Patent ID: 7931841
Filing Date: 2011-04-26
Classification: B29C,H05K

Abstract:
1. A method of making a microreplicated article including an opaque web having a first surface and an opposing second surface, the method comprising: passing an opaque web having a first surface and an opposing second surface through a casting apparatus having a first patterned roll driven by a first motor and a second patterned roll driven by a second motor; contacting a first liquid with the first patterned roll and the first surface; curing the first liquid to create a first microreplicated pattern; contacting a second liquid with the second patterned roll and the second surface while the first microreplicated pattern is in contact with the first patterned roll; curing the second liquid to create a second microreplicated pattern; receiving in a control module of the casting apparatus input from a first primary encoder, the input being related to the position of the first motor; receiving in the control module input from a second primary encoder, the input being related to the position of the second motor; receiving in the control module input from a first secondary encoder, the input being related to the position of the first patterned roll; receiving in the control module input from a second secondary encoder, the input being related to the position of the second patterned roll; and controlling the position of the first and second patterned rolls using the control module, wherein the position of the first and second patterned rolls is based on the input from the primary and secondary encoders, wherein the first and second patterns are registered to within 100 micrometers.