Patent ID: 7927525
Filing Date: 2011-04-19
Classification: B29C,B29K

Abstract:
1. A process of forming at least one of a micro and a nanostructure surface in a part formed of PTFE, the process comprising the steps of: inserting one of powdered PTFE and granulated PTFE within a mold cavity of a compression isostatic mold; forming at least one of a micro and a nanostructure surface, comprising at least one shim, on one of a surface of a compression anvil, for applying a compression pressure, and a surface of the mold; providing the at least one of the micro and the nanostructure surface, comprising the at least one shim, with one of a pitch and a depth ranging 0.040 μm and 1000 μm and surface geometries dimensions between 0.1 μm to 3000 mm to form one of diffractive and diffusion structures for shaping and directing light emitted from coherent and incoherent radiation sources; determining a depth of compression of the compression anvil using the at least one shim of the at least one of the micro and the nanostructure surface; forcing the compression anvil into the mold cavity of the compression isostatic mold with a compression pressure of between 10 psi and 10,000 psi and cause the one of the powdered PTFE and the granulated PTFE to engage with the at least one shim of the at least one of the micro and the nanostructure surface, and designing a perimeter surface of the compression anvil so as to closely conform to a perimeter of the mold cavity; providing a seal between the perimeter surface of the compression anvil and the perimeter of the mold cavity of the compression isostatic mold; applying a vacuum of between 760 Torr and 1×10 integrating a heating element into at least one of the compression anvil and the at least one shim of the at least one of the micro and the nanostructure surface; preheating the at least one of the compression anvil and the at least one shim of the at least one of the micro and the nanostructure surface, via the heating element, for at least one of reducing and removing moisture contained within the PTFE, and initiating a temperature rise of the at least one of the compression anvil and the at least one shim of the at least one of the micro and the nanostructure surface, wherein said temperature rise of the at least one of the compression anvil and the at least one shim of the at least one of the micro and the nanostructure surface begins heating the PTFE during compression; heating of the compression isostatic mold to a temperature of between 100° C. and 450° C., via one of an oven and the integrated heating element, so as to fuse the PTFE, while under vacuum, to the at least one shim of the at least one of the micro and the nanostructure surface, such that the PTFE conforms to a shape of the at least one shim of the at least one of the micro and the nanostructure surface; quenching the compression isostatic mold while still maintaining the pressure on the compression isostatic mold for at least a portion of the quenching; and thereafter removing the part, formed from PTFE with at least one shim of the at least one of the micro and the nanostructure surface, from the compression isostatic mold.