Patent ID: 8105526
Filing Date: 2012-01-31
Classification: A61F,B23K,B26F,B29C,B29L,B33Y,Y10T

Abstract:
1. A method for making an apertured forming structure having columnar protrusions extending therefrom, the method comprising the steps of: a) providing a forming unit; b) providing a backing film; c) providing a foraminous element; d) juxtaposing the foraminous element and the backing film with respect to the forming unit so that the backing film is interposed between the foraminous element and the forming unit; e) providing a liquid photosensitive resin; f) applying a coating of the liquid photosensitive resin to the foraminous element; g) juxtaposing in contacting relationship with the coating of photosensitive resin a mask comprising both opaque and transparent regions, the transparent region being continuous, and defining a plurality of discrete opaque regions; h) controlling thickness of the coating between the backing film and the mask to a preselected value; i) exposing the liquid photosensitive resin to light having an activating wavelength through the mask thereby inducing partial curing of the photosensitive resin in those regions which are in register with the transparent regions of the mask; j) removing the mask; k) removing un-cured resin from the foraminous element and partially cured resin; l) exposing the foraminous element and partially cured resin thereon to light having an activating wavelength to fully cure the partially cured resin, resulting in the forming structure having a continuous network of cured resin defining a first surface having a first surface area, and further defining a plurality of discrete apertures therein; and m) laser machining into the first surface of the continuous network of cured resin a plurality of generally columnar protrusions n) wherein a forming structure is formed comprising the foraminous element, and the continuous network of cured resin comprising the plurality of generally columnar protrusions extending from the first surface of the cured resin, wherein the columnar protrusions have an aspect ratio of at least 1 and adjacent protrusions have a center-to-center spacing between about 100 microns and 250 microns.