces according to  claim 17 , wherein the structured transfer film is temporarily laminated to a release liner 
     
     
         22 . A method of making patterned structured solid surfaces according to  claim 17 , wherein the receptor substrate comprises glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite. 
     
     
         23 . A method of making patterned structured solid surfaces according to  claim 17 , wherein patternwise curing comprises photocuring through a photomask. 
     
     
         24 . A method of making patterned structured solid surfaces according to  claim 17 , wherein the patternwise curing comprises using a rastered laser. 
     
     
         25 . A method of making patterned structured solid surfaces according to  claim 17 , wherein allowing the uncured areas to reflow further comprise applying heat. 
     
     
         26 . A method of making structured solid surfaces comprising:
 filling a structured template with backfill material to produce a structured transfer film;   patternwise curing the backfill material;   laminating the structured transfer film to a receptor substrate;   blanket curing the structured transfer film; and   removing the structured template layer.   
     
     
         27 . A method of making patterned structured solid surfaces according to  claim 26 , wherein the backfill comprises a silsesquioxane. 
     
     
         28 . A method of making patterned structured solid surfaces according to  claim 26 , wherein the structured transfer film is temporarily laminated to a release liner before patternwise curing the backfill material. 
     
     
         29 . A method of making patterned structured solid surfaces according to  claim 26 , wherein the structured transfer film is temporarily laminated to a release liner after patternwise curing the backfill material. 
     
     
         30 . A method of making patterned structured solid surfaces according to  claim 26 , wherein the receptor substrate comprises glass, metal sheet, metal foil, ceramic, silicon, polymer, or composite. 
     
     
         31 . A method of making patterned structured solid surfaces according to  claim 26 , wherein patternwise curing comprises photocuring through a photomask. 
     
     
         32 . A method of making patterned structured solid surfaces according to  claim 26 , wherein the patternwise curing comprises using a rastered laser. 
     
     
         33 . A method of making patterned structured solid surfaces according to  claim 26 , wherein allowing the uncured areas to reflow further comprises applying heat. 
     
     
         34 . A method of making patterned structured solid surfaces according to  claim 26 , wherein areas of low adhesion are removed from the receptor substrate creating vias. 
     
     
         35 . A method of making patterned structured solid surfaces according to  claim 1 , wherein the structured transfer film comprises a dyad of two transfer layers. 
     
     
         36 . A method of making patterned structured solid surfaces according to  claim 7 , wherein the structured transfer film comprises a dyad of two transfer layers. 
     
     
         37 . A method of making patterned structured solid surfaces according to  claim 11 , wherein the structured transfer film comprises a dyad of two transfer layers. 
     
     
         38 . A method of making patterned structured solid surfaces according to  claim 29 , wherein the structured transfer film comprises a dyad of two transfer layers.