Directed energy assisted in vacuo micro embossing

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS FIG.
1.
shows a diagram of one possible configuration of the embossing machine/station.
A drum 1 and pressure roll(s) 2, 3 confine a web (roll or sheet) substrate material 4 to produce a nip 11 with an embossing tool which is clamped or bonded to the drum at its leading edge 5 as is the case for multiple other individual tools 6.
Herein "web" is defined as the bulk forms of substrates as delivered form manufacturers, including but not limited to sheets, rolls, tapes, and the like.
Directed energy is concentrated into the nip area from source position A for beam quanta which are directly absorbed by the substrate or alternatively from source position B for those quanta which can penetrate the substrate and deposit energy at the opposite surface either by virtue of the quanta energy chosen and/or surface treatment of the substrate.
The energy is directed into the substrate and the embossing tool surfaces in proportions which are dictated by the nature of the polymer molding mechanism which is employed (i.
e.
thermoforming, cross linking, or thermosetting).
The entire machine is contained in a vacuum pumped chamber 7 which can hold a vacuum similar to that used for typical vacuum coating purposes as diagrammed by the coating heads 8.
Enhancement of the surface of the substrate, prior to embossing, can be accomplished by vacuum metalization, ion implanting, dye/polymer coatings, and/or other treatments can be done for example by the coater head(s) 9.
Also, the surface of the stamper tools can be cleaned, preheated, coated or otherwise conditioned by directing energy from plasma ion infrared photon, and other sources at locations 10.
This chamber can be a single large vessel containing all process steps or a compartmentalized structure if isolation of the process steps produces better conditions due to differential pumping, baffling or similar krnown vacuum system designs.
It should be noted that pressure roll 3 is optional and not necessary if wrapping the substrate on the drum can be avoided as is desirable since this produces less pattern distortion